DNA Owners Club
DNA Owners => 4thirty Chat => Topic started by: Darren on May 23, 2009, 11:13:21 PM
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I'm a newby on this forum so thought I'd introduce myself, and my project so far
The DNA 430 is a lovely conversion, but lacks the V8 feel, so first off I've been researching the donor car capabilities
The famous toystar V8 was my first port of call. This is a transversely mounted northstar auto, unfortunately the engine sits partway into the firewall.
Next step was Hilly's true v8 set up in a lotus esprit
http://www.motorgeek.com/phpBB2/viewtopic.php?t=9648
So does the Audi A8 V8 with a 20ltr tdi 6 speed box fit in the MR2? yep!
http://www.woodsport.org/joomla/index.php/engine-conversions/51-v8/28-v8-conversions.html
I have spoken to Custom code and they're pretty sure that they can recode the ecu to ignore the original quattro gearbox.
I need the whole A8 car for extra bits when doing the transplant ie cooling system, cats wiring loom etc..
With over 300hp standard and V8 torque the engine will now give me the satisfaction of a replica and still be cheap to service, who knows a little further down the line a supercharger may be in the pipeline (I prefer the almost instant power as apposed to turbo lag)
I have been looking to build a replica for over 15 years but haven't had the time, now I do and can't wait.
First purchase will be the A8 4.2 quattro, a 1995-1998 for around £1600
The car will have the ecu sent away for reprogramming and remapping.
Next my Mr2 purchase, I'd like to get one with the precat destroyed engine, who knows. Budget £2500 max
Once engine is running in the car I will purchase the 430 kit, I'm quite happy to do the suspension mods myself as I've built and raced short circuit cars for over twenty years, I'm not to fond of the large wheel spacers, I'll speak to the GAZ and LEDA guys later.
Colour- ferrari met black with tan leather interior, One of my old mates is a great refinisher and sprayer, he'll spend a whole week preping and spraying in ICI
Just need to find the two cars to make a start!
Darren
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Hey dangerous,
sounds very interesting, have thought of Audi V8, this will make it go like f---
MADMAN ;D
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Paul ( Woods) is currently working on the MK1 V8 conversion, I'm currently developing the Mk3 we're not formally working together but sharing information on the conversions. As you've seen the Mk1 has an easy drivshaft configuration, where as the Mk3 is not that simple, well if you want to keep the ABS that is.
it wont be a simple conversion and youre looking at a price of about £10K to get it done.
PS I already have a subframe to convert the MK3 to V8 as a bolt in kit, this lengthens the wheelbase of the Mk3 to the 430 wheelbase and takes away the need for hub extensions at the rear.
IHowever, t would require a new mould from DNA to reposition the wheelarches to the match the 430 wheelbase.
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cheers for that paulm,
I think after reading this it may be wise to go supercharer, what do you think?
MADMAN
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£10000?
I have been welding, cutting/shutting, fabricating adjusting my whole working life, the new powerplant will go in without any problem for me, I research, visit salvage yards, breakers etc and that's before I even pick up my cutting torch, I'm second generation damage repairer (retired, now field service engineer) and have full workshop facilities at my disposal.
The only question is the ECU, Custom code haven't cofirmed a reprogram yet. Hilly has a great working aftermarket ECU for the v8 and he will build one complete with loom for around £1100 (depending on Euro strength)
I'm a little confused as to where the £10000 has come from, even resplining the drive shaft for Audi to toyota is only £75/pair
I'm sure this will open some sort of debate as to "have you thought of this and that"
Truth be told the budget for engine conversion is unknown, but I'd be suprised if it goes past £3000 for me with all bits included.
An 'adjusted' rear subfame will be made to fit the engine and car with possible lower wishbone mounts or oem.
Not sure yet but may have to fab up a new fuel tank, at the end of the day it's no different to my superbanger builds or saloon stock fabbed up engine bays.
It's like most things if you've been doing it years you think nothing of it, if you're a newbie it's a mammoth task. I'm sure Madman can build these replicas with his eyes closed, but as he implied "Give me a spanner cutting torch welder and no probs stick me infront of a computer and I can turn it on. Just an example of where knowledge an experience lies (I know you can do more M, just using it as an example from one of your early posts)
I have found Paul very helpful so far and his development will help me no end, they look to be dedicated professionals, and for his team to take this on they too felt that the MR had V8 potential
As an added note, I can't thank Hilly enough for the advice and extensive build diary. If It wasn't for him I would've still been scratching my head around the Ls400 V8
Darren
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The £10K figure comes from Mr Woods, for the conversion to be done on the MK1, if you want to do it DIY, t would be much cheaper, as you'd be using your own capabilities.
Madman - A supercharger is a very good option for a fast MK3, obviously there are some Mk3 turbo's around too, but if it me and were sticking to 4 cylinder I'd go for the suprecharger. If wanted to get away from the four pot, theres a realtively simple V6 conversion using teh camry option, it gives similar power output to a supercharged Mk3, but with a V- engine burrble adds a bit more authenticity
PS Darren - are you aiming to fit the V8 in within the current firewall, wheelbase configuration
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I measured an MR2 up a couple of weeks ago and it's 27" from fire wall to the driveshaft, V8 engine pulley to driveshaft centre is 26"
The fire wall may have to be altered to allow for drive belt servicing etc, but the driveshaft will sit slightly off centre aswell, from memory 5* is max recommended
D
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I think you need to be aware of the total length required vs available and not just the firewall to driveshaft distance.
Which in a Mk3 is 40" available, unfortunately the length of the engine and box is 47" and I would double check your driveshaft to firewall measurement, is more nearer 20" rather than 26", which would put the driveshaft angle at more than 17 degrees.
What that means is you have a gearbox that would stick out of the back of the car, like so and have a 17 degree drivehsaft angle
(http://i48.photobucket.com/albums/f228/Subarupaul/100_0594.jpg)
But there is a way around it
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wow liking the sound of this build very intresting would it matter about it sticking out a bit cos if your putting a dna kit on it it should hide it, unless of course it sticks out underneath.
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IMHO if you went with it as it looks, it would physically fit in, but I think the driveshaft angle at 17 degrees + is too extreme, so there are two options,
One is for a DNA body kit which moves the wheel araches back, this brings the wheelbase more into line with the original car, then you would have the simplicicty of a bolt in kit, which when mounted on a subframe would look like this.
