Terry's tale. (S3 resto ++)

Terry's tale. (S3 resto ++)

Author
Discussion

Alan Whitaker

1,928 posts

117 months

Tuesday 6th December 2016
quotequote all
Mick, Did you have a Blue Peter badge when you were young, Have you forgot the rear light lens?

magpies

3,766 posts

117 months

Tuesday 6th December 2016
quotequote all
Alan Whitaker said:
Mick, Did you have a Blue Peter badge when you were young, Have you forgot the rear light lens?
yes forgotten (reminder required - no matter how embarrassing}

Blue 30

Original Poster:

244 posts

52 months

Tuesday 6th December 2016
quotequote all
Excuse me !
Kitchen roll tubes if you don't mind. smile
TerryB

No, I missed that stage out, & went straight to B&Q to buy plastic waste pipe & bends.

Offside (bad pic)


Nearside

Blue 30

Original Poster:

244 posts

52 months

Tuesday 6th December 2016
quotequote all
After all, it is a plastic car, so why shouldn't it have plastic exhausts ?
TerryB

The nearside plastic in situ.


I didn't take a photo of the offside plastic in situ.
But here is the real thing.


And the offside in situ.

Blue 30

Original Poster:

244 posts

52 months

Wednesday 7th December 2016
quotequote all
So other than fitting a new gasket & bolting it down, that's the offside in place. That's including the next pipe section that takes it horizontal & towards mating up with the original long centre silencer.
However the nearside has been another story. My plastic mockups only have a 5mm flange thickness, & the pipes are about 5mm in diameter narrower than the steel pipe.
On the offside this wasn't a problem, but on the nearside it was. I have now returned the 'tweeked' NS manifold for the 3rd time. Don't get me wrong, it hasn't been anyone's fault that it didn't quite fit. Its just that it does really need to hug the contour of the engine, so that it has maximum space away from the chassis (for engine rock).
In theory all I'm waiting for now, is for it to be seam welded up.

Once they're both on for good, I am not going to complete the exhaust system just yet. As I can boltup the engine & g-box mounts for good, & then get a custom propshaft made up.
Plus I can cut the Jaguar gearshift linkage down to suit its new location. Maybe then, I can sit in the car and pretend to be driving it !!
I can also get on and do the fabricating of the alternator, pas pump, & belt tensioner brackets.

This is where I'm at today (7/12/16), waiting on the NS manifold. So my messages to the thread will now slow down somewhat.
And I am not thinking forward of the jobs as listed above.
Although there's loads to do....
Cooling system
Tank, fuel system, & TB
Ecu & electrics
Interior work
Fit new hood I already have
Conclude brakes
Conclude Pas
Bonnet hinge mod
Boot release cable
Sort out slow ns door glass op.
Get steering/suspension setup/aligned
++++++
TerryB

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Alan Whitaker

1,928 posts

117 months

Wednesday 7th December 2016
quotequote all
So should be done for Xmas then
xmas

Blue 30

Original Poster:

244 posts

52 months

Wednesday 7th December 2016
quotequote all
Yup !
Not forgetting my ongoing Panther jobs, getting the stripped 2.8 heads back on after they've been converted to unleaded.
Getting the body panels over to the blasters ready for its respray ++++
Blooming good job I'm not working anymore smile
TerryB

Blue 30

Original Poster:

244 posts

52 months

Monday 12th December 2016
quotequote all
The nearside manifold is back from the fabricators, and what's more it fits (trial fit only). So I can get both exhaust/head faces cleaned & readied for final fitting.
They both might even be in place (for good) including bolting down the engine and g-box mounts, before the new year!

Photo of the ns manifold in situ (its not as close to the chassis as it looks).
TerryB



Oh, I didn't mention that the exhaust fabricators I used are... Custom Chrome of Nuneaton. Who will also be doing the fabs for the next sections of exhaust. Plus a custom system (my design again) for my 2.8 panther.


glenrobbo

12,014 posts

85 months

Monday 12th December 2016
quotequote all
Beautiful work Terry bow

DamianS3

1,712 posts

117 months

Monday 12th December 2016
quotequote all
Hello Terry

I think I shared these with you.. if not apologies, but some pics of my manifolds with engine out of the car for the benefit of others..

We should write a how to guide lols..





As was previously mentioned these need to hug the engine to fit in, especially with my standard chassis. Also IIRC these mate up to the standard exhaust where the J tubes previously ended.

Thanks

Damian S3 Duratec

phillpot

14,410 posts

118 months

Monday 12th December 2016
quotequote all
Am I the only one with "the little boy in me" saying go on, fire it up with the plastic manfolds on wink


Blue 30

Original Poster:

244 posts

52 months

Monday 12th December 2016
quotequote all
Agreed Damian...
It just shows that the same thing can be done differently but achieve a successful result.
On Damian's phono of the nearside, the new engine mount can be seen (towards the front of the engine) which means it needs something to attach to on the chassis. That's where mine is totally different, that I need that engine space for one of the belt driven ancillaries (probably the alternator). So my engine mount is much further back & attaches to the original 2.9 chassis mount. Which in turn means that the exhaust manifold is a different design too, as is my os manifold.
But all should make note of our joint words, & common fact that it IS essential that both manifolds closely follow the contour of the engine if you want them to exit rearwards.

