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teamilluminata
teamilluminata HalfDork
1/7/21 7:42 a.m.

Storage Unit Rally Car Build - Week 13: Axels & Heater Lines

AXLES

One day we are going to find a new building and will have to push this thing back out and into the trailer. With the axles out the wheel bearings flop about so we didn’t want to struggle with it again like we did, pushing it in. We decided now was a good time to reinstall the axles, even though we haven’t refurbished them yet.



Don’t worry, we cleaned them up a bit. We’re not peasants.

When we dug them out of hiding it soon became apparent that there were two long ones and two shorter ones. But where did they go, front and rear, left and right, where? It turns out, opposite corners!



We’re sure there’s a good reason but just for giggles we did try to install one in the wrong place, just because, well, we’re idiots to be honest. It was too long.



HEATER PIPES

The 45* bends we were waiting for from Pegasus Racing came in so we got to finish heater pipe installation.



We’ve also located a brand new double grommet for the bulkhead!



teamilluminata
teamilluminata HalfDork
1/14/21 8:22 a.m.

Week 14 of the Storage Unit Rally Car Build

IACV (Idle Air Control Valve)

Yep, we’re now struggling to find things we can install while working in the storage unit. Picking at straws so to speak. Next on our list is therefore the idle air control valve. IACV. If you don’t already know, this ECU controlled valve bypasses the throttle at idle to allow it to, well, idle. Of course, with our fancy aftermarket intake manifold it won’t just bolt back in place. There is a connector for it at the back of the manifold be we’ll still have to tee into the intake tract before the throttle at some place. Here’s the valve with its rubber mounting ring and the nifty bracket that it sits on.





It is quite heavy so we think we should try to mount it using the OE bracket if possible. The inlet to the manifold is towards the back directly underneath, but whatever the IACV mounted off before is no longer apparent. So, we contrived a bracket extension off the engine mount arm as there were already three threaded holes in that. Engage CAD design mode.





We’re not really setup to make this in our storage unit so we’ll either make it later or outsource it. The inlet is a straight-ish shot to the back of the intercooler end tank but we’ll need to weld a bung on for it so, job stopped!

SEALS

Our searching through various boxes for various parts revealed the window and aperture seals so we decided to take inventory and install some because, well, we’re running out of things we can do and we have to keep moving forward somehow.

Door seals



Windshield seal



Under hood cowl seal





Trunk seal



The rest of the window seals are already on the respective windows hidden away, somewhere. These pieces seem to be still in good shape and were surprisingly satisfying to install.

teamilluminata
teamilluminata HalfDork
1/21/21 8:26 a.m.

Storage Unit Rally Build - Week 15 (Quick Update)

I'm back to working on the fan mount. You may remember that our beautiful afterthought of a fan shroud would not allow us to fit the actual fan as it interfered with the frame rails because we didn’t think it through. So, we ordered up six of these fan mounting brackets and went to town.





The fan is quite weighty so we thought some vertical hanging type mount would be a good idea. We cobbled one together.



That’s better.



Fits too!



teamilluminata
teamilluminata HalfDork
2/4/21 9:08 a.m.

Week 16 of the Storage Unit Rally Build

It's been cold so we felt inspired to hook up the heater controls. This week we learned all about “Bowden Cables”! These clips are hard to find new but we found some.



And dug out the rest of the system.





The control sliders went in easily but hooking up the cables and clamps was a bit fiddly. Surprisingly satisfying once done though.











Now we just have to figure out how to direct the air from the heater box to various body parts and bits of glass.

teamilluminata
teamilluminata HalfDork
2/18/21 10:42 a.m.

Week 17 of the Storage Unit Rally Build: A Sharp Intake of Breath

We’ve been back and forth on what to do about an intake system for the car for ages. We’d like to have our cake and eat it too but we just can’t see a way to get there. This is what we’d like to have:

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As used on the works rally cars. It looks iconic and sucks air from the high pressure cowl area where, conveniently, there are louvers in the hood above for that very purpose. There are a few problems with this. Firstly we have a MAF sensor to incorporate in the intake track, ideally in the stock location as we have an aftermarket U shaped intake tube that houses connections for all kinds of other bits and pieces that we need. This really doesn’t mate up to that.

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Secondly, if we did this it really would have to be made of carbon Kevlar to pass muster and making one from scratch would be very expensive and time consuming. You can, in theory, buy one but we’ve heard it’s of dubious quality and it still wouldn’t mate to our MAF sensor.

We tried prototyping an alternative route to the cowl that goes down the bulkhead to an existing 3” hole before doing a 180 into the passenger compartment and back up through another existing hole in the cowl. We think we could terminate this into an oval shaped pancake filter with a lid. It would probably work and we think we could make it look half decent but our fear is that it would just look like a poor substitute for the original.

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We could just whack a bloody great cone filter on the end of the MAF sensor and declare “job done” but there are a few problems with that too. It would be sucking air from right next to the turbo and also be right under the hood louver that lets hot air out of the engine bay and, not great, water in. So we dismissed this too. Here it is mocked up with a small filter.

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We looked at modifying some OE intake boxes but they don’t seem to be suitable either.

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So we’ve settled. Settled on another U bend with a cone filter behind the headlight. This is not under the louver so should stay dry and it gets a good cold air feed from the grill and light surround. We also think we can shield it from the engine bay quite easily and, although it is a bit rigged it will hardly be visible so it doesn’t matter if it looks it.

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If nothing else it will do to get the car running. Maybe we will revisit this later, or not.

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