(http://i48.photobucket.com/albums/f228/Subarupaul/Picture136.jpg)
Complete with full size brakes and 360 exhaust system.
OR
which is what I'm working on at the moment is a conversion that fits inside the standard wheelbase MK3, although I' still not sure if it will work, due the the physical restrictions, but until you give it a go you never know.
After all that wethen get into balance and weight issues.
Essentially I'm giving it ago and if it works and its safe, I'll be happy to put it out to the public. Obviously if its not safe, I'll be smeared over the safety rail at Brooklands corner :'(
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I knew it was tight, if the numbers don't add up then it'll be a v6, my concern is the drive shaft angle, they start to humm and wear out quickly, the fire wall will need to be addressed, the 27" came from the the front subframe to the chassis mount for the lower wishbone.
Have you addressed the ecu issue?
D
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Not yet, although i do know that the gbox ecu generates a up and down transmission signal thats based on a 26khz carrier wave, I think it was 3.14 v p-p. worst case would be to replicate that signal with some electronics to fool the ecu. Although I dontt hink thats the best solution as would be liable to interference, which could mean erratic ecu performance. Not the thing you want on a 340hp engine :o
If you can se in the photo above theres a reasonable amount of shaft angle and thats with the wheelbase moved 4" back, putting the hubs 4" further forward for a standard wheelbase creates a pretty big angle and as you say driveshaft failure....although no-one is willing to say how quickly.
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I wondered how you were going about this Paul. Didn't realise it would need a whole new rear of the kit moulded.
What's the craic with the standard wheelbase then, are you moving the tank and front crossmember i take it? Where would that have the rear of the gearbox sitting?
V6 with a SC is a good option for 260bhp to whatever your wallet will stretch to. And with the Berk system it sounds pretty authentic : http://www.youtube.com/watch?v=XAuPoQ58iFU (http://www.youtube.com/watch?v=XAuPoQ58iFU)
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What you doin on here Ollie ! :P
Wait for sunday and I'll be able to update in brutal fashion, if you know what I mean.
Essentially by Sunday I'll have the engine in the silver Mk3 , the gearbox will fit in, in the confines of the standard bodywork no worries
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Finally got back to Custom code regarding the ecu, they said the work involved is estimated at £1500, but he said because I had the whole car why not keep the gearbox ecu and relative sensors. fool the gearbox ecu into neutral, it will just let the engine rev of it's own accord, any error codes could be dealt with easily.
I've had my searchers looking around for a damaged A8 and I think they've found one for £900.
Now to find a decent MR2 mk3.
I'll be looking to take out the front crossmember and fuel tank to make room for the engine and box. I'll fabricate a new one, once all dimensions are finalised.
Darren
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£1,500 sounds a bit pricey, when you can get a complete third party ECU unit for about £500-£600. I guess they dont want the business that much.
I've got a list of parts that should work as emulator, which costs £14.73 including a project box, so for that money its worth a go.
Darren, You may still need to put signals into the gearbox ECU, the gearbox has a multi pin plug which links into the ECU, this will be where you may need to generate a signal or two.
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Holy moly sir.
I cannot wait to see this mofo done.
Did you get rid of the old shell btw?
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Yep , the old shell has moved on , got a nice little silver MK3 with a gutless 1zz in it, well, it did have, the engine and box have been sold off and there now a bit of a..ventilation gap inbetween the driver and passenger, check out TB tonite
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It's a Twobrutal invasion! lol
Just thought i'd add my own 2p seeing as PaulM and i are sharing as much info as we can with each other.
The £10k price tag i mentioned was for a turnkey conversion supplied and fitted by a specialist like ourselves, in truth we do not even know what the final bill would really be, all we can do is project costs based on costs as they stand on our own builds.
My V8 mk1 up to now has cost....
AHC v8 engine with all ancilliaries £1000
01X 6 speed gearbox £200 (normally £500 though)
Driveshafts £280 (including new CV joints)
Flywheel £280 (includes delivery)
VEMS ECU and harness modification by Hilly £1050 (the way to go in my book)
Clutch £150
Exhaust £200
So that is my "basic" budget up to now, around £4k in parts alone, i have not added all of the little things that i have pulled from the parts bin at work, mk3 shifter cables,engine mounts,box steel,toyota alternator... the list goes on.I probably have another £1000 to spend in reality on traction control and various items.
All of this is without accounting a single penny in labour, we estimate 8-12 weeks of work in doing one full time.So i think circa £10k turnkey is a reasonable estimate at this stage.Obviously if you build one yourself then it's just parts cost, but i wouldn't like to attempt anything like this with less than £5k as a budget.
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seems very reasonable
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I'd also add on £150 worth of new bushes for the rear end
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I agree there is an immense amount of work involved, and have only looked around my old haunting grounds getting ROUGH dimensions, I have been in and out of salvage for over twenty years, and my father was damge repairer for his whole working life, I can only thank hiim and his contacts for letting me rummage around their well organised yards, I was and will probably always be 'Colins' son
I can get a 01x box with all the ancilleries for £350, I have the choice of a v6 manual box with bits aswell, but Paul and Hilly advised me on the 6 speed diesel.
It seems for now the A8 car is not a problem, just looking for a square abused MR2 mk3, preferably grey or black.
D
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I'd also add on £150 worth of new bushes for the rear end
Is that for the car or your own rear end? ;D
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I'd also add on £150 worth of new bushes for the rear end
Is that for the car or your own rear end? ;D
TBH I'm not sure which one would be looser when I get round to driving it ! :o
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This is how it fits
(http://i48.photobucket.com/albums/f228/Subarupaul/035.jpg)
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Just a quick update with the exhausts and backbox (ferrari 360) fitted.
(http://i48.photobucket.com/albums/f228/Subarupaul/036-Copy.jpg)
Its looking nearly complete, so I totted up the things that still needed doing.
