More Progress – Getting there!

Like everyone else, I’m hampered with work and the weather (it’s winter here in Australia) getting in the way so I apologise for the slow progress.
I was hoping to start on the wiring today, but I broke my pin extractor tool I use for removing/fitting the crimp pins on the DB37 cables as supplied by DIY AutoTune. I was using this tool to remove redundant cables so as to make the wiring loom smaller and also so I don’t have to hide them. If I were to require the wire again, it’s an easy job to just re-insert it back into the loom and appropriate connector (MS3 or MS3X). I’ve ordered 2, 1 for a spare, hopefully be here soon.
Otherwise I have managed the following in the last few days or so.

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  • Remove existing MegaSquirt relay board, and existing wiring for EFI sensors.
    Day 1  – done.
  • Fit EFI fuel filter under the car and connect hoses.
    Day 1 – done.
    Day 2 – removed and painted the filter housing as it was crappy.
    Day 4 – refitted all done.
  • Remove standard engine driven fuel pump and fit blanking plate
  • Fit new 30PSI fuel pressure sensor (for PWM control of fuel pressure).
    Day 3 – sort of done.
    Day 6 – fitted barbs and 30PSI sensor using Loctite 567 Thread Sealant.

    30PSI Fuel Pressure Sender
    30PSI Fuel Pressure Sender
  • Fit new injector to throttle body.
    Day 1 – done.
    Day 2 – removed it to make sure bottom ‘O’ ring was sealing, had problems with this in the past causing erratic fuelling as it was dribbling all the time. I’ll perform a leak test when I get fuel pressure up.
  • Fit new solid state relays (SSR) for PWM control of injection fuel pump and radiator electric fan
  • Clean and paint corner of bulkhead where brake fluid has removed paint and caused surface rust.
    Day 2 – have obtained correct ‘Indigo’ blue paint in a can.
    Day 5 – removed Brake master cylinder so as to gain access to damaged paint. Wire wheeled and sanded area and treated it to rust converter.
    Day 6 – seam sealed, primed, sanded and top coated with Indigo blue acrylic paint. Done.

    Before repair and paint.
    Before repair and paint.
    Notice original colour of car ‘Shadow Blue’ not ‘Indigo Blue’.
    Needs seam sealant

    Rust converted, seam sealed and painted
    Rust converted, seam sealed and painted
  • Finish fitting new Bluetooth radio.
    Day 1 – done.
    Day 2 – played many tunes on it today!
  • Fit new relay and fuse block,
    Day 6 – will locate fuse/relay block over the black plate in above picture using alloy spacers so as to allow access for wiring loom. I will also be getting rid of the original 2 fuse (30A each!) block and using indivual circuit fuses along with relays for some of the high current items e.g. lights etc.
    Wiring loom will come through firewall near black  plate using 1 or 2 cable glands. I’m not sure yet on number, my thoughts being to separate high current/noisy wires from the low current and analogue signals. Will it make any difference?
  • Wire new EFI harnesses to relay/fuse blocks and to sensors
  • Fit MS to bottom of dash rail using nut inserts (more secure).
    Day 6 – have looked into this,  and will use 3 4mm allen cap head screws into 3 4mm nut inserts into dash panel tray on right side of car. Can only fit 3 fastners, as there is a great big hole where the right one would go, plus the screw head is partly obscured by the DB37 connectors.
  • Test and set-up PWM for both fuel pump and radiator fan control
  • Need to adjust tappets, as I have re-torqued the cylinder head.
  • Fit new windscreen washer bag to hang under the R/H fender and connect it up
  • Relocate power brake booster backwards by ~ 2″ to allow for a cold air/filter box to feed the MAF sensor that will be fitted at a later date.
    Day 2 – removed, waiting for me to make new 3/16″ pipes and new brackets.
    Day 5 – not happy with the VH44 brake booster, so have ordered a MK3 Cooper ‘S’ booster, should be here by the end of the week.
    Day 6 – booster has arrived along with new brake master cylinder.

    MK3 Cooper 's' Lockheed Brake Servo
    New MK3 Cooper ‘s’ Lockheed Brake Servo
  • Replace the Cooper ‘S’ discs and pads.
    Day 4 – removed discs and ultrasonic cleaned callipers.
  • Replace with new and paint both L/H & R/H top suspension arms.
    Day 1 – 1 done.
    Day 2 – done.
  • Replace rear competition bump stops with standard bump stops.
    Day 1 – done
  • Check rear wheel brake cylinders for leaks and also that they are 5/8″ bore.
    Day 1 – found one cylinder seized, replaced both sides, as well as brake shoe springs and adjusters.
  • Fit new brake hoses.
    Day 1 – 1/2 done.
    Day 5 – removed R/H/F hose… what a PITA that was… Hamish swore at me and said I should get an American car as they are easier to work on!
  • Fit the new heater.
    Day 2 – bench tested to make sure it works… it does
  • Fit the new boot brackets and make a boot board to fit on top of these brackets.
    Day 2 – bought marine ply and carpet to make it. Also trial fitted brackets.
    Day 4 – brackets painted car colour (indigo) and made cardboard pattern of required boot board size and transferred this to 12mm ply and cut-out with jigsaw. Fits like a finger up a b**.
  • Get wheel balance and alignment
  • Day 2 – fitted new roof mount aerial… what a PITA! Done
  • Day 2 – continued to feed my ultrasonic cleaner various greasy/dirty bits… ongoing
  • Day 4 – fitted new black accelerator cable, so as to get rid of crappy yellow one
  • Day 4 – I couldn’t sell the NGK spark plug leads so I obtained some genuine NGK 90 degree plug ends and fitted them  to the shortened NGK leads. Looks a lot better as leads are closer to engine.
    Day 5 – obtained new BPR6ES NGK plugs and fitted them.

    Audi NGK leads with R/A NGK plug ends
    Audi NGK leads with R/A NGK plug ends
  • Day 5 – discovered that brake master cylinder was a little weepy, they cost so little, so I ordered a new one instead of fitting a kit.
    Day 6 – fitted new brake master cylinder. Need to do the pivot pin and its split pin though!
  • New Brake Master Cylinder
    New Brake Master Cylinder
  • Day 6 – painted one of the front disk callipers a nice bright red… I used old pistons, top seals, inlet pipe and a set bolt to fill/cover all important openings from the paint.
    Lockheed Cooper 's' brake calliper
    Lockheed Cooper ‘s’ brake calliper


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