Sabretooth tiger
///Member
I remember Jaco also build one a few years back. Will go like stink.
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Read the WELCOME ALL BMWFANATICS post.
Corsa C Ute - Another Toy Story
- Thread starter gavsadler
- Start date
gavsadler
///Member
Ok update time:
Engine is in, and hanging on all it's mountings. We had to make a couple of changes to some of the mountings, but that's top secret Intellectual Property now
. Here's a pic of it in it's glory:
Last Saturday I went and did some of the kak jobs on the Ute - that being dropping the tank to remove the fuel pressure regulator, and also taking measurements for the fuel surge tank. Here's some pics of the regulator removed:
I have also been working on the mountings for my fuel surge tank. I finished that up earlier this week:
And went and fitted it on Tuesday:
I've also removed the old fuel supply line, and run a new 10mm supply line, and a 8mm return line. All I need to do now is mount the Walbro, and also the fuel filters. Pics of that to follow in the near future...
Currently, we're busy sorting out the wiring harnesses, the throttle body, and also the side shafts and steering knuckles. I'll post updates as things happen....
Engine is in, and hanging on all it's mountings. We had to make a couple of changes to some of the mountings, but that's top secret Intellectual Property now
. Here's a pic of it in it's glory:
Last Saturday I went and did some of the kak jobs on the Ute - that being dropping the tank to remove the fuel pressure regulator, and also taking measurements for the fuel surge tank. Here's some pics of the regulator removed:
I have also been working on the mountings for my fuel surge tank. I finished that up earlier this week:
And went and fitted it on Tuesday:
I've also removed the old fuel supply line, and run a new 10mm supply line, and a 8mm return line. All I need to do now is mount the Walbro, and also the fuel filters. Pics of that to follow in the near future...
Currently, we're busy sorting out the wiring harnesses, the throttle body, and also the side shafts and steering knuckles. I'll post updates as things happen....
Sabretooth tiger
///Member
raise:
now that the engine is in there is plenty space :rollsmile:
gavsadler
///Member
Ok another update, things are really progressing along now.
The smaller belt has been fitted. We had to slot the alternator bracket to adjust the tension, but that is working fine. Notice how tight the clearance is between the belt and the oil feed lines:
Here's a pic of my new Walbro 255lph high pressure pump:
Here's a pic of the surge tank with all the lines fitted. I also added an elbow to the fuel supply line, just to give it a bit more clearance underneath the car:
We also completed the wiring for the fuel pump, and tapped into the existing fuel pump power lines to draw power for the relay for the new pump. In the pic above you can just see the relay in the background.
Here's a pic of the fuel pump fitted, along with the new fuel filter (I had to shop around to find a filter with a 10mm inlet and outlet, to prevent this being a bottleneck in the fuel supply process):
Here's a teaser pic of us measuring space for the radiator and cooler:
Everything fits! Although space is extremely tight. It's a good thing I slotted the radiator brackets when I initially fitted the radiator, as it came in handy to make some more space for the cooler.
Then the throttle body has been fitted. I also had to purchase an idle control valve - this will come in handy when setting up the management system, it should ensure smooth idling:
Then I also splurged on a new filter. This will compliment the theme of my engine bay nicely:
So what's left to do:
> Finish fitting water pipes
> Finish top intercooler brackets
> Fit new bearings and hubs into new knuckles
> Check if sideshafts and CVs fit.
Then it will be mostly complete, and then it's time for exhaust and boost pipes.
The smaller belt has been fitted. We had to slot the alternator bracket to adjust the tension, but that is working fine. Notice how tight the clearance is between the belt and the oil feed lines:
Here's a pic of my new Walbro 255lph high pressure pump:
Here's a pic of the surge tank with all the lines fitted. I also added an elbow to the fuel supply line, just to give it a bit more clearance underneath the car:
We also completed the wiring for the fuel pump, and tapped into the existing fuel pump power lines to draw power for the relay for the new pump. In the pic above you can just see the relay in the background.
Here's a pic of the fuel pump fitted, along with the new fuel filter (I had to shop around to find a filter with a 10mm inlet and outlet, to prevent this being a bottleneck in the fuel supply process):
Here's a teaser pic of us measuring space for the radiator and cooler:
Everything fits! Although space is extremely tight. It's a good thing I slotted the radiator brackets when I initially fitted the radiator, as it came in handy to make some more space for the cooler.
Then the throttle body has been fitted. I also had to purchase an idle control valve - this will come in handy when setting up the management system, it should ensure smooth idling:
Then I also splurged on a new filter. This will compliment the theme of my engine bay nicely:
So what's left to do:
> Finish fitting water pipes
> Finish top intercooler brackets
> Fit new bearings and hubs into new knuckles
> Check if sideshafts and CVs fit.
Then it will be mostly complete, and then it's time for exhaust and boost pipes.
Sabretooth tiger
///Member
awesome progress:thumbs:
gavsadler
///Member
Ok right, time for another update.
A lot has happened in the past week or so. First up, I ended up getting some CDTI steering knuckles, as the original plan of machining my existing knuckles was not going to work. This has actually turned out to be a better option, as these knuckles take a nice big bearing. Here's a pic of us pressing in the bearings and hubs:
Then here's a pic of the hubs pressed into the knuckles:
Then some other noticable milestones are the fitment of the downpipe (approx. 68mm):
Also the back gearbox mounting has been finally mounted with the 2 bolts into the box:
And here's a general pic of the engine bay. The silicone bends are all finalised, most of the wiring is also done (for the Corsa harness):
So all that's really left to do in the engine bay is the last few water pipes, connect the gear shifter cables, and then top up the gearbox with oil.