(http://i48.photobucket.com/albums/f228/Subarupaul/038.jpg)
Fit new drop links
Modify rear roll bar
Fit rear roll bar
Weld fire wall
Weld X member
Fit torque mount
Wire up ECU
Panel fire wall
Modify tail pipes
Fit battery
Seam seal fire wall
Modify centre pipes
Modify battery position
Modify CV joints
Modify driveshafts
Fit coolant pipes
Modify alternator
Fit expansion tank
fit alternator
Build fuel tank
Modify sender
Fit fuel lines (out, in, evap)
modify battery position
Fit battery
Vacuum resovoir
Vacuum drive
Modify A/C pipework
Change bushes
Re trim subframe
Change cambelt, clutch plate
Extra support for subframe
Fit A/C compressor
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awesome job m8.. not much left to do now.. should be finished by say 2pm tomorrow if you dont stop for dinner ;D
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optimist, it'd be at least 2.30 :P
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I'm a little behind but just took delivery of the 4.2 V8 Audi, the car is 100%, almost a shame to tear it apart
:'(
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Paulm,
Are you using Hillly's ecu set up? And screw fitting the fire wall for future engine access?
I plan to utilise as much of the A8 as possible, even some of the suspension and the wheel hubs, new wheels are already sourced, they're a close match to the HAMANN race forged light, i need to purchase the wheels early for a correct wheel base to dna430 body kit fitment
wheels are Inovit DTM Black Stainless 8.5 and 9.5j
Lot of research going on in the background while looking for the MR2
Darren
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I'm aiming on using the audi ecu or an emerald ECU at worst, the firewall will be welded for me to make it secure
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I've got the Elwin workshop manual for the A8, it's used by Audi and Contains every bit of info about the whole car, over 8gb of pictures and work instructions, I'll send you a copy of it if you wish, just email me with you're address.
It has to be installed on your computer and comes with installation instructions via the set up disk
Darren
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No need ,I have the bentley manuals instead thanks tho
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Got the MR2, the engine's broke. Just prepping the workshop to receive the car (chucking out all the bit and bobs from my house building days).
It's been in the wars but every important bit is 100%; roof, all electrics, air con, low mileage, inner body panels, FULL SERVICE history, HPI clear, and after having a good look around- all body panels are original to the car- so damage free, Cool!
Just a few things to finish off then I'll strip the car almost to the chassis in preparation for it's colour change and a fair bit of fabrication for the V8, gearbox, suspension, and Audi brakes.
D
I'll visit DNA and purchase a body shell when the engine and gearbox are in the car.
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Hey D,
check with DNA there may be a waiting list, just a thought.
cant wait to see the finished V8.
MADMAN 8)
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Spoke to them a little while back and they warned me to schedule the wait into the build, I need to sort the basics before doing the panel work, like engine etc... Hope to have the car finished by Xmas.
Still gathering various bits for the build
D
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any pics of your new motor darren
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Audi and MR2 together, front drive is a little cramped at the mo
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Looking ahead, how have you guys found selling the unwanted MR2 body panels etc. Just curious
D
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Looking good, I'll buy the nearside rear wing from you.
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all mine sold quick, all I have left is the o/s/rearquater and engine cover, in silver.
must be a god send to MR2 owners.
MADMAN. 8)
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Got this Saturday off from work, all being good may start to strip out the back of the MR2
Will start a build diary, with camera/video footage soon.
Also carried out more research and viewings. Colour change in hand from black to.... The colour is true to Ferrari and a little more expensive, I'll confirm when I've bought the paint. Sorry to be a big vague but Ferrari looks good in so many colours, so I may change again!
Bought a new camera for video and photos, hope they look better than what I've recently posted
D
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Had a Sunday with the car, roof off, back end panels gone and engine out. Job Done
Next week I'll start the Audi
Small car takes up loads of room!
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You are certainly living up to your username!
But I have to admire the dedication, confidence and skill - well done mate!
Keep us all posted on the detail of the running gear mods etc - yes you prob know I'm a sucker for safety - wish someone would develop ESP for the MR2 Mk3...
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Keep us all posted on the detail of the running gear mods etc - yes you prob know I'm a sucker for safety - wish someone would develop ESP for the MR2 Mk3...
Have you looked at the SMT version? which has what they call VSC (vehicle stability control).
- tenpin
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I haven't mate, thanks :D I didn't know that
I always dismissed it as I thought I'd be changing the motor and box anyway.
Does anyone know if you can keep this if you make the V6 voncervsion though? (sorry my knowledge on the stability control is limited - i.e. what you can/can't change and keep it working as standard).
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Continuing with the boring stuff, today was the turn of the Audi
Also booked my appointment with DNA, earlier this week
Job Done!
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Top driveway work, bet the nieghbours are wondering whats going on !
PS the gearbox's are worth a mint, dont let it go too cheap
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Thanks Paul, I've lived here for 16 years, the neighbours are always seeing and hearing strange things, one side has a 'wonder what he's doing now attitude' while the other side are genuinely interested, as their son-in-law works at Fords Dunton research facility.
I noticed that when I was unbolting the underside of the engine, gearbox and exhaust, all of them were either new or copperslipped, then I remembered the earlier conversation with the previous owner 'I've had the gearbox leak done at..... costing over £300', I have the receipt, another bonus with the car, Quattro box with no end seal leak.
Easy weekend coming up, new wheel bearings on my Van, Strip the Mr2 interior and front of the car. May also start dismantling the front subframe and suspension from the Audi, I plan to modify it for the engine/gearbox to the MR2, and utilise the suspension mounts for the front suspension/anti roll bar/hub/brakes
More photos to be posted
D
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Paul ( Woods) is currently working on the MK1 V8 conversion, I'm currently developing the Mk3 we're not formally working together but sharing information on the conversions. As you've seen the Mk1 has an easy drivshaft configuration, where as the Mk3 is not that simple, well if you want to keep the ABS that is.
it wont be a simple conversion and youre looking at a price of about £10K to get it done.
PS I already have a subframe to convert the MK3 to V8 as a bolt in kit, this lengthens the wheelbase of the Mk3 to the 430 wheelbase and takes away the need for hub extensions at the rear.
IHowever, t would require a new mould from DNA to reposition the wheelarches to the match the 430 wheelbase.
Hi Mate,
Are DNA thinking of creating the above panels??
Cheers
Scott
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Dont use these guys
I know this wont apply to most of you guys, but if you ever consider doing a audi conversion I wouldnt risk getting your flywheel from these guys
10/8 - Ordered flywheel, "yep got it in stock mate no worries will send it out."
