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Date |
Event |
07/08/2005 3hrs
Fuel Tank |
I've spent quite a while mulling over the fuel tank ,
fuel pump and filter interconnection. I decided that the inline pre-filter
that I had was not ideal for the job. Whilst on holiday in North
Somerset I called in to Nostalgia and picked up the Sertec filter that
they use. the installation is improved by using this filter because it
is more compact and the filter element is replaceable. I refitted the boot
well top anf temporarily fixed the sides of the boot well in place today
using spire bolts. This was so I could determine the position of the
exit hole for the tank outlet. I trial fitted the compression fitting
to the tank ,but I had some doubts on the clearances and routing of the pipe
in the vicinity of the diff and disk brakes, so I abandoned this idea.
I decided to use the simple way and fix a length of rubber fuel pipe
to the tank outlet. This is easy enough to do, in principle, but I've
stopped while I work out the best routing for the pipe
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10/08/2005 5hrs
Fuel Tank |
At last I think I've broken the back of the fuel tank and
pump plumbing. Its taken a lot of thought as well as trial and error,
but I think I'm there. The result is a culmination of ideas and
discussion with Simon at Nostalgia. I've abandoned the complex
solution in favour of the simple one. I've connected a length of
copper pipe to the tank outlet with a short length rubber hose. The
hose is bent in a right angle, as tight as possible without flattening the
hose. The copper pipe is routed across the inside of the boot and out
through a hole in the front RHS of the boot well. The copper pipe has
been shrouded in 3/8" rubber hose to protect is as it passes thought the GRP
of the boot well. the copper pipe (and hose shroud ) is bent to follow the
external contour of the boor well as close as possible, ensuring the copper
pipe is not kinked or flattened. I've cut the copper pipe off in front
of the mounting plate for the fuel pump. Next I've connected a length of
rubber fuel hose to the copper pipe and routed this under the fuel pump
mounting plate to the in line pre filter. I still have to work on
securing the fuel lines and pre-filter to the boot well and make the final
connection of the pre-filter to the fuel pump.
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11/08/2005 5hrs
Fuel Pump |
I connected and secured the pre filter to the sides of
the boot well. Using 5/16" fuel pipe there is enough flexibility in the pipe
to secure it, using "P" clips either side, and close to the filter to give
it maximum support. I then cut the remaining flexible pipes to size to
connect the pre filter to the fuel pump, using the adapter I made earlier to
make up for the difference in pipe size. Lastly I cut a new length of
pressure (240 psi) pipe to connect the fuel pump outlet to the main
fuel filter. I made a bracket and secured this to the fuel pump / filter
mounting plate then secured the pressure pipe to the bracket with a
"P" clip, to make sure the pipe was secure and could not come in to contact
with other components. The installation is not bad, fairly neat and
should be easily to maintain. If I have a criticism of it is
that it contains too many joints and therefore, jubilee clips to look really
tidy. Perhaps a winter job after SVA when the build is finished. I
still have to connect the outlet of the main filter to the feed to the fuel
injection, the return to the top of the tank and the atmospheric vent. once
all that has been trial fitted I can finish fitting the boot well.
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12/08/2005 2hr
Boot Bridge |
I took the opportunity when I was at Nostalgia last week.
to see how much flexibility there was at the centre of the boot bridge once
the stays were fitted. The vehicle I looked at also had the filler panel
fitted between the boot bridge and the boot well top panel. There was
still some movement, about ¼", which was about the same as mine. I
refitted the boot bridge stays today, ready to make the final connections to
the fuel system. I'm still toying with the idea of riveting or
bolting the boot bridge support panel to the body to give a little
extra support at the centre. I don't think it will place any undue stress on
the body, providing the hinges and boot lid are free moving with no catching
or binding.
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13/08/2005 4hrs
Boot Well |
I dismantled the fuel system in the rear offside wing.
disconnecting all the pipes so that I could remove the top panel of the boot
well. I removed the boot well itself and finally the slam panel.