As Confucious says, the devil is in the detail, of which there are many & varied, to consider.
TerryB

Edited by Blue 30 on Monday 12th December 20:26

Blue 30

Original Poster:

244 posts

52 months

Monday 12th December 2016
quotequote all
Hi Mike..
If I were doing the conversion for you, I would if you wanted me to. smile
Perhaps we could 'fire up' one of those plastic 'working engine' kits (if I get one for Xmas) but I think its slippers, although could be racing boots...
TerryB

Top Gear TVR

2,182 posts

89 months

Wednesday 14th December 2016
quotequote all
hi - interesting project. How much room do you predict around those exhausts when the body is on?

Blue 30

Original Poster:

244 posts

52 months

Wednesday 14th December 2016
quotequote all
Hi...
If you look at the photo of my Blue 'S' on page4, that's when I refitted the body. So since then, all engine fitting work including designing & fabricating the exhaust manifolds has been done with the body on. The closest the exhaust manifolds piping gets is about 1/2" (13mm) inside of any chassis tubing. I have left the original heat proofing matting that was/is on the body/engine bulkhead side walls, plus I have over covered that with sheet aluminium, the type that ventilation/air-conn guys use on buildings. So that should be enough to protect the GRP, if that's what you were concerned about ?
The manifolds will connect to the original centre positioned large tubular silencer, so the ground clearance remains no closer to the ground than the original layout, plus it no longer runs under the engine.
TerryB


Blue 30

Original Poster:

244 posts

52 months

Sunday 26th November 2017
quotequote all
Blimey was it really the 14th Dec 2016 when I did my last posting !!!
The reason being that around that time, my dads health took a turn for the worse, and passing away in Feb this year. So with that, & then dealing with his estate the year has just flown by.
In car terms, I have totally finishing the restoration of my latest Panther Kallista 2.8, which was a great distraction at times. Especially going out to shows etc. Which as you might guess, any progress on the S has been minimal. Other than completing the fabrication of the ancillaries brackets, including designing an adjustment facility of the drive belt. Over the last few weeks I have been tapping out & labelling the Jag engine loom, fitting the Emerald Ecu & doing the same with its loom. The 2 ends are now ready to be mated together.
But instead of getting on with that job, being as the winter is rapidly approaching, I don't want the shiny Kallista left outside in the cold !!
My garage is located in the front garden, of which can't be extended in either width or length. But what about going up ??
The roof was made up of engineered trusses, so I have converted those to a vaulted roof (under approval of a structural engineer). And now I've bought a 4-post lift (Automotech), currently laid out on the floor, but should be in situ this week. Then the Kallista can go up, and the Tvr will slot in below it. And if I've got things right, I should still be able to carry on with the wiring work etc, although I might need a hardhat when I've hit my head a few times !!
Is it too early to wish you all "a very merry Xmas" ?
Oh well, I've done it now...
TerryB.

Blue 30

Original Poster:

244 posts

52 months

Wednesday 14th February
quotequote all
Here where I'm at today 14/02/18.
The 4-post lift is in, & the top bunk is occupied by the Panther Kallista for the winter period. I was just about able to use the top notch on the lift, so that leaves me about 3" to bump my head when working on the S. More if I climb aboard, but you only do it once... Or twice.
I have attached an led string under one of the platforms which gives me decent lighting, plus side mounted wall strip lights.
As I'm working on the wiring now (engine side & under the dash both sides) I have removed the nearside door, which makes access nearly as good as being outside, only slightly warmer.
Hopefully around Easter the Panther will be ejected, & the S will go on the lift so that I can do the under car wiring, fuel lines, pump, tank, gear linkage, prop shaft, etc etc.
Only once again I've been distracted !! As I'm now helping with the brother in laws new house purchase modernisation...
TerryB.



Edited by Blue 30 on Wednesday 14th February 23:01

Blue 30

Original Poster:

244 posts

52 months

Saturday 19th May
quotequote all
Ah, tis 19/05/18 now.
The Panther is out there now being used in this luverly weather we're enjoying at the mo. And since my last posting I have been getting on with the S.
Boy have I had enough of fabricating custom brackets, but it is amazing what you can do with a welder, a grinder, and bits of mild steel !!
All of the ancillaries are now bolted in place, unique both to suit the S and the Jag engine.
On photo1, the alternator is bottom right, the pas pump is bottom left, x2 new idler wheels one with belt adjustment, and the idle air valve top right.
Photo2 shows the new gear selector linkage, yet to be adjusted to suit the driver (me) !
The 3rd photo is where I'm currently at with the exhausts. I will be using the 'standard' single silencer & twin outlet arrangement.
All of the ecu wiring is done, but with a fair few surplus wires still hanging about on the Jag engine loom, not required as they are foir such things as the cat sensors, variable pas, fly by wire throttle etc. I haven't cut them away yet, as I might be able to re use some of them (too late once cut off).
My neighbour has dropped a few serious hints now for my bonnet to be moved from his garage, so I am getting ready to implement my version of the wide open
bonnet mod. Oh, I'm also 1/2 way through doing the steering column refurb & bearing mod, plus a new Ford brake servo & ms, so I suppose I had better complete those next....
TerryB.






Blue 30

Original Poster:

244 posts

52 months

Saturday 19th May
quotequote all
Oops, the IAV is top left on the first photo.

DamianS3

1,712 posts

117 months

Saturday 19th May
quotequote all
Looking good there Terry..

What TB and inlet manifold are you using..?

When do you think she will be on the road.?

Also whats your plans for the rest of the exhaust..? i should have gone X pipe then independent each side but have a std looking system atm.

Cheers

Damian