TF Race Car Build

[flyingbanana]

So these arrived today

[flyingbanana]

Much swearing later and thankful someone cut a big hole in the bulkhead, the inlet manifold is off and the throttle bodies loosely fitted to start working out how to make it all work air intake wise. First observation - make hole bigger to allow Elise airbox to fit, so will be cutting the top rail off the fire wall across the hole and welding some 20mm box section in to replace it.
Dropped allen key stopped play .

[flyingbanana]

So hole now bigger , and airbox on. Looking at it, I'm going to cut it where the white line is and rotate the end 180 degrees and re-join. The box is GRP so easy job.

[flyingbanana]

On a roll, airbox cut and bodge taped back together for test fit - bob on. Just got decide how to close up the holes to provide an nice smooth finish. I have an idea which will involve an old t shirt or cardboard and polyester resin.

[mgtfnut]

I have an idea which will involve an old t shirt or cardboard and polyester resin.

Funny that, I've done that using old shirts in the past - it's the new composite replacing carbon fibre

[flyingbanana]

The plan, using tape I have created the shape I want for the top join to create a smooth join. Will do a single layer of mat, then one cut to desired dimension, draw round it, cut out the existing material of the intake curved area. Sit the first piece in the, with tape on the inside and then build up and join the two parts together. The rear is still a WiP in my head.

[flyingbanana]

Funny that, I've done that using old shirts in the past - it's the new composite replacing carbon fibre

so true

[flyingbanana]

Not pretty, but now a single unit again. Ran out of resin, so couldn't put a layer around the joins on the inside. Made use of the bit I cut off the top/out side part of the neck and reused it with a bit of cutting and shutting for the back - happy with the result .

[flyingbanana]

Plans for the air intake in the boot lid, and a bit of aero.

[flyingbanana]

Modified intake for the ITBs refitted and utilising CAD, I have come up with a rough airbox/intake design.

[flyingbanana]

Polycarbonate box built, function over form/looks.

[flyingbanana]

Whilst waiting on bits not coming overnight from Japan, thought I'd crack on with other things. Box section welded in across the big hole with chassis stiffener bracket attached.
Idle control valve manifold made from 12mm nylon block with cut down straight connector superglued in.
Various bits reconnected: extinguisher lines, wiring, vacuum manifold secured to new box section, ECU, catch tank, header tank.

[flyingbanana]

So throttle bodies bolted in and everything plumbed in - bar the fuel pressure regulator. I now have spotted an issue though, with the throttle cable fitted and the adjuster would all the way out, the butterflies are open not closed.

[flyingbanana]

Another job done, NACA duct bonded into boot lid and airbox fitted and cut to allow duct to sit in it. Just need to tidy up and repaint that section of the boot lid.

[flyingbanana]

So good news bad news-found solution. Good news Abingdon wheels clear the rear 2 pots, bad news even at 300mm they don't clear the front 4 pots, without a 5mm spacer. But my 15" TD Pro Race 1.2s clear 300mm. So...onto ebay and these will do the job nicely, just need to get the PCD redrilled and maybe some spigot ring adapters to take it down from 69mm to 66mm. Current disc height is 43mm.
https://www.ebay.co.uk/itm/235099301849 ... BM1O2ajrxi

[flyingbanana]

Last piece of the air intake system arrived today - the 150mm flange for the airbox. But now i've offered it up ready for hole cutting and bonding, I've decided I'm going to cut the bottom corner off the box under the ducting, to reduce the weight and create some space . Of course if the 100kg sitting in the drivers seat could lose some weight that would be even better.

[flyingbanana]

Backplate for the throttle body airbox back from being welded back up and outlet for the idle control valve and MEMS3 combined MAP/Air Temp sensor bolted on.

[flyingbanana]

It's always gratifying when things work out like planned (hoped). Idle control system plumbed in and fitted to the throttle bodies and everything test fitted...and fits .

[Rob Bell]

Great job! Are those ITBs from an MGF Cup car? They don't look like Jenveys...

[flyingbanana]

Great job! Are those ITBs from an MGF Cup car? They don't look like Jenveys...

Yup, 2nd gen ones.