Monday 26 January 2009

Fuel Pipes - RHS inner

Started to fix the solid fuel pipes. The complication I had is that 2 of the fuel pipes plus the front to rear brake pipe run along the same side. There isn't a lot of space along the lowered part of the floor. Having looked on several build sites for suggestions on routing I realised most of the builders I had links to were LHD cars which didn't have the same issue. The brake pipe is on the opposite side which means there are 2 fuel pipe on one side and a fuel pipe plus brake pipe on the other.

The picture below shows how the much space there is (I used a couple of bits of scrap pipe):


Some people run the brake pipe between the fuel pipes. Some attach to the box section of the chassis rather than the lowered part of the floor. I adopted to start with the fuel pipes then see how it looks later!

Front end:
On the suggestion of another builder (Inge Jonsson) I made the lengths of the 2 pipes different. This makes connecting the flexible hoses simpler later as the clamps are offset. I started the bend 170mm from the end of the inside pipe and 190mm on the outside pipe.
I also took the tip from Inge about mounting the pipes slightly away from the panel. You can do this as you are attaching to a panel rather than into the chassis box section. Inge used a 10mm length x 10mm dia. piece of brass pipe with a M4 bolt/locknut. As a temporary measure I used one of those plastic blocks used to fix the corner of bookcases. Fixing the pipe 10mm away from the panel also has the advantage that you can put a simple right angle bend without having to put a swan neck in.
The inner pipe has to be min 25mm from the inside edge of the tunnel. This means there isn't enough space to the master clutch cylinder for the 2nd pipe to be connected by jointly riveted P clips (like in the picture above). The approach most builders seem to take is to make the pipes converge towards the front with separately riveted P clips then let them diverge after the pipes are past the clutch cylinder.



Mid-section:
The inner pipe just needs a simple bend in the middle.
The holes for the rivets go are through the floor of the chassis rather than into the box section so you have access to the other side. As a consequence I could temporarily attach the P clips using M4 bolts trough the 4.1mm holes (the only ones to hand were courtesy of Ikea bookcase connectors). When I come to do the final rivets I'll probably rivet the front section from the inside so the flat part of the rivet will be on the inside and so the carpets will be flat.



Rear:
The 1st bend was okay but I got the 2nd bend slighly in the wrong place so the pipe went along the centre of the chassis section rather than the edge. I might try to straighten out the bends to move it over slightly. As you are attaching to box section, rivets must be used so I can't use the same trick of a space like I used at the front. Instead I bent the pipe down so it was away from the chassis providing clearance for the flexible hoses and clamps.

Sunday 11 January 2009

Completion Kit - BOM

Here is the list of items you get in the completion kit. I have tried to put them in some logical groups for the photos. I've not got pictures of some of the larger items. The items are listed left to right, top to bottom.

Cooling:

1 x RADIATOR - ALUMINIUM (not shown)
1 x WATER PIPE-1600I H/TANK-RAD (not shown)
3m x HOSE - 5/8" BORE WATER
7 x HOSE CLIP 14-22MM
1 x HOSE CLIP 22MM/30MM
9 x HOSE CLIP 30-40MM
1 x HOSE CLIP 35-50mm
1 x HOSE-EXPANSION TANK RETURN
1 x WATER PIPE-EPX 1FT LENGTH
1 x WATER PIPE-ZETEC EPX
1 x HOSE-RADIATOR
1 x HOSE-RADIATOR BOTTOM
1 x HOSE-90 DEG OFFSET
1 x HOSE-STRAIGHT ADAPTOR 5/8-7/8
1 x TANK- EXPANSTON (W/O CAP)
1 x CAP - EXPANSION TANK
2 x BRACKET-RADIATOR MOUNTING TOP
1 x PLATE-AIRBOX MTG-MAZDA SDV-EPX
1 x FAN MOUNT/G BRKT TOP-MAZDA SDV
1 x BRKT-MTG EXPANSION TANK
1 x PLUG-M22 FINE THERMOSTAT BLANK

Fuel:

1 x FUEL TANK+SEND SHORT RNG MULTI (not shown)
3 x FUEL PIPE 1830MM ZEi
3.23m x HOSE - 8MM BORE FUEL
10 x HOSE CLIP 11-16MM BZP
18 x P CLIP 8MM
1 x FUEL PUMP RVRV8 SERP-BUSA-BIRD
1 x BRACKET - FUEL PUMP / FILTER
1 x FUEL CAP/INLET ASM-UNLEADED
0.15m x HOSE - 57(2 ¼ ) NITRILE FUEL
1 x HOSE-5.4MM CARBON CANISTER
1 x ADAPTOR FUEL TANK 12MM HOSE
1 x ADAPTOR - FUEL TANK RETURN 8MM
2 x CLAMP-HOSE 50MM/70MM
2 x FUEL TANK STRAP-SHORT RANGE

Steering:

1 x STEERING RACK RHD - ALL MODELS
1 x STEERING COL SHAFT ZETEC EPX
2 x BALL JOINT-MAZDA SDV TOP FRONT
1 x S/RACK MTG RUBBER RH (LARGE)
1 x STEER RACK MTG CLAMP-LARGE EPX
1 x S/RACK MTG RUBBER LH (SMALL)
1 x STEER RACK MTG CLAMP-SMALL EPX
1 x UNIVERSAL JOINT - STEERING COL
1 x u bolt (this was not in the completion kit)
1 x BRACKET-COLUMN MTG EFi EPX
1 x STEERING COLUMN BUSH TRZ

Suspension & Mountings:

2 x SHOCK ABSORBER STD FRONT
2 x SHOCK ABSORBERS REAR - STD
2 x SPRING 300X8"X1.9 V8 FR BLK/WH
2 x SPRING 195X9"X1.9 SEI RR WHITE
2 x ENGINE MOUNTING RUBBER
2 x GEAR BOX MOUNTING RUBBER MT75
2 x SPACER-STEERING ARM-XTR2 BZP

Exhaust:

1 x EXHAUST PIPE-MAZDA SDV (not shown)
1 x SILENCER WIDE SS 5 1/2"DIA (not shown)
1 x EXHAUST COVER 5 1/2" DIA
2 x HOSE CLIP 130-160MM
1 x BAND CLAMP - SILENCER 51-55MM
1 x CLAMP U EXHAUST (2 1/8"Y) 10 PAK
1 x DNO SILENCER MOUNTING PLATE
1 x EXHAUST MOUNTING (5/16 UNF)
2 x 5/16 UNF NUT NYLOC (there were 2 non-nyloc nuts on the mounting, not sure if these are the items listed)
1 x SILENCER MOUNTING BRKT EPX
1 x M10 X 65 HEX HEAD BOLT P&P
1 x SPACER-SILENCER MTG 5 1/2"

Electrics:

2 x HEADLAMP 5.75 BLACK RHD HALGN
2 x INDICATOR POD - PLASTIC
2 x INDICATOR- FRONT C/W BULB
2 x LIGHT-REAR UNIT
1 x FOG LIGHT-REAR E11 0030
1 x LIGHT-REVERSING
1 x LIGHT-NUMBER PLATE
100 x TIE RAP CLIP
2 x GROMMET-WIRING 3/4X7/l6X3/16
1 x LEAD-BATTERY POSITIVE CVH/OHC
1 x LEAD-BATTERY BLACK NEG BAT3L
1 x CLAMP-BATTERY
1 x BATTERY TRAY
100 x TIE RAP NYLON 200 X 4.8 PCT1
1 x ECU MOUNTING PLATE MEGA
2 x SIDESCREEN LOWER HINGE PLATE (used to mount the ECU plate)
2 x SIDESCREEN TOP HINGE LH (used to mount the ECU plate)

Trim:

1 x INTERIOR PANEL PAIR SEiW ZK-V (not shown)
1 x COV SEATBACKFINISH V SEiW/8/ZK (not shown)
1 x CARPET SET-MT75/SEIGHT (not shown)
12 x VELCRO HOOK 25MM BLACK S/A
12 x VELCRO LOOP 25MM BLACK S/A
1 x UNDER SCUTTLE PAD-VINYL (PAIR)
1 x KICK STRAP-PAIR-W.BDY ZK-VINYL
1 x NOSE GRILL EXPANDED METAL EPX
1 x CRASH PAD COVERED-V-ZK SEiW V 8

Body:
1 x ROLLBAR W.FIELD - PLATE EPX
1 x GRP-DASHBOARD-MAZDA SDV RHD
2 x SEAT-SPORT-VINYL-ADJUST

Fastenings:

1m x 7MM TUBE-SPLIT/CONVULUTED
1m x 11MM TUBE-SLIT/CONVULUTED
1m x 17MM TUBE-SPLIT/CONVULUTED 0-33
22 x BRAKE PIPE CLIP
22 x P CLIP 5MM
2 x BONNET FASTENER CLIP BFC1
2 x BONNET FASTENER CATCH BFC1
2 x PIN-BONNET LOCATION
1 x FASTNER KIT-SDV COMPLETION KIT
1 x SVA PLASTIC COVER KIT
2 x M14 1.5 HEX LOCK PL&PASS NUT (not shown)

Windscreen:

1 x WINDSCREEN BLACK HEATED (not shown)
2 x MIRROR BLACK LH/RH
1 x MIRROR-INTERIOR E11
1 x WINDSCREEN PILLAR RH EPX BLK
1 x WINDSCREEN PILLAR LH EPX BLK
2 x WIPER ARM - XYLAN BLACK
2 x WIPER BLADE XYLAN BLACK
1 x WIPER RACK TUBE SET WIDE BODY
1.22m x 4 ID WASHER POLYTHENE TUBING
1 x JET-WINDSCREEN WASHER-BLAC
1 x WIPER EXTENSION WIRING LOOM
1 x SWITCH - HEATED WINDSCREEN
2 x WIPER WHEEL BOX WSC
1 x WINDSCREEN WPR MTR+PAD/STR KIT

Harnesses: