Got up early, went to the garage, and continued to work with the car. It started to rain (to make things more complex), so I needed to cover areas, where holes were made for roll cage to connect to the front struts... It was quite a rush to connect, fix, bolt everything that is needed for car to run. Speedo was not working so managed to borrow GPS unit and make loom for it to work, etc.
When the time for the meet has come - I have noticed, that I have lost registration documents for the car... That was final hit, which put me down. Three weeks of "Go go go!" type activity, and that's it, FIASCO!
After few hours of searching - managed to find them (they fell out of radiator area in the car), however motivation was lost, event sports part has ended already, etc. Went home, and tried to relax and rest. It was too much for me.
In the evening, few finished touchings, and tried to go around the block. It was magnificient. Impressions are hard to describe (car with sound insulation vs car with roll cage and many holes to outside). It runs and feels like racing car (what a surprise). It was worth all the pain I've suffered in past three weeks.
Sunday, May 25, 2008
2008.05.16 Struggling with time...
Less sleep, more work! Trying hard to finish car until 05.17 (per4m forum meet). Managed to put glasses (hardcore story, no pictures) not mentioning that roll cage - was not allowing to put them in). Somehow managed to assemble everything outside the car. Also put driver's seat, racing harness'es etc.
Started to feel and think like zombie. Working for 8-10 hours per day for two weeks - started to bring the results, almost finished car, loads of cuts and bruises on the arms, legs, head... The PAIN in every muscle. Started to use weak analgetics to help the progress...
Started to feel and think like zombie. Working for 8-10 hours per day for two weeks - started to bring the results, almost finished car, loads of cuts and bruises on the arms, legs, head... The PAIN in every muscle. Started to use weak analgetics to help the progress...
2008.05.14 It's alive! ... and leaking coolant ;)
Not much pictures, but managed to bleed cooling system and start the engine. Oh, how nice it sounds, and revvs happily. Very satisfied by change (of flywheel). Rolled the car out of garage on it's own engine:
After a while it started to leak coolant from everywhere - I forgot to tighten few clamps. Starting to get very tired, thus making stupid mistakes. Not good.
After a while it started to leak coolant from everywhere - I forgot to tighten few clamps. Starting to get very tired, thus making stupid mistakes. Not good.
2008.05.13 Putting everything back - part III
Day was completelly spent on fixing some old engine swap mistakes, and assembling everything around the engine. Some wiring for radiator fan and alternator was rewired and properly fixed:
Also eliminated dead end for activated charcoal valve (was leaking boost and doing nothing):
Replaced oil pressure sender (one contact VDO to some noname two contact). Reason for this is employing oil pressure check unit fom KV engine. It is using two pressure sensors to operate properly. So I put two contact sender (gauge and warning), and found plug in the block where I managed to put old pressure switch from KV.
Put the radiator in, connected everything on the driver's side:
Also eliminated dead end for activated charcoal valve (was leaking boost and doing nothing):
Replaced oil pressure sender (one contact VDO to some noname two contact). Reason for this is employing oil pressure check unit fom KV engine. It is using two pressure sensors to operate properly. So I put two contact sender (gauge and warning), and found plug in the block where I managed to put old pressure switch from KV.
Put the radiator in, connected everything on the driver's side:
Monday, May 12, 2008
Putting everything back, part II
So after yesterday's disappointment - needed some time to rest and think. It gave a result, went to local autoparts store, bought newer clutch slave cylinder (dirt cheap, hope it will last for a while), put it in the gearbox, bleeded, and SUCCESS! Clutch is working. So started to bolt everything again. Propshaft (not visible in a picture, but believe me - it's bolted already):
Bolted driveshafts (took a while , because my measurements were wrong, driveshaft flanges from typ44 are bigger, and I forgot, that I had typ44 flanges on my spare gearbox, which was used as reference - they were given to my friend some years ago). And if you notice, turbocharger went from the floor into engine bay ;)
Also wrote more blog entries with past dates. Had no time to do this before, because my schedule for these two weeks was - eat, sleep, work in the garage, or search for the parts. Enjoy...
Bolted driveshafts (took a while , because my measurements were wrong, driveshaft flanges from typ44 are bigger, and I forgot, that I had typ44 flanges on my spare gearbox, which was used as reference - they were given to my friend some years ago). And if you notice, turbocharger went from the floor into engine bay ;)
Also wrote more blog entries with past dates. Had no time to do this before, because my schedule for these two weeks was - eat, sleep, work in the garage, or search for the parts. Enjoy...
2008.05.11 Trying to put everything back
First, old clutch was inspected. It had no obvious signs of damage, however it was visible, that it had contact with oil (which is leaking from valve cover gasket), and was burned somehow. There were a lot of copper and feredo debris inside flywheel. Also pressure plate was looking suspicious. Old:
New:
There's visible difference of leaf spring height. So decided to use all the stuff (release shaft, bearing, etc. from apropriate type).
And the fun started. New gearbox requires different type of clutch slave cylinder. So after few hours of grinding, I came with somewhat which can be called as typ85 type clutch cylinder adapter for newer gearbox. We pulled engine back in, bleeded the clutch. And the result was soft and spongy pedal. Inspection showed, that hydraulic fluid is leaking from gearbox. That was a disaster :(. Pulled slave cylinder - it was too short, and spitted a rod under pressure :(. I hated all world and had no strengths to work further...
New:
There's visible difference of leaf spring height. So decided to use all the stuff (release shaft, bearing, etc. from apropriate type).And the fun started. New gearbox requires different type of clutch slave cylinder. So after few hours of grinding, I came with somewhat which can be called as typ85 type clutch cylinder adapter for newer gearbox. We pulled engine back in, bleeded the clutch. And the result was soft and spongy pedal. Inspection showed, that hydraulic fluid is leaking from gearbox. That was a disaster :(. Pulled slave cylinder - it was too short, and spitted a rod under pressure :(. I hated all world and had no strengths to work further...
2008.05.09 Engine pulled out
After many hours of fighting with oil cooler fittings, cutting some bolts, badly injuring my right hand, and many dirty words - engine was successfully pulled out and gearbox was separated.
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