I broke it quickly...And repeatedly...Chaste White Rebuild

[Francob]

Car is back, now a vast amount of jobs to get through to get it running.

A few shots on the trailer which to be fair is its natural habitat. In fact now I think about it, it’s probably covered more miles on a trailer in my ownership than I’ve driven it myself.

 

[Francob]

Back from a weeks holiday and getting stuck into getting this FD up and running. I spent a week with wife and daughter trying to switch off but I’m not going to lie I spent most of the week dying to get back into the garage to get things moving.

I’ve sent the upper inlet back to the Colum to have the water/meth bungs changed as they were the wrong thread pitch (my fault) hopefully have that back towards the end of the week.

Current state of affairs looks like this. A bit of a mess but trust me it’s organised chaos. I’ve fitted VAC block and have MAP sensor now plugged in.

I started this morning with fitting the 3D printed dash surround courtesy of Tom at Advocult, followed by the Syvecs/LR D4 dash itself.

The cars been sat in the garage for over a week whilst I’ve been away so connecting the battery and getting it powered up felt good this morning. A quick test of D4 dash and Motec keypad, excuse the coolant buzzer in video, I need to add coolant.

The rotary dials and D4 keypad need programming - I had to pop to Curry’s today to buy a CAT6 cable and CAT to USB converter - fucking £50, total rip off.

Here is the end goal for the Motec keypad as seen in video. I just need to label and make some brackets for my centre console.

Here’s the current state of play in the boot. A mate is going to help me knock up some basic brackets and fixing points for PDU, battery and water/meth pump. I can then hopefully fit the carpet and side panels back in to keep the OE look.

Still a large list of things to do. Tomorrow I’m going to remove turbo, manifold and down pipe so I can add longer manifold studs - I can then fit the hot side completely and plug in/fix 02 sensor and EGT probes.

I also need Magnecor to make me some custom leads so hope to get my measurements over to them too.

Still loads to do but aiming for an August first start.

 

[Ferrox117]

Car is back, now a vast amount of jobs to get through to get it running.

A few shots on the trailer which to be fair is its natural habitat. In fact now I think about it, it’s probably covered more miles on a trailer in my ownership than I’ve driven it myself.

View attachment 36701View attachment 36702

It got to a point where I was the same, pushed it in and out the workshop more than I had driven it such is the life of an FD I guess, yours atleast looks the part!

 

[Francob]

To speed things up and have the job done properly rather than me fucking things up with some half assed brackets
I’ve sent the car to Tom at Advocult to finish up the brackets for the PDU, water/meth pump and battery in the boot.

A few 3D scanned images - should look neat.

Whilst it’s there he’s going to sort a few more smaller jobs with the oil lines etc.

Colum sorted the water/meth ports on the upper inlet for me too so ready to go on that front.

Still on course for an August first start.

 

[Ferrox117]

To speed things up and have the job done properly rather than me fucking things up with some half assed brackets
I’ve sent the car to Tom at Advocult to finish up the brackets for the PDU, water/meth pump and battery in the boot.

A few 3D scanned images - should look neat.

View attachment 36851View attachment 36852View attachment 36853View attachment 36854

Whilst it’s there he’s going to sort a few more smaller jobs with the oil lines etc.

Colum sorted the water/meth ports on the upper inlet for me too so ready to go on that front.


View attachment 36855

Still on course for an August first start.

August 2024 when you’ve finished collecting the last few infinity stones? must admit the 3D scanning is something I must pick up for the useful nature of not messing around! I think I will end up doing the same location for the battery! You have the pump and tank also
In the spare wheel well?

 

[Francob]

A quick update from Tom today.

Final bracket design for the water meth block.

Oil lines all complete including turbo oil feed and return to filler neck.

Coil packs securely mounted.

The TIP sensor remotely mounted.

Still to do:
Make coil tube for turbo sensor
Mount pdm bracket
Mount battery bracket
Mount meth pump
Run lines for meth pump to distribution block.
Mount distribution block

Hopefully back complete next week and then things really get interesting.

 

[rx_dreamer]

Top work

3D scanning has come way down in price. Last time I was at the dentist, I got my mouth scanned got some funny looks when I asked the dental nurse for a homer to scan some brackets

 

[Francob]

August 2024 when you’ve finished collecting the last few infinity stones? must admit the 3D scanning is something I must pick up for the useful nature of not messing around! I think I will end up doing the same location for the battery! You have the pump and tank also
In the spare wheel well?

The water/meth pump is in the wheel well with battery but the water meth tank uses stock location of rear wiper washer bottle.

 

[rx_dreamer]

I'm feeling like I want to plagiarise....

What did you do with your Knock and OMP? did I miss it?

 

[Francob]

I'm feeling like I want to plagiarise....

What did you do with your Knock and OMP? did I miss it?

What do you mean about knock? If you mean sensors I am running 2 x new OEM knock sensors.

OMP has been deleted.

 

[Francob]

A few more updates from Tom today, the job is almost complete. Just waiting on the two custom brackets to come in from the laser cutters for PDU and battery. Other than that it’s just a case of running the water meth line under the car to the distribution block.

First up the water meth tank has had its fitting fitted followed by the pump being secured and then the relevant filter and dampener fitted.