18/8 - Chased them, " just getting it balanced up, we do em in batches you see will be going out asap"
24/8 - Chased them, " yep posted it on saturday should be with you in a couple of days"
27/8 - Chased them - "Oh glad you called I was going to call you, I realised it was a the wrong flywheel, so I went to fed-ex on saturday and got the package back, I'm just getting some new ones made now"
It seems all the others where the wrong type (8-bolts)
When I asked why did he tell me they were in stock on the 10th and your still showing stock. "the website doesnt update itself and some people order direct"
He'd forgotten that i'd spken to him directly and he confiemd that he had the flywheel ther ready to go.
When Ii asked why did he tell me on Monday that he'd sent it on saturday and now on Thursday your telling me that you didnt send it saturday. "erm well, em, i cant remember that conversation "
What a fucking joke
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I hope I don't have the same problem. although I am looking at more sources
Just an example:
http://209.85.229.132/search?q=cache:REiQ2_HSjmoJ:forums.vwvortex.com/zerothread%3Fid%3D4208223+s4+flywheel+single+mass&cd=4&hl=en&ct=clnk&gl=uk
Or, because I've got the ring gear, I may turn a flywheel, using the stud pattern and clutch kit as a template. Not thinking seriously enough about it yet.
D
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Vortex have some good stuff, I'm sure your aware but none of those flywheels will fit, they're the wrong bolt pattern. I'll be having a chat with MRC to see if they do anything.
Ooh, I think I've sorted the ECU problem with the help of a friend whose a VAG developemnt engineer at their training college.
Should be able to use the standard ECU as a standalone control unit.
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I'd be Very interested in the ECU outcome, if it works I'd put a hefty drink his way to sort out my ECU
D
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;D Would need to be a hefty drink its costing me £250 ! ;D But that is £750 less than a 3rd party ecu would cost, so maybe no that bad.
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Suprise Suprise it's a bank holiday weekend, extra time on car/s. But went out las night so took it a bit easy today
Stripped the Mr2 a bit further
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Tell me how much you want for the nearside rear wing Darren or send me a pm
Cheers
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Haven't even thought about prices, I'll get back to you
D
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Either of you have a fuel tank you don't need?
I'll purchase it if you please.
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I have the fuel tank, but need to keep the pump/sender unit
D
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i'm re using bits of mine Ollie, you going to JAE?
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Afraid not man, moving home this weekend and the Mk1.6 is off the road this week for a strip down and rebuild.
Saying that though, might be the perfect re-run in to take it down to JAE next weekend. Hmmm.
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Visited DNA today and laid some hard earned cash into their hands, should be able to pick up the panels when I'm top in the queue.
Even though I've spoke to the guys on previous occassions they still had time to chat about the kit and my requirements, whilst working on a number of cars in the shop.
I Should have a finished car for Stoneleigh.......
Picked up more advice on my chosen colour, which I may change again
Darren
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Carried out some more work on the car today, stripped out the fuel tank, all pipe work and electrics around the new engine bay extension, then set to it with the grinder
Sourced a gearbox and bought a lathe
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Shit, thats one hell of a hole!
I thought I was the MADMAN ;D cant wait to see it completed, keep it up Darren.
MADMAN 8)
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Keep it going darren,looking good on the width although you may want to cut a bit more out of than that to get it to fit on the height, so it looks a bit like this.
(http://i48.photobucket.com/albums/f228/Subarupaul/005.jpg)
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This is the first rough cut before all the trimming takes place, I need to cut more off the top for a straight shelf, and sides for access.
Paul I like the mounting of the ecu, I was wondering where to put it for minimal weather and temperature intrusion.
I notice you've left more room at the front, I propose to mount it as close as possible with a vertical centre cover plate in between the seats allowing all fluid and air runs up this channel although it's only a thought.
I've twisted the gear cables all over the place and they're still free moving, I may run the new ones under the car, I went to snetterton a few years ago and was lucky enough to have a go in a GTA looking kit with a ford cossie lump, the gear linkage was too complicated but the cable run was extensive, gear change still felt very precise, so I'm not too concerned with it just yet.
I spoke to the gearbox supplier and he's willing to part with all the 'useless' bits in the deal. With the V8 ring gear plate, diesel flywheel and clutch I should have enough info to fab up my own billet steel V8 flywheel.
Work is crazy at the moment and I'm being kept away from my own project, one day a week is not enough!
Looks like you've come a long way in a short time. Any more pics to wet the appetite?
Darren
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For teh ECU. I'm running from the old bettery position and re positioning the battery, its a fairly damp place, but I'm sticking it inside a rally bag, so called as its used in rallying to protect the ecu's, so should be good for the job.
All fits in with the roof down
(http://i48.photobucket.com/albums/f228/Subarupaul/036-Copy.jpg)
Custom drive shafts
(http://i48.photobucket.com/albums/f228/Subarupaul/003-1.jpg)
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Quick question, does the speedo take it's signal fron the ABS on the MR2?
And have you sorted the ECU with your VAG technician?
D
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The speedo signal comes from the ECU same as the audi it takes it electronically from the gearbox. Most ECU's need a speed input to reference and compare, from there it will go on the can bus over to the instrument binnacle.
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Looking really good m8 :-) When I was playing with the speedo pulse on my DNA I found it to be around 3 volts and it pulses at a ratio of 1:1 ie.. 60 pulses = 60mph found this out when I was doing a working concept on some electrics for my murci kitcar.. http://www.youtube.com/watch?v=4ZEpdilqG-U
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Steve, Was that a square wave pulse 0v low and 3v high ? Over what time frame ?
Cheers
Paul
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Hi m8,
Yes Square / on or off pulse this was over a time of 1000ms cycle. 1 pulse = 1mph it seemed. It was between 3v and 5v.. I cant remember. I was going to put a protection 5.1 zener diode in just in case anyway. I was using a arduino device connected direct to the speedo pulse wire measuring the pin. Maybe you could using something similar to convert your input signal.
