KVA / SGT build

Udo

GT40s Supporter
Welding of the gearbox mounts done, bracket for bowden wire installed (1st pic.). After rear clip re-assembly a fowling of clip and air filters, mounted on the left valve cover, became obvious - I will try to exchange covers against standard ones, since a oil catch tank is available in the workshop anyway :nice:. Nevertheless, the eightstack is looking nicely trough the rear clip, as desired!

Next was the installation of the fuel pressure regulator, pic. 3. The return line to the fuel catch tank across the engine bay will be hose number 4, almost no space left any more, but also no plans to add another one ...

The water pump pulley is located partly in the vehicle interior, so a dent is required in the rear bulkhead. Last two pictures show fitting work, and the final cover before welding. I saw similar staff in Spa over the last years, so quite satisfied with the design :laugh:

More to follow, and a happy new year to all readers,

Udo
 

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Welding of the gearbox mounts done, bracket for bowden wire installed (1st pic.). After rear clip re-assembly a fowling of clip and air filters, mounted on the left valve cover, became obvious - I will try to exchange covers against standard ones, since a oil catch tank is available in the workshop anyway :nice:. Nevertheless, the eightstack is looking nicely trough the rear clip, as desired!

Next was the installation of the fuel pressure regulator, pic. 3. The return line to the fuel catch tank across the engine bay will be hose number 4, almost no space left any more, but also no plans to add another one ...

The water pump pulley is located partly in the vehicle interior, so a dent is required in the rear bulkhead. Last two pictures show fitting work, and the final cover before welding. I saw similar staff in Spa over the last years, so quite satisfied with the design :laugh:

More to follow, and a happy new year to all readers,

Udo
Hi Udo,

Really appreciate the info you sent. Just wondering if your gearbox gear selector shaft replacement was done using a knock in pin or did the original in your box have the friction welded option. If the latter, how did you go about separating it from your shaft. ?

I’m doing the same on an 01x. Very pleased with the GT Racing parts I received. Just a question of getting the selector component off that original hardened shaft.

I’ve access to a large lathe so I know I can bore out the 5mm of the old shaft that is now surplus to requirements if I have to.

Best.

Nick D.
 

Udo

GT40s Supporter
Hi Nick,

luckily my shifter has the knock in pin option, so I got around to remove the friction weld. It sounds like some heavy machine work. And I didn't found the original selector shaft as spare parts either so far. Good luck,

Udo
 

Udo

GT40s Supporter
Wheels came yesterday, got assembled and "short term stored" (optimistic approach) close to the car. Gearbox brackets are back from paint and got boltet to frame and 01E.

Unluckily, I forgot to install the hose from fuel pressure regulator to catch tank before the engine was mounted, so I needed to work under the car for installation (for some reason, I only can upload one single picture, but try to manage with another post later, so my four hose arrangement will become public). Catch tank shows really maximum number of fuel lines now ...

Finally, I attached the alternator to the engine, no collision here. I now can work on the water pipes, as soon as rotateable water inlet gets delivered - the current one almost fouls with the frame :furious:

More to follow,

Udo
 

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Udo

GT40s Supporter
My first approach with the rear bulkhead bulge was not that successfull, since simply too small to cover the water pump pulley. Second build took only a fraction of first time consumption, and can be welded now (fig. 1). Decided afterwards to install some further hardware from Mick. Gearbox crossmember got assembled without issues (no fouling to my 01E), but rear stabiliser showed massive collision to my self build aluminium wheel arches (fig. 2). After fitment, overall vehicle weight could be reduced a lot :shy:.

I was also curious about fitment of the wheels, especially the rear 295 R15 50, and got no surprise, because rear clip couldn't be opened with installed wheels. Some shortening of the rear clip (fig. 3 shows an intermediate approach only), and the issue was solved. Clip needs some finish, but I want to wait until I can work outside in spring ...

More to follow,

Udo
 

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Udo

GT40s Supporter
Bulkhead came back from welding, a bit distorted, but after some rework, it now fits perfectly, without collisions. After some polishing, it's really an optical brightener ..

The 360 degree rotatable water inlet was next topic. Changed the original straight nozzle for the water expansion tank against a 90 degree one to avoid excessive bending of the hose. One bolt is nicely located behind the water pump, which required adapted tools :thumbsup:. Got finally mounted, and water expansion tank is now also ready for use (I don't know why fitment of nozzles and hose is that sluggish - the hose clamps seems simply not being required at all :huh:.

