Hello but I'm not building a Haynes roadster, quite

[Davey]

I'm expecting 30+ MPG from it when driving sensibly Andy, it did up to 32MPG dragging the Granada shell around when cruising at 70MPH so with more efficient breathing and a lighter body to haul it should be OK.

D.

[Davey]

Progress of late has been patchy but I've had a decent day on it today and I now have the lower steering cloumn bush mounting and drivers footwell end plate tacked in. I've also been working on the pedal box, I've opted for top hinged pedals so as to mount the brake master cylinder higher up than the Haynes design, this should make bleeding the system a whole lot easier as gravity will be on my side . I've acquired a master cylinder from a Saxo so I've set it up using that but I really need to calculate the pressures/clamping forces and pedal travel using this and Granada calipers so I've only got the MC mounting tacked in place for now.

I've also looked at shortening the steering rack centre shaft as it is about 25mm too long and giving rise to an unacceptable amount of bump steer. The good news is it looks like it will be really simple! The centre shaft is made from mild steel (checked with a nick from a hacksaw) so it won't be difficult to hack 25mm off the nearside end. The track rod knucle jonit is screwed into the centre shaft on a M14X1.5 thread and my local tool supplier is getting me a tap for tomorrow morning so I should be able to just tap further into the centre shaft (there is plenty of hollow length available), hack 25mm off the nearside end and refit the knuckle joint with thread lock. I think I will almost certainly need to make some track rod extensions though.

I'll try to get a few photos tomorrow afternoon and I also need to update my website.


D.

[Davey]

No progress to report sadly as I've been floored with serious manflu for the last two weeks . I have been to the workshop twice in that time, once to fetch the van for a ride to Norfolk to collect a trailer and once to meet up with Triff for a good old chinwag, (thanks for the mushies bud, I haven't been close enough to the Dragon to try them yet but they look good and I'm sure they'll fit a treat ).

I had intended to spend at least half of this fortnight working on the Dragon but this manflu has beaten me down, I even had to go see a doctor type person in hospital the other day .

Anyway down to the real purpose of this posting, my next door neighbour is a mature single woman who has in ther last few months found a male companion. today he said to me "you've got my old motor in your place" which nonplussed me a bit. My face obviously gave away my confusion 'cos he then said "little two seater sports car in green"! My first thought was I hope he hasn't read my description of the car when I got it.

Apparently he had a Zetec in it but it suffered really bad bump steer. his description was that it was "bloody awful at 80MPH"

Would you believe it?

D.

[AshG]

inlet manifold looks ok now its been tarted up my mate tom could never get the hang of ali he always said to me you dont need to be a good welder as long as you are good at grinding things lol.

i have finally managed to get the nack of ali but it took me a good year and about 3 big bottles of argon at £50 a pop. i found that a little bit of high frequency pulse helps when doing thick stuff to thin. will have a look at what the numbers on my welder say for the freq settings that i use for that sort of stuff (i just remember the positions not what it says on the switches lol).

Also i found that using Ceriated tungstens made life easier on ali, they can also be used on steel so double bonus.

[Davey]

Cheers Ash, I've done plenty of ali work in the past but it was many years ago so my skills are a bit rusty, your mate does have a point . I'm pretty sure I am using ceriated tungstens now, the originals that came with the TIG were plain tungsten but I had to buy some more because you only get a couple of really thin ones as standard. The manifold does still need some more work and fettling but its coming along. I'm just working out a little deal that will hopefully pay for the Emerald ECU, fingers crossed that it all works out .

D.

[AshG]

at the end of the day its function over form that is important. ali is usually my last choice when it comes to materials think i would have done the manifold with stainless

been tinkering out in the workshop and have made a charge cooler out of ali and shortened the sump on the new engine which is also ali. dont know what the composition of the ali on the sump was but the thing was a total pig to weld even using rods with extra silicone especially for welding cast.

will stick some pictures up when new year is all done and dusted and im let back out in the workshop.

[Davey]

I made a good start on shortening my sump today, yes its ali and full of all sorts of crappy inclusions so just like yours Ash its been a pig. I managed to reduce it by 35mm which should be sufficient (damn well better be ) using a reciprocating demolition saw with a coarse metal blade. i've taken a few photos as I've gone along but I'll wait to post them till its all sorted and I know it don't leak .

D.