KVA / SGT build

#1
For almost 18 month, I am working on my mixed KVA (panels) and SGT (chassis) MKI project, feeding a blog in German so far. Since still people are reading my stuff, I decided to also let the world know what I am doing in my spare time.
It all starts with really bad panels, that I bought for a low price, and with frame and aluminium panels from SGT. The first two pictures give an impression about my early work with fibre blankets and filler. The pictures show how "perfect" the panels fitted.

But that's all past, in the meantime, progress has been made, and my last results look more promising. Fans are mounted to the radiator, and the Ford 347 engine with eightstack injection has been delivered also.

For those who are interested in more insights about the past month, here's the german blog: Udo's GT40 build log.

More to follow ...
 

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Randy V

Administrator
#2
Nice to see another build log here!
I’ve looked over your build log site and found a great deal of work being done!
One thing I would encourage you to do would be to install door gaskets and place windshield in the spider before you finalize your bodywork.
Your body is not much at all different from the body I had. It took a lot of work to make it all come together the way I wanted it to...
Carry on sir!
 
#3
For my fuel system, I decided to use a catch tank and aluminium fittings and related racing steel hoses. Most of the hoses were already installed during the last months, and the final one from catch tank to fuel pump was completed yesterday. I hope that I did all fittings well sealed - the future will show.

Having completed this, more electrical wiring and the installation of the frog eye plate lights were next things to do.

Final achievements (besides ongoing laminating of wheel houses in the rear clip (the KVA panels came without wheel houses) were the mounting of my rear mesh grills.

Plan for next week is the installation of the two fuel pumps between sill tanks and catch tank, and a bit more of endless wiring work ...

More to follow ...
 

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#4
Missing hardware for the two primary fuel pumps arrived, and I installed them as low as possible in the car. Too bad that all this is not visible once the car is ready :uneasy:.

My help for the electrical installation had a good day yesterday, a lot wiring got completed. The switches in the cockpit are now connected, and a first trail showes that everything works as desired. Great stuff :thumbsup:.

Also the seats arrived last week, and I was eager to mount them into the vehicle. In opposite to Micks advise, I am not very optimistic to directly mount them to the aluminium floor. Therefore, two "crossmembers" have been welded, and I attached them to the steel frame - this feels a lot better now. With the seats mounted into the vehicle, the convenience level entering the car got reduced another time - luckily, the steering wheel got a quick release, which will make me not locking too bad while entering the car.

More to follow ...
 

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#5
Hi Udo I see why you wanted to fit crossmembers and not just bolt the seats to the floor as the SGT seats are completely flat on the base which spreads the load your aftermarket seats would want the ribs across to make them safe and have you decided how the seat belts will be compatible with the seats .
Regards mick.
 
#6
Hi Mick, yes, in opposite to your seats, my require a spacer between seat and seat mounts, so I have a pretty local stress distribution, that makes x-members almost a "must". I already mounted the seats to the x-members, and all fits nicely, so far ...
 
#7
The installation of the left seat was on the agenda today. I mounted the Holley control unit without seats on hand, and now, with delivered seats, I needed to re-mount the box. At the end, all worked well, and also the seat crossmembers were in place.

Next was the installation of hoses between fuel tanks and primary fuel pumps. Latter show a 15mm diameter, while fuel tank out diameter outlet is D6 / 12mm. Fuel tank outlet is done with a 180 degree fitting, nice looking, but invisible during use - too bad :furious:

Final for today was some more wiring, the thermostat for the radiator has been delivered, and got connected, same as fans and horn. Electrical installation may be finished as X-mas gift ...

More to follow,

Udo
 

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Paul Hendrickx

Silver Supporter
#8
Hello,
Nice job overall, but one little thing, which I find not good. (Sorry my English is limited!)
The switch for the cooling fans in the radiator.
In my previous car (Alpine 310 v6) I had the same set-up.... engine in the back switch in the front, and in heavy traffic engine was overheating, because the liquid coming out of the engine was hotter than when it reaches the radiator and the fans came actually late in action.
I put a fan switch nearby the engine at that time, and the fans coming on faster and no overheating anymore in heavy town traffic.
When I going to start my rebuild on my mk3 in March 2018, I will do exactly the same.
But really congratulations, your building standards are high!