Steve
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Cheers Steve,
I'll scope off the back of the audi ecu to see what comes out of the box
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http://www.dakotadigital.com/pdf/sgi-5c.pdf
May make things a little simpler
D
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A little more time on the car,
Took off the Quattro box (weighs a ton!) and matched up the 01X box
Wheeled the engine and box into the car, drive shafts are spot on, no need for any rear clip modification
Also removed rear crossmember from Audi, this houses the suspension and hubs etc
put it up to the Mr2 and noted that the mount points are extremely close to the line of the chassis rail, and the wheel base width looks to be very close to the dna/ferrari
A good news day
The Audi wheels have an offset of 45et, I'm looking at 25et so the wheels will sit even further out from the hub
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A good weekend of work there fella :-) loving your diary so far.. you got a time scale on it ? be good to see it in the flesh maybe at stoneleigh.
keep it up m8 :-)
o.. btw whats a 01X box ?
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good stuff there ,keep it going ,will be good to see this motor car finished.
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I certainly hope to have the car done for stoneleigh.
From 2003 onwards Audi introduced a revised version of their standard 6 speed gearbox, luckily enough nearly all the gearbox bellhousings match up to most off their engines. The Audi 4.2 V8 (ABZ 1995-2000) and six speed 2.0ltr tdi six speed gearbox ref no 01X.. marry up quite nicely.
Visiting the holy grail of engine conversions
http://www.motorgeek.com/phpBB2/viewtopic.php?t=29891&postdays=0&postorder=asc&start=50&sid=116eae647611b6d27e37241a977beb52
A guy has converted his 4.2 auto to a manual without changing his ECU and it works! He only gets a 'No signal from Transmission ECU fault code' I can live with that since it will save me around £1100 for a VEMS ECU and wiring harness. ;D
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Darren, for it to work that way, you'll also need a set of audi clocks in the car to complete the handshake between the three components.
Also, I guess you've noticed this already the engine speed/timing sensor is in a different position on a manual box to an automatic box. A way round it is to use an independent timing wheel like this.
http://forums.twobrutal.com/showthread.php?p=203628#post203628 (http://forums.twobrutal.com/showthread.php?p=203628#post203628)
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Still looking at the speed sensor as the 01x box I've got has no place for anything except the reversing switch, the torque plate has got some sort of sensor coming off it, haven't delved into the wiring flow diagram as of yet.
D
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When I say speed sensor I mean the engine speed sensor, which is on the bell housing at 2 o clock (looking at from the front) on the auto box the sensor is located at 4 o clock, roughy speaking, so you'll need a seperate timing ring if your using the oem ecu.
Something like this, which I made a btch of 10 over the weekend !
(http://i48.photobucket.com/albums/f228/Subarupaul/P1000692.jpg)
which when it spins up produces the correct output
(http://i48.photobucket.com/albums/f228/Subarupaul/P1000693.jpg)
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Had some good news this evening, An Audi ecu specialist can install a new moddified custom chip into my original ECU with new parameters to suite my application. I'll send it off end of the week, should get it back in around 3 weeks.
Paul, Engine speed sensor will be retrofitted with new bespoke flywheel.
Added note
rolled the audi subframe under the car
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Paul, Engine speed sensor will be retrofitted with new bespoke flywheel.
as long as you reposition it to fit the different pick up positions it should be ok
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Picked up the jig saw puzzle today, watched the dvd, I'll start some fab work Sunday. Rear clip laying on the car, the audi subframe is very close, I'll speak to the wheel guys for ET specs on my new wheels, I'll know then if i need to widen the wheel base even more
D
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Work and Christmas is affecting time spent on the car but I've managed to do some more work on the rear and seats
A few weeks ago we went on the look out for some 'recaro' style seats for the trimmer to work on. Originally I was going to go for some Alfa spider seats, but I came across some rover 220 coupe seats, the basic design is close to the 430 with the trimmer adjusting for fine contour and detail (he's seen the seat and is happy with my choice). The next job was getting the MR2 runners to fit, two days and many refits later I've got the seats low to the floor with a bolt fit, the problem was the rover seat frame sits approx 60mm higher than the MR2, when I completed the first fit and sat in it, my head was higher than the window frame, I felt like Jeremy Clarkson!
Next job was to cut the Audi subframe to sit at the correct height and central to the new 430 wheel arch. Getting to the MR2 chassis meant removing the stabiliser mount on both sides, then to allow for the Audi top camber arm I had to cut 60 mm out of the chassis. With both sides of the subframe cut to slide up and rest on the original Mr2 mounting points I lowered the car, and hey presto, the rear of the car is at the desired height without and modifications to the rear wheel geometry.
I need to pick up some more steel to fabricate mounting brackets, once I've done that I can take the rear clip off out of harms way, I'm so wary of damaging it.
Once the rear clip is removed I'll strengthen up the Mr2 chassis and fit new coil over mounts, then it's onto the gearbox and engine mounts.
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looking good darren, keep pushing on
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Finished work early yesterday, so I popped down to GAZworks engineering and spoke to the Technical director regarding my suspension damping requirements, came away with fabrication specs for a sport/road setup using coil over adjustable dampers. Also went down to the paint suppliers with regard to the sovlent and water based paint topic. They're confident that their solvent stock will take them past April 2010 and they have 'back street clients' using water based without any problems as long as they adhere to the correct method of applying this type of paint ie extra ordinary clean air movement within the paint booth for drying.
D
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Hey , hows it going, do you think you'll be in time for Stonleigh ?
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Work takes priority most of the time, so no. The rear subframe is done, and I'll be fitting the engine & gearbox mounts this week. But I'm on call from Friday night....... and so the story goes on.
D
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I'm not sure where the weekends go either !
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Starting to get back into the car.
I've now completed the subframe alterations and it's securely mounted to the car, or should I say that the car now sits on the subframe.
All the body work cutting is done.
The Engine and gearbox are correctly positioned in the rear with the subframe wrapped around it.
The chassis has been strengthened where I've cut it.
I'll farbricate the engine and gearbox cross member/mount next week.
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Fantastic work m8.. looking really good.
Keep them pictures coming :-)
Steve
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UPDATE
UPDATE
UPDATE
WERE ALL WAITING ;D
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engine and gearbox mounts are 99% finished.
Next it's the front Audi subframe and suspension
NB These items will be sent to be sand blasted and painted once all fabrication has been done
D
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Nice ;)
Darren have you mounted any of the kit to the car yet or will you be waiting untill you complete all the upgrade to the mr2??
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I had to mount the rear clip to get all the suspension geometry correct for the DNA and original MR2. This is where I confirmed the width of the Audi subframe/suspension and wheel offsets.
Shown in an earlier post.
D
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Had some time on the Audi and Mr2 this weekend.
