Its finally in etch prime! Woohoo

[damienengland]

Hey Alien

Good idea and actually that would be trick...but (and there's always a but) the throttle body has to be upstream of the bypass valve that's in the rear corner of the intake manifold and connected to the intake pipe. This would put it over the fuel rail as a minimum and that's where i'm tight for room. I've been told this valve is for bypassing the compressor rotors at low revs and it switches back over as your foot goes down and the revs rise above 1000-1500rpm. You can see the manifold hole in the pic below where the blue silicon tube is. Cheers!

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[damienengland]

Ok, the intake came back tonight all finished and powder coated with the throttle body pointing in the right direction. Happy with the results...

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[damienengland]

Ok, so i put my determined pants on today, got underneath and punched a 60mm hole in the body under the floor for the fuel fill pipe. The mock up is now ready for the professionals and i think it runs downhill ok. Will be looking to make up a one piece recessed box with hinged tail light for cap access.

Pics as usual

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[rallyvan]

Hey Damien,
Have you fitted an exhaust to the van yet? Is it exhaust getting routed between the tanks near the drive shaft or are you doing something different?

[HXsman]

Hey Damian,

How is the build coming along. Any update photo's for us ?

[damienengland]

Hey HXsman, well that bit me on the arse didn't it! Dobbed you in to update your build thread without realising that i didn't have any good progress to share...so now i'm scratching...

Ok, where do i start? So it looks like its been about 8 months since the last updates here. Work has been crazy busy...and well i guess that's a common story for many. So i jumped out into the shed and had a look today for what's happened since the last update here. Probably of note, i got a few fabricating items completed, along with most of my engine wiring installed and decided along the way to move the wiper motor behind the plenum and also move the power steer and A/C compressor off the engine (yep, going electric with these items) ...and convert my heater core to electric so i could get rid of those pesky water hoses. End result should be a super clean engine bay.

Shall we check out some pics?

Yep still here...with a new family member...might cause some controversy on this site!
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Fuel fill pipe made and fitted
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Designed a throttle cable bracket
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Had a good mate come around, re-sanded the inside and etch primed it again
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Finished 98% of the engine wiring. Its all here in these pics.
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Moved the wiper motor behind the plenum. Its a VT unit and i made up custom aluminium tube rods with rod ends.

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And a video if i can get this to work...
https://photos.app.goo.gl/RmGpP5wfcHxYrde48

[Sandaro]

Some nice custom tricks (and time consuming to get right) there Damien. Good to see the route of the filler tube, looks all downhill to the tank.

[axistr]

Gday Damian, the Holden Astra electric pump would be a good choice. Astra pumps around 2006(TRW Aluminium housing) draw bugger all power, reasonably light and compact, and pump around 1,000 psi. I use one to pressure test my racks after overhaul. I picked up mine for $60 from the local wreckers.

[damienengland]

Thanks Guys. Yeah Sandaro, the fuel fill pipe does head downwards all the way, but only just as it runs along the rail. Axistr, yep that's exactly what i did, got a 2006 Astra pump and gonna insert it under the drivers side inner guard near the front.

Cheers

[damienengland]

Ok, so the Covid situation has me working from home like a lot of people and i thought it would be a good chance to get some more progress on this thing...silly me, work is even busier now than ever! Anyway, didn't stop me from daydreaming during the week on the next steps. Hit the shed this weekend and had some console fun. I wanted to lock in how everything is going to fit under and inside the console (EFI computer, MAP sensor, ignition module) before i start cutting and shutting wires into the computer and getting 12 volts up and about. Decided a plan in my head and had a crack. Happy with the results and that everything fits together with a bit of room to spare. Pics as always...

Console with computer, MAP sensor and ignition module mounted inside it (not on the tunnel like i previously thought)
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Hmm, but that means the console lid with cassette holder wont fit back on. What to do?
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Well i haven't owned a cassette for years, so maybe we can just get rid of the holder and do something else
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Reckon i can use the cassette hole for some switches. (left to right - seat heater, map light, antenna, fog/spot lights, rear demister, seat heater)
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Fits nicely together again. Now i just need a bit of laser cutting for a new switch plate
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Front view. Now i can cut and shut wiring...
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