I opened out the holes drilled in the rear cross member to fit the slam
panel and fitted them with 5mm Rivnuts. I drilled out to 4mm clearance
the holes in the chassis to fit the sides of the boot well. I'm
undecided whether to secure the sides of the boot well with rivnuts and
countersunk screws or large headed pop rivets. Whist the
boot well was out I tried fitting the fuel hoses to the copper pipe that run
the length of the chassis. I managed to fit the fuel feed, but it was
a tight fit and only the minimum acceptable amount was pushed over the
copper pipe and secured with a jubilee clip. the return pipe fitted easily
on to the tank but could not be pushed far enough on to the copper return
pipe. I left it while I had a thin about it. I decided the
movement of of the support plate on the boot bridge rubbing on the body as
the boot lid opened and closed, causing the boot bridge to flex, was more
damaging than securing the support plate to the body. I removed the
support bracket drilled it to accept a 4mm Rivnut in the top. Before
fitting the rivnut I refitted the bracket and drilled through it in to the
boot aperture flange, I fitted the rivnut and fitted the support
bracket. I countersunk the hole in the flange to accept a 4mm
countersunk screw. The screw will not be seen on the finished car as
it will be covered by the seal around the boot aperture. the end
result is the flexing of the boot bridge is eliminated
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14/08/2005 5hrs
Fuel hose Boot Well
Slam Panel |
I'm convinced that the High pressure fuel hose I have is
too small to fit the copper tubing. I lost a little time coming to this
conclusion and researching a suitable alternative. I think I have
found a suitable alternative from SPEEDFLOW. I'll place an order with
them tomorrow. I went back to the fitting of the boot well and
realised I needed to do another trial fit to countersink the bolts securing
it to the slam panel and to complete the fitting of the slam panel. Once the
boot well and slam panel was in place I temporarily secured them with spire
bolts at the side and M5 Pan Head screws to the slam panel and cross member.
I then removed the pan head screws one at a time to countersink the hole in
the boot well combing and secured with M5 x 25mm countersunk screws. I
then clamped the slam panel to the underside ot the boot well and drilled
through the floor securing holes in to the slam panel. I temporarily secured
the slam panel to the boot well using M5 bolts. Ultimately it will be
secured by the floor securing bolts. I need to make some slam panel
side closing panels. These small "quadrant" panels are described but not
shown in the build manual. I think I understand them, but I need to talk to
Nostalgia to determine if I am right or exactly how and where they fit and
are secured. During the day I have been painting the fuel system
stand off plate and brackets and fitting all this other stuff in whilst I've
bee waiting for them to dry.
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21/08/2005 8hrs
Fuel Hose / Fuel Pump Boot Well / Slam Panel
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I ordered some fuel hose from SPEEDFLOW and while I was
at it I ordered some stainless steel overbraid and hose end covers. These
last two items are really necessary but It will improve the appearance
of the fuel pump installation and pipe work. I've completed the
paint job on the mounting plates and covered the pipe work in the overbraid.
I decided to mount the boot well with stainless countersunk screws. I
removed the boot well, again to put Rivnuts in to the chassis to secure the
sides of the boot well. There are times when building the car that
lots of work is being done with very little to show for it, then when final
assembly is done you seem to make great progress. The boot well is a
case in point. I removed the boot slam panel ran a bead of sealer on
the chassis cross member and refitted it. I ran a bead of sealer
across the slam panel and down the sides of the chassis, where the boot well
will fit. I loosely fitted the boot well. Before securing it I
fitted the aluminium panel to the join the rear of the boot well together,
making site it was sealed I then fitted the boot well to the slam panel with
stainless countersunk screws. I secured the sides of the boot well to
the chassis and temporarily fastened the underside of the slam panel to the
coot well using the floor board holes. I then ran a bead of sealer
around the top front edge of the boot well. I fitted the top boot cover with
countersunk screws and penny washers. I ran extra sealer in to any gaps that
were left. Using a damp cloth I cleaned all the surplus filler from
all of the edges of the boot well and left it to dry. All of the trial
work on the fuel installation now paid off with all the components
either mounted or pipe work cut to length and covered with overbraid.
It was a relatively simple matter to mount these on the car and connect them
up. I still have the return connection and the supply connection to
make but I have run out of overbraid and must order some more. I also
have a little work to do to mount and secure the return pipe and the
breather pipe to the tank.
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Total hours this month = 32hrs |
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Total hours
to date = 1192 hrs |
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