Stripped out the Audi front suspension after bracing it in place. The 'jig' keeps the geometry correct while fitting it to the Mr2
Took a couple of pictures
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Hey Darren,
any updates?? This is nail-biting!!!
Hasnain
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I'm working on the front today, I'll post when the front is all welded and bolted in.
D
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A cut here a weld there and the subframe is in, top arms and rack still to put in, here's some pictures of the new wider front track.
Lovely big discs and brakes stare at me through the Audi 17" std wheels
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Add Note;
The front clip was placed on the car to confirm correct wheel alignment to kit. Then put safely aside.
The Mr2 wings were replaced to set the subframe mm perfect before welding in bolt mounts, I'll cut the steering rack mounts to fit the new Audi frame.
The hub is cast steel, I'll bolt and weld the new steering arm last.
Mr2 wide boy!
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Looking Good D :D
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Yep keep it going D
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Went shopping earlier today.
BOC gas and gear Cast Steel/iron rods, 1kg £80! But the most suprising thing is that they cold weld. No preheating neccessary, although the max weld length is around 1" and needs to be peaned while cooling, the process is repeated along the total weld length, Item being welded must not go above 70*f
Second, the proper shock:
Spoke to the exhaust specialist regarding the bespoke stainless exhaust
Here's a breakdown of the cost
i) Each manifold £300
ii) Each Metal cat £400
iii) Back box £500, tuned to my specification
iv) Pipework and ancillaries £400
Approximate cost £2300
So Looks like I'm going DIY, with a Second hand 430 box and cats.
Get the tig welder out again!
Doing the front hub uprights and steering arms today.
D
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Shocking on the exhaust, :o
Mind you the manifolds you dont really need, or if you wanted to play around you can get a set from a red bull or torro rosso on ebay for about £300.
Sports cats in stainless are now less than £200 each, but make sure you get the shortest ones as the centre pipes are only about 350mm long..see below.
Back box might be a good option though, if you cant find a cheap Ferrari box.
This is what myself and DNA looked at doing together at the end of 2008. This back box is the 360
360 or 430 box will work, the 430 may be better but harder to get hold of.
(http://i48.photobucket.com/albums/f228/Subarupaul/Old%20shell/Picture138.jpg)
(http://i48.photobucket.com/albums/f228/Subarupaul/Old%20shell/Picture137.jpg)
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Cheers Paul, I'll look into this when I'm back onto the rear of the car fabrication.
D
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Hi D
I bought a 360 exhaust over a year ago payed just over £400 for it if you want it just make me an offer and its yours, It wont be any good to me as i think it will sound funny coming from a standard 1.8vvti engine compared to a V8 monster conversion ;)
So thats the back box with both tail pipes ;D
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I've pm'd you
D
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Work is slow at the mo, a lot of head scratching to make parts fit, there isn't enough room in the wheel arch for the Audi bits. So I've had to start moddifying.
i) The top trailing arms are too long so I've cut drilled and tapped joing each section together with some studding, they're now adjustable. ditto for other side
ii) The hub upright is too long, again it's a cut and shut.
iii) The steering arm's on the wrong side, so I'm moving it to the other side.
A majority of these changes are welded in place and although I am a welder I've spoken directly to the filler/rod manufacturer regarding their recommended procedure. I've produced a couple of test pieces and hit them with all my might, not one failure, I'm now happy.
The front alteration is going slower than I'd like but it's definitely doable.
I just take one look at the disc and caliper to keep me motivated.
D
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Thanks Mate ;)
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A pleasure Darren
I went down to see the great V8 Build, Ive got to say you is one gifted guy ;D, The kit really is a solid piece of work, il be visiting the guys them self soon ............. WATCH THIS SPACE
I hope its works out for you just pm me when your ready
p.s i hope im one of the first to experience the power of your beast ;)
Speak soon and keep up the great job
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Your kit will probably be finished before mine!
;D
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;)
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Thanks for letting me borrow the exhaust, it gave me a chance to look at the Ferrari option, unfortunately it would have meant too much work, the tubi design will be a possible alternative.
Thanks again.
NB; Now you've got your Large DNA workshop almost finished things will really start moving ;)
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It's been a busy few weeks with the front suspension and steering set up.
My main problem was to overcome the wheel hitting the two top arms, I've had to reduce the hub height twice!
To keep the hub mounts correct I fabricated two more jigs before I could even start to think about welding it together.
The hub steering arm was in the wrong place So with the aid of another jig it's gone from the top back to the bottom front, this is welded and bolted in place.
The nickle rods have been a pleasure to work with and I've completed several strength tests on discarded bits of the wheel hub, I was satisfied with the outcome.
There are a few reasons I've perservered.
1) The width of the Audi wheel base is close if not the same as the Ferrari (no spacer/stud pattern converters)
2) It holds massive discs and calipers as standard
3) The suspension geometry is a work of art, which ever way the steering is pointing the front wheels are cambered accordingly; both wheels are pushed into the tarmac
A suspension web blog describes it as the next step in suspension/steering evolution
4) Again with the suspension- each top and bottom arm is independent and offset, so when you turn the steering it will take the wheel back and forward, opposite to that of a standard set up, with the correct wheel there's no arc of movement as the steering is turned.
This has turned out to be as much work as the back and I'm glad it's almost over, I just need to fabricate mounts for the steering rack.
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Here's a picture of the extended steering arm, I shortened the toyota arm and ran a 12mm die down the end, then tapped out the cut up Audi steering arm ball joint and joined it together, no welding involved just a lot of screwing!
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just awesome work fella.. I hope I get to see the car one day :-)
Are you intending to keep her?
Steve
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I always considered a 'joy factor' shelf life of 2 years.
Let's see what happens
Once I've bolted down the steering rack, I fancy a little cleaning up, so I'll sand blast the front calipers and hubs, spray with zinc ready for paint.
D
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This thread makes me warm and fuzzy all over.
Dangerous, are you still utilizing the stock Audi suspension geometry? Will you be using an aftermarket coilover setup? If so, will you order them for an MR2 or the Audi? Or do you have a trick up your sleeve we don't know about yet? :)
Really great project, keep up the fantastic work!
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Due to the lack of space I'll be using Mr2 struts, but these will be adjustable from GAZ who are just down the road from me. They manufacture their products in house, the Tec Dir said they could produce anything I require. COOL!