Oh and last but not least, I booked the Ute in for it's exhaust and boost pipes at TNT for next week.
Almost there..... :rollsmile:
A lot has happened in the past week or so. First up, I ended up getting some CDTI steering knuckles, as the original plan of machining my existing knuckles was not going to work. This has actually turned out to be a better option, as these knuckles take a nice big bearing. Here's a pic of us pressing in the bearings and hubs:
Then here's a pic of the hubs pressed into the knuckles:
Then some other noticable milestones are the fitment of the downpipe (approx. 68mm):
Also the back gearbox mounting has been finally mounted with the 2 bolts into the box:
And here's a general pic of the engine bay. The silicone bends are all finalised, most of the wiring is also done (for the Corsa harness):
So all that's really left to do in the engine bay is the last few water pipes, connect the gear shifter cables, and then top up the gearbox with oil.
Oh and last but not least, I booked the Ute in for it's exhaust and boost pipes at TNT for next week.
Almost there..... :rollsmile:
gavsadler
///Member
Just a quick update:
The Ute is on it's wheels again. The bonnet has also been refitted, so it's looking much more "complete" now.
When finalising the water hoses, they noticed some corrosion on the thermostat housing, so that has been replaced now. The rest of the small bits will be done today, in readiness for it's transfer to the surgeons at TNT.
We also cranked the motor for the first time last saturday. It seems to crank a little quicker than before as well (perhaps it's because I've done away with the aircon compressor and tensioner pulley). Also, the Walbro switches on and off the same as the OEM fuel pump, and there is fuel pressure at the rail (so I'm glad my efforts under the back of the Ute seem to be working fine!).
Hopefully for my next update, the Ute will have some nice stainless steel bits on display.
The Ute is on it's wheels again. The bonnet has also been refitted, so it's looking much more "complete" now.
When finalising the water hoses, they noticed some corrosion on the thermostat housing, so that has been replaced now. The rest of the small bits will be done today, in readiness for it's transfer to the surgeons at TNT.
We also cranked the motor for the first time last saturday. It seems to crank a little quicker than before as well (perhaps it's because I've done away with the aircon compressor and tensioner pulley). Also, the Walbro switches on and off the same as the OEM fuel pump, and there is fuel pressure at the rail (so I'm glad my efforts under the back of the Ute seem to be working fine!).
Hopefully for my next update, the Ute will have some nice stainless steel bits on display.
:rollsmile:
Sabretooth tiger
///Member
:joy:
man I cant wait to see this done and running
man I cant wait to see this done and running
gavsadler
///Member
Time for another update:
The Ute went to TNT last week for it's exhaust and boost pipes. Here are some sneak pics of when they were fabricating the exhaust:
Flex-joint under the motor & flange on downpipe:
Middle box:
Back box:
I went and collected the Ute on Saturday morning, and brought it home to do a few last minute bits and pieces. I removed the boost pipes and gave them a good clean, and also filed off some rough edges etc:
Here's some pics of the completed exhaust system:
Then I also cleaned the coolant bottle, and filled up with fresh water and coolant. Then a few other bits and pieces in the engine bay to get it ready for the next step (Management).
The past week or so I've also been doing some work on a new bumper I purchased, and then I did the same to my grill. Here's a sneak pic:
All this took ages, but eventually I got everything done. There were also a few hiccups along the way, but managed to sort things out. Anyway here's a peek of what the engine bay looks like now (special effects lighting courtesy of my sensor light for the driveway, lol):
Then this morning it went off to RBTS for the management system. They are starting work on the Ute today, so hopefully I'll get it back by the end of the week if all goes smoothly.
The countdown has begun.... :joy:
The Ute went to TNT last week for it's exhaust and boost pipes. Here are some sneak pics of when they were fabricating the exhaust:
Flex-joint under the motor & flange on downpipe:
Middle box:
Back box:
I went and collected the Ute on Saturday morning, and brought it home to do a few last minute bits and pieces. I removed the boost pipes and gave them a good clean, and also filed off some rough edges etc:
Here's some pics of the completed exhaust system:
Then I also cleaned the coolant bottle, and filled up with fresh water and coolant. Then a few other bits and pieces in the engine bay to get it ready for the next step (Management).
The past week or so I've also been doing some work on a new bumper I purchased, and then I did the same to my grill. Here's a sneak pic:
All this took ages, but eventually I got everything done. There were also a few hiccups along the way, but managed to sort things out. Anyway here's a peek of what the engine bay looks like now (special effects lighting courtesy of my sensor light for the driveway, lol):
Then this morning it went off to RBTS for the management system. They are starting work on the Ute today, so hopefully I'll get it back by the end of the week if all goes smoothly.
The countdown has begun.... :joy:
wont it be crazy loud... thats almost just pipe :rollsmile:
Sabretooth tiger
///Member
Super excited:joy:
JeeeeeeepersCreeeeeepers
Thread's like these make me very jealous for my lack of knowledge and more so technical skill!!
I take my hat of and can but only appreciate the effort sweat and tears that goes in to a build like this!!
raise:
And also a biggup for sharing this epic adventure of a previous dull 'Oupel' to serious build.
raise:
One can only gain inspiration from such a thread.
Thread's like these make me very jealous for my lack of knowledge and more so technical skill!!
I take my hat of and can but only appreciate the effort sweat and tears that goes in to a build like this!!
raise:And also a biggup for sharing this epic adventure of a previous dull 'Oupel' to serious build.
raise:One can only gain inspiration from such a thread.
