Engine Wiring ... Throttle Linkage issues?

Sat/Sun 20th/21st February 2010 - Work time = 8hrs ... Build Time To Date = 110hrs

Another 8 hours spent, not a great deal to show for it but lots of little things ticked off the "to do" list.  Started off by making up a template for the cut out for the exhaust through the side body panel.  Lot's of cutting and gaffer tape!

Next job ... wired up the starter motor to the engine loom and live feed from the battery and the RPM sensor wich is near the starter.  I managed to route the battery live feed cable along the lower chassis rail ... with more things in/on the car now it's difficult to get access to drill holes for things like the cable tie saddles ... had to resort to snapping a drill in half to shorten the length so I could get the drill in!

I then fitted the screen washer bottle ... more rework required as the wire to the pump wasn't long enough... I needed to undo some of the cabling which I had so neatly cable tied and covered in tubing ... no wonder al this is taking so long!

With the near side engine wiring now complete I moved to the other side to connect up the injectors, alternator, air temp, coolant temp and oil pressure sensors.  I had a few issues with all this:

1. Once I'd connected the No2 Injector it was fouling the throttle linkage ... hmmm something not right here ... I think the throttle linkage is in the wrong place ... needs a call to Westfield 

2. The Coolant Temp sensor wire is nowhere near long enough to reach the sensor at the front of the engine above the alternator ... another call to Westfield

3. The connection on the oil pressure sensor doesn't match the wiring loom connector nor the pictures in the manual ... yet another call to Westfield to check.

I'm sure some of this is going to need to get moved but here's some pictures cos the throttle bodies just look soooo cooool ! :-)

Stop press !!!   Collecting the body, seats and carpets etc on March 6th ... better start being nice to Sandra as I might need to store some bits in the lounge !!!

Battery & Radiator installation

Sat/Sun 13th/14th February 2010 - Work time = 8hrs ... Build Time To Date = 102hrs
With the engine back in I could start to connect up all the wiring and cooling system.  First task ... install the battery.  I had seen various other Westfields with the battery stuck on the scuttle and some with it low down at the front just behind the steering rack.  I opted for the latter.  This required a sheet to be fabricated to mount on the two chassis rails either side of the steering rack.  I have a small sheet of aluminium in the garage from the Cobra so this was duy cut to size.  Along with the battery tray I painted it hammerite black and then spray painted satin black.
Here's the finished installation ... nice and neat I must say !

Next step to assemble the radiator and fit it.  I checked the radiator and it had a bleed outlet at the top that wasn't mentioned in the manual.  There were no small hoses shown going to the radiator so I blanked this off with an M6 bolt.  This would have been a tricky thing to rectify later on when the body work was on and I was wondering why there was engne coolant everywhere!  The rest of the install should have been a straightforward job but all the M6 bolts I had left to fit were too long so I had to hacksaw a few to shorten them.  Also when I fitted the radiator the bottom hose seemed very close to the chassis upright and was getting compresssed ... a few gentle blows with the mallet moved the mounts across a 2-3mm so there was a bit more clearance.  I fitted the horn next and tidied up the wiring to the horn, fan temp sensor and the fan.  Here it is all fitted.

I then trial fitted the exhaust manifold.  I needed to turn the oil dipstick tube and reshape the mounting bracket as in its standard position it fouled the first exhaust port. With the manifold in position I can see that I will need to be very neat with the starter motor wiring.  I can also fit the windscreen washer bottle and mark out a cardboard cutting template for the exhaust hole in the bodywork. 

I ordered the bodywork and vinyl earlier in the week ... collection date early March.  Confirmed the colour Orange and Black, with a few upgrades ! (3" harnesses, sports turbo seats and an RAC Rollbar).

Engine back in ... this time it fits!

Saturday 6th February 2010 - Work time = 3hrs ... Build Time To Date = 94hrs

With Andy's help (and Rob as well !) we set about the engine installation for the second time.  With the newly drilled and fitted gearbox mounting and the rerouted wiring loom it went in a dream!

I also filled the gearbox with oil ... still a two person job but much easier with the hole in the passenger side bulkhead.

Wiring Loom re-routing ... part 2 & Radiator Prep

Saturday 16th January 2010 - Work time = 3hrs ... Build Time To Date = 91hrs

Managed to finish off the wiring loom rerouting today. 

Now ready for the engine re-installation ... scheduled for Saturday 6th when Andy comes back.

In the meantime I painted the radiator fan shroud and brackets with hammerite and then sprayed them satin black .. figured they would look better than the bare metal finish.  Here they are before the spray coat.