D
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My main problem was to overcome the wheel hitting the two top arms, I've had to reduce the hub height twice!
To keep the hub mounts correct I fabricated two more jigs before I could even start to think about welding it together.
The hub steering arm was in the wrong place So with the aid of another jig it's gone from the top back to the bottom front, this is welded and bolted in place.
The nickle rods have been a pleasure to work with and I've completed several strength tests on discarded bits of the wheel hub, I was satisfied with the outcome.
Im having a hard time visualizing what exactly it is you did to the hub. Was portion of the hub cut off and rewelded into a higher position in order to clear the top arms?
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Original hub on page 7, new cut and shut hub page 9.
D
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ahhhhhhhhh i totally get it now. very interesting, i'm really looking forward to many videos!! :)
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Been away from the car for a while, I've been searching for an estate to replace my van, 6 weeks later I've bought an Audi A6 2.4se avant. It's an old one with high mileage but cheap.
I've just carried out a FULL service (nearly three weeks work) new sump, rocker and front flange gaskets, new cam and crank oil seals, new belts, new roller/idlers, plugs and fluids. Plus a few other bits.
The elsawin manual has proved invaluable, but there's a small hitch, when you carry out this type of work I always disonnect the battery; the manual and Audi forum informs me that I need to do electronic resets, so I've purchased Vag-com leads and @*@@? software. The advantage of this is that I can now diagnose, reset fault codes and set parameters to my preference including the engine in the MR2.
Bonus!
D
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wow think i might follow in your footsteps. you could be the ferrari 430 killer if you could get more poweerrrr comming outa that engine!!!! keep us all up to date with your engine
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Wow, I coulda had a V8?! ;)
What is the weight differential of a v8 vs. a 1zz, 2zz, v6? Is it gonna change the drivability much? (ie. front/rear balance)
With such a light car, what is a good HP target range for a screamer that isn't overkill as far as hookin up the tires? I know at some point, too much hp makes a car hard to drive. Where is that point for an MR2 spyder DNA 430?
Would love if someone could give an overview of the various options for more performance.
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Well, the obvious option is to tune the standerd vvti engine, but there is a limit. Safely, you should be expecting no more then about 185-190bhp. The easiest engine swaps are the 3vz-fe 3.0 V6 from the 1992-1993 Toyota Camry. This comes with 150bhp as standerd, but can be easily tuned to produce 180bhp. The other logical swap would be the 1mz-fe 3.0 V6 from various Toyotas and Lexus' again with 180 odd bhp. The vvti model was into the 190's, and Toyota offered a supercharger upto 242bhp, but you can extract upto 270bhp from them. Both V6's require a mk2 MR2 'box and modified linkages and serious engine bay work. You can follow dangerrous and fit an Audi 4.2 V8, but it's complex. Both these V6's are transverse still, so make sense.
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I just picked up a 7k mile MR2 so the engine is virtually new and worth keeping. What cost then to supercharge and where best to do so? What power without sacrificing reliability?
DoveUS
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I just picked up a 7k mile MR2 so the engine is virtually new and worth keeping. What cost then to supercharge and where best to do so? What power without sacrificing reliability?
DoveUS
Google for supercharge mr2 spyder , tons of info will come up.
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The mr2 mk3 Can be tuned much higher than 200 bhp!....
This kit will give you 350 bhp. http://www.turbo-kits.com/mr2_s_turbo_kits.html
This kit gives you 240 bhp. http://www.silverstoneperformance.co.uk/
I have seen on the net some where with 400 bhp!... The real car has'nt got much more?
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I'd be careful going for a kit like that (350hp)t, theres been no end of problems with guys trying to get those figures on MR2roc, wth water seals oil seals and gearboxs blowing.
A low pressure turbo or supercharger set up is best way to go if you want to keep the 1zz, for me preferably the supercharger, then either the V6 or V8 option. I'll be selling my V8 next year to move onto a zonda kit
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The mr2 mk3 Can be tuned much higher than 200 bhp!....
Notice I said SAFELY!!!! The engine will have no end to problems at that power! It just wasn't built to cope with it. The whole ethos of the MR-2 is not to be fast but to handle beautifully.
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the 3 cars in this youtube clip were all running rotrex superchargers and all 3 well over 200bhp
http://www.youtube.com/watch?v=AbqMxF-BzIE&feature=related
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200bhp where? Flywheel or wheels. It makes a massive difference. I wouldn't try adding anymore then 100bhp to an engine, so 240bhp at the wheels would be my limit. My Rover V8 started at 180bhp. It now has 242bhp at the flywheel. That is as much as it is built to cope with. Superchargers get very very hot under bonnets, so extra cooling would be needed, plus the cost of the supercharger and the faff of re-arranging the pipework. Not worth it imho. The car would be good enough as is.
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these were at the wheels and they did have a little bit more I must admit they had toughend engines tricky diffs and more along with new ecu and more etc etc they were are awsome to drive I have driven lots and lots of MR2's now over the years infact I would like to find someone who has driven more I have, Ive driven them with camry V6 engines and turbos etc etc but nothing compared to these cars!
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FWIW, I believe the supercharger option to be the best option if your going to stick with the 1zz, you dont have the heat of the turbo in the engine bay for one thing and another big plus is you wont have the sound of a dump valve ( whether that be an external or internal)going off, which really blows the cover of it being a rep.
Although having said all that each time a start up the V8, it frightens me stupid, then I start giggling :)
Apologies to Darren for hijacking his thread, (if anyone would llike to start a 'what engine is best' thread it'd be a good idea)
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Turbochargers are the Answer!
The Aftermarket age-old question endures, I am looking to boost my engine, do I supercharge? This is not a quick answer, but let's look at some features that make the turbocharger the most powerful and economical power adder for your engine.
A Turbocharger is:
More Versatile - A turbocharger is equally appropriate whether your goal is a mild street application or an all-out drag racer. A properly matched turbo can provide superb response and the ability to run boost levels that will push your limits.
So-called Lag - Modern GT-series high-flow wheels are smaller than ever to reduce inertia, and in combination with the ball bearing system give throttle response that has to be driven to be believed. Additionally, a turbo's smaller and more compact package allows for greater flexibility in installation locations.