Paul
 
#9
Hi Paul, thanks for the recommendation. To overcome critical heating, I foresee a switch in the dashboard, so I can overrule the thermostate. Anyhow, I will check your alternative setup during the next days in the workshop. Regards, Udo
 
#10
Hi Udo,
Nice to see a Mk111 coming back to life
Looking at the photo of your radiator, it needs to be rubber mounted, otherwise as the frame flexes it will twist the radiator and eventually lead to failure.
Keep up the good work
Regards,
Andy
 
#11
Hi Andy,

thanks for the hint. In fact, I used in total eight rubber-metal blocks to mount the radiator to the frame. To me, this sounds like strenght (eight!) and low vibration (rubber) at the same time. Your thoughts?
Best regards,
Udo
 
#14
Besides some further work on the wiring harness, i decided to mount the gear lever into the car. As well known, it is tight in the car, so I needed some iterations to find a suitable position for the lever, avoiding collisions to dashboard, steering wheel and body. Since an Audi 01E gearbox will be installed, it seemed the easiest way to gear shift via bowden wire. The future will show if that's the right choice. The attached pictures show the shifter unmounted and installed in the car, and I'm not sure if I will install a cover for the bowden wires (once their lenght has been determined and they got delivered) ...

While I was working on the the gear lever, it was a good time to have a deeper look to the conversion kit between Ford engine and Audi gearbox. All parts, as expected, needed some modifications to make them fit, and I am currently not sure if the starter motor will make it without collisions, but will know more next week.

More to follow,

Udo
 

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#15
Today was a quite productive one. First, new wiring for the connection from fuel tanks to primary fuel pumps installed, and assembled into the vehicle. Fuel filters were attached to the fuel pumps to avoid noises and waer with cable retainers and rubber mat.

Majority of the build day was about installing the engine to the Audi gear box. The adaptor kit worked half way, some modifications required (engine starter bolts with collision to gear box, missing holes in adaptor plate), but after some rework, everything fitted together nicely. Reinforced clutch was easy to assemble, and finally the gearbox made it to the engine. Also, the bowden wire attachment to the gearbox got installed, good stuff, all works perfect, at least at this stage.

Christmas is close, my wish to install the engine soon may become truth ...

More to follow,

Udo
 

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Markus

Lifetime Premier Supporter
#16
Hi Udo,

Do you have access to the starter bolts when the gear box is installed (can't see on the last pic) - would be big PITA when starter is broke and for exchange you need to remove the gear box first.......

Markus


Today was a quite productive one. First, new wiring for the connection from fuel tanks to primary fuel pumps installed, and assembled into the vehicle. Fuel filters were attached to the fuel pumps to avoid noises and waer with cable retainers and rubber mat.

Majority of the build day was about installing the engine to the Audi gear box. The adaptor kit worked half way, some modifications required (engine starter bolts with collision to gear box, missing holes in adaptor plate), but after some rework, everything fitted together nicely. Reinforced clutch was easy to assemble, and finally the gearbox made it to the engine. Also, the bowden wire attachment to the gearbox got installed, good stuff, all works perfect, at least at this stage.

Christmas is close, my wish to install the engine soon may become truth ...

More to follow,

Udo
 
#17
Hi Markus, yes, that's the risk, but a trial with the starter yesterday showed that this relatively small unit (my beetle starter has larger dimensions) at least is able to turn the engine, so there is hope for the future ...

Udo
 
#18
Hi,

Just noticed you have chosen the GT Racing (side reversal of gear change position) for your gearbox.

I have already purchased the same and will be fitting to my 01x.

Do you have any further info on how the procedure went and any pictures of how you have mounted the cable assembly.

It would help enormously

You can send directly to [email protected]

Many Thanks.


Nick D.
 
#20
Great days: engine got mounted into the vehicle, what took only a few minutes. But: adaptions required some more! First picture shows engine mounted, but clearance from 01E to my frame was not sufficient (frame is build for UN1 or ZF). So, the left gearbox cap shows collision to the frame, and got modified accordingly, 2nd picture, with two counter sunk bolts, but not enough, also cap ribs needed to be removed (3rd pic) - just to let SGT / 01E builders know that rework is required :thumbsup:

As engine has been mounted, also thr 01E needs brackets, which I build from steel tubes, flat steel and angled profiles. Left and right side shows different conditions, therefore also the brackets look differently.

Welding is next ...

More to follow,

Udo
 

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