Last thing yesterday was the first rough adjustment of suspension geometry, which meant wheels on, taking measurements, wheels off, adjustments, wheels on, ... . At the end, it should be good enough to survive the first careful ride once the car is running (at an undefined point in time in the future).

More to follow,

Udo
 

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Dave Bilyk

Dave Bilyk
Hi Udo, great work
I hope that your bulkhead mod does leave enough clearance for engine movement under acceleration and braking, and any loads you might transmit through the seat back.
I know I am late with that comment, but I hadn't seen until now. :)
My car has a fibreglass bulkhead, so when I leaned back in the seat, it sometimes caused a rub.

Dave
 

Udo

GT40s Supporter
Hi Nick, isn‘t this quite old-fashioned school english? Try to post funny wording in the future
 

Udo

GT40s Supporter
Hi Dave, thanks for the hint, it‘s never too late. There is some clearance between pulley and aluminium, and if I look to the engine mounts (so small amount of rubber), I hope to be save. If not, I know how to build a larger bulkhead piece, for the third time
 
Hi Nick, isn‘t this quite old-fashioned school english? Try to post funny wording in the future ������
Udo, I thought it was brilliant and perfect English, I only wished I had thought of it to reply to the numerous "when is it going to be finished questions" from my neighbours over the last 10 years :)
 

Udo

GT40s Supporter
Worked on the left valve cover yesterday. For some reasons, two filters are mounted on the cover, make it impossible to close the rear clip, fig 1. Besides the option to purchase new covers, I decided to change to a setup with an oil catch tank, and replaced tubes and filters on the cover by nice looking Dash10 elbows (I hope but don‘t think that this is common speech, but anyway). Fig 2 shows the setup before welding, need to persuade my TIG welder to help out again. Plan is to connect both elbows with the catch tank later.

Fig 3 shows the engine without valve cover, quite heavy duty stuff :thumbsup:

The catch tank shows also a filter on its top, of course also fouling with the rear clip. Since I want to avoid excessive cutting to the clip, I decided to allocate the filter in a non-fouling position. This required another two Dash10 connectors, fig 4. The free length of the hose, hard to identify, is excactly 8mm, and somehow a waste of material, but looks impressive (to me).

With this modification, I was able to close the rear clip almost, but not fully. Last collision took place with the ring line of the fuel injection system. My only idea was to do what I tried to avoid before: cutting the rear clip, but this was the only option.

Rear clip is fully closed now, valve cover and oil cooler assembly are next things to come.

More to follow,

Udo
 

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Randy V

Admin
Lifetime Supporter
Two breathers on the left side cover = Circle-track/stock car left side cover.
Right side generally has no breather on those engines.
 

Udo

GT40s Supporter
Left valve cover got ready during the week, with Dash10 adapters welded to it. I found a new welder, who did a really good job, fig 1 (aluminium welding is not part of my skill set). Oil catch tank is located very close to the cover adapters, and a direct connection looked not recommendable, since the steel jacketed hose is quite stiff. Therefore, I decided to arrange the connection in a loop, fig 2. A lot of dash fittings, but I like this stuff a lot, and left side of my engine bay showed less hoses compared to the right side anyway, so this is good for a „balanced“ situation. Since I am still waiting for the delivery of the oil filter adapter plate, getting connected to the oil cooler, I just could assemble the cooler fittings (fig 3), and found surprisingly no further collision :thumbsup:

That‘s all for this part of the construction area for now, but also the water cycle was still not closed. The stainless elbows got weld marks on their ends to avoild that the silicone hoses slip off, and the final setup is shown in fig 4 (the line is nicely running around the alternator, I just need to install a clamp to fix the hoses to the body to guarantee a save fit).

Things to do for next week ...

More to follow,

Udo
 

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Udo

GT40s Supporter
Clamp to avoid water inlet pipe collision with the alternator got assembled, so inlet part of water circulation is done, fig 1. To fully close it, I just needed to mount a 90 degree elbow for the outlet, fig 2. Sounds all easy, but like almost, small unpredictable things showed up here and there ...

As I already worked on liquid circles, and since the oil thermostat arrived last week, the oil cooling was the logical next thing to do. My engine builder strongly warned me about too low oil temperature, so I replaced the standard oil thermometer by a version working at 95/110 Celsius, fig 3. Bolted to the engine, I fould exactly one position which allows to exchange the oil filter, but one position is all I was looking for. Finally, the hoses were attached between oil cooler and thermostat - I like Dash 10 fittings a lot :cheesy:.

More to follow,

Udo
 

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