The plan is to whack the boot carpet over this so should be nice and neat and leave me with full boot space. When funds allow I’ll buy a parcel shelf too.

Tom knocked up a 3D printed bracket for the water/meth manifold.

The exhaust pressure sensor compression fitting proved a bit of a challenge but got there in the end. This gives me data from both inlet and exit pressure. Will be really able to tell how the turbo, manifold and down-pipe are performing.

Ran out of time and budget with Tom so going to finish the rest of the jobs myself apart from finding someone local to drill and tip a smaller fitting into the end of the water/meth manifold block to add a pressure sensor.

Still need to do:
Purchase oil and fill.
Add coolant.
Buy and fit catch can and lines (AN10).
Drill and TAP water/meth manifold - 1/8NPT for pressure sensor.
Properly fit exhaust manifold - longer studs needed.
Properly fit turbo.
Properly fit down pipe.
Fit waste gate & screamer (7psi spring).
Plumb in boost solenoids/ MAC valves.
Fit coolant pressure sensor.
Fit EGT sensors.
Fit 02 sensor.
Fit Motec Key pad.
Fan loom from Matt

Once I’ve taken care of this we are good to go. I reckon last week of Aug/first week of Sept first start all being well.

 

[Francob]

Boot finished, cracking job.

Shame to put all the plastics and carpet back to cover it all.

Leads arrived today - hopefully they are right.

 

[Ferrox117]

Boot finished, cracking job.

Shame to put all the plastics and carpet back to cover it all.

View attachment 36947View attachment 36948

Leads arrived today - hopefully they are right.
View attachment 36949

Are the boot plastics going to fit back on okay?

 

[Francob]

Are the boot plastics going to fit back on okay?

Will need a little fettling - possibly some cutting

 

[Francob]

Unfortunately the leads are slightly off so need to get them amended, some 90 degree boots on the leads side should sort it.

I painted the water pump and alternator pulleys today with some cheap satin black I had lying around, not great finish but it will do. Did the top rad bracket too.

The M16 to 1/8 adaptor I bought for coolant pressure sensor was some shit quality fitting so bought a better quality one which should arrive early next week. Oil is on order too.

Off to a family christening tomorrow so no more time until next week.

Engine bay is coming along - need to sort a boost hose for throttle body to cooler.

Going to swap the alternator positive terminal cover to black, my eye can’t help be drawn to it

 

[Francob]

Rolling around on my driveway under the car yesterday has not done wonders for my ageing back but a big step in the right direction.

The manifold is fully fitted with correct length studs, turbo, down pipe and wastegate all on too. The wastegate is a tight squeeze but just about fits.

First time fitting new 02 NTK sensor and EGT probes all connected back into loom.

Also filled oil for the first time.

Had some issues connected to PDU, dash and ECU. Turns out it was my modern work laptop not liking using a Ethernet to USB adapter but my 10year old MAC running windows worked just fine so pleased to have all of those connections sorted ready for calibration/tuning.

I painted my pulleys and rad bracket satin black as doing away with all of the blue.

Next up I had no front lights or wipers - turned out these were unplugged from the fuse box, must have been the bodyshop guys. All working now.

to do:
Buy and fit catch can and lines (AN10).
Plumb in boost solenoids/ MAC valves.
Fit coolant pressure sensor.
add coolant
Fit Motec Key pad.
Fan loom from Matt
Coil earth
Fit alternator + terminal cover
Throttle body boost hose
2x M8 bungs for boost hose

This won’t be far off the finished article though a black turbo inlet joiner instead of blue.

 

[rx_dreamer]

I was thinking about investigating some replacement caps for the headlight winders... Then all u need is a new black FPR

 

[Francob]

Edging closer but like anything in life challenges present themselves.

I’ve filled the coolant, oil and for now 5 litres of distilled water in order to test water/meth set up. Unfortunately this fitting is ever so slightly seeping coolant, it’s just a push fit fitting but when I tried pulling it out it snapped on me, so need to drill and tap to fix it. A job for the weekend.

The to do list is gradually getting shorter.

The fitting arrived to install the pressure sensor for the water/meth manifold.

I’ve been adding the stickers to the Motec 15 butting kepypad. I have some more stickers to add to PDM and numbers 1 & 2. I’ll have a few blank for now until I integrate cruise control.

I’ve sent this off to Tom today so he can mount it correctly in my centre console.

90 degree reducing elbow arrived today so I can knock up a temporary boost hose for running in period. When I’ve recovered from this financial disaster I’ll ask Colum or Tom to knock up some new much snazzier boost hoses.

Will need to shorten this elbow slightly but I reckon we can knock something up to work in the interim.

This is all that’s left to do before systems check, spanner check and first start.

Buy and fit catch can and lines (AN10).
Plumb in boost solenoids/ MAC valves.
Fit Motec Key pad.
Fan loom from Matt
2x M8 bungs for boost hose
Drill and tap water fitting

 

[marco]

How are you doing the pressure monitoring on the wi? Is it 'just' a lower limit or is it looking for an expected range based on manifold pressure and injection duty? I'm guessing it is a returnless system?

 

[Francob]

How are you doing the pressure monitoring on the wi? Is it 'just' a lower limit or is it looking for an expected range based on manifold pressure and injection duty? I'm guessing it is a returnless system?

No idea mate, that’s what I’m paying the tuner for.