More Efficient - The turbo uses energy that is otherwise wasted through the tailpipe, where a supercharger has high parasitic drag since the power to drive it comes off of the crankshaft. Garrett's modern GT-series compressor and turbine aerodynamics push the state-of-the-art limit for stage efficiency and flow range.
More Durable - A turbocharger only has one moving part, the rotating assembly. No pulleys, belts or geared transmissions. This makes for a less complicated device with fewer things to go wrong.
Information Provided By: Garrett Performance Products
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How many Ferraris have turbochargers ?
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Real ones or replicas ???
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Lot of Ferrari's have turbo's not as standard....
http://www.fantasycars.com/1/News/Twin-Turbo_600hp_Ferrari_360_M/twin-turbo_600hp_ferrari_360_m.html
Problem with the mr2 is, not how much you can get the bhp up.it's if the chassis can take the power or not, maybe if you don't see a bend it`s ok but when you turn in at speed then you will feel the whole car twisting. Good handling, yes the mr2 has got this but only at moderate speeds. You but a v8 in there and you will have more weight and more twisting. Like the mini cooper all them years ago "Fantastic around the bends"but the car could only do 90 mph flat out. The difference in the mr2 and a ferrari are miles apart as far as handling is concerned the faster the car can go the more every thing has to be uprated and that cost's money! Even a Farrari at speed needs to be handled with care and attention or it will bite your head off littarly. So my point I guss is, drive carefully with all that bhp and enjoy your cars.
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Most powerful MR2 is about 700hp, so theyre a pretty capable chassis.
PS you can always up the level of bracing and therfore aid turn-in
A couple of points about twisting.
The V8's the myself and Darren have are longitudinal so , theres actually a small reduction in the twisitng moment when power is applied.
If you mean twsiting due to extra weight, the audi V8 is an aluminium engine, the extra weight is about 100KG ie a passenger. However in this instance the extra weight, rather than sitting out off axis as a passenger would, is along the longitudinal axis and within the wheel base, so what you get is more grip at the rear, but no extra moments of inertia in regard to 'twisting'.
However you do get more understeer, but this is cancelled out by two things, one is moving the fuel tank forward, as it is in Porsches( or thats what I've done) and by having adjustable platform shocks and corner-weighting the car back to OEM balance.
Job done.
It doesnt handle as crisply as a 1zz powered roadster, and is little bit slower in transition, but in esssence its a faster set up.
Heres a video of a silver V6 powered MR2 versus a MK2 turbos ( more powerful than the mk3 turbo) on the race track. The V6 weighs within a few kilos of the V8 you will notice how it goes around the corners !
You'll notice the silver V6 slowing down due to him selecting 5th instead of 3rd, he then finds third and the V6 is gone
http://www.youtube.com/watch?v=3OIAW-nlUHM
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Getting a few hours back on the car, fabricating the gearlinkage, driveshaft adapters and moving the handbrake.
D
Pictures next week.
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cant wait for pics dangerrous 8).
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Has anyone ever fitted the Supercharged engine from the Lotus Elise SC?
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Spent most of the weekend designing and fabricating the gear linkage, this uses a quick shift from Mr2 Mk1, and a combination of the original Mk2 and Audi gearlinkage with extensive modification. I'm getting new extended pushpull cables from cable-tec
I'm very pleased with the precise gear change feel. I'l post a video when I've got the cables installed
I've used the Mk1 gear selector to give me a low centre console and now I can fit a 6 speed 'H' gate
Must admit it's been a refreshing change to get away from the, now completed, front steering/suspension.
I've had a look at the driveshafts, unfortunately there's not enough room for an adapter (my bad) so need to cut&shut, weld, lathe and possibly balance a pair from the A8 and a set from a diesel A6 (or equivalent).
While I'm down the breakers I'll look around for a decent hanbrake, as the A8 is too big!
D
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hi dangerous
thats some engine build your doing there buddy,ive got to say you must be multi talented to fit and make those parts fit.its going to be a top class job when done.really cant wait to see some more pics.
i admire your workmanship buddy :)
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Thanks
Just wish I was a far as you and some of the other guys in the build ???
D
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it will get there buddy.i dont think anyone on here has underaken such a complicated modification and i for one think its something to be proud of.it will be one hell of a car finished,will have everything,sound/style/speed and thats what these cars are about.my dad used to do these type of conversions,he was a panel beater for ove 50 years until he retired,now i have him working for me on and off.(he would be bored at home) lol he made some crazy engine changes into smaller cars.......
keep up the good work buddy :)
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I agree,
This is gonna be an awesome sounding and performing car. Cracking work Dangerous. I guess i'll hear you before i see you, when it's finished.
Keep the posts coming.
Beany. ;D
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Since I'm working around the transmission area I need a clutch kit which is rated at around 370bhp BUT has a diameter around 210mm, I'll contact AP racing tomorrow.
Can anyone throw any more Clutch Manufacturers at me, it's for an Audi 2007 2.0ltr diesel 01x six speed box
Cheers
D
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Depends on what flywheel you've gone for Darren, I went for the S4 unit and advised Paul W to do the same, which fits with the flywheels we have.
One of the key things is the dowel size, on some fly's theyre're 6mm on others they're 10mm.
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Not an issue, making my own flywheel
AP racing - around £650
D
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Not an issue, making my own flywheel
AP racing - around £650
D
I admire your dedication, this flywheel cost me IIRC about £350 with the S4 clutch plate and pressure plate (good for about 440bhp) for about £180.
(http://i48.photobucket.com/albums/f228/Subarupaul/P1000827.jpg)
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Just a quick update, drive shafts are taking a little longer than anticipated, they required more lathe work, serves me right for using one from an audi and one from a golf, although both are 2.0ltr tdi's.
Had a look at the diesel dual mass flywheel again this week, I might be able to fabricate the new one and use the S4 clutch kit, the ring gear and engine speed sensor might fit behind the pressure plate dowel and bolt rim- a lot of maybes but I'm optimistic
Pictures at the end of the weekend
D
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These V8 conversions are serious builds guys and i take my hat off to you. An inspiration to all of just how extreme you can go with these cars. Looking forward to the end product.
Beany ;D
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ditto beany
its going to be one hell of a monster.cant wait to see it and hear it.
hats off to dangerous for this conversion.....
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How would a 2ZZ swap and supercharger compare?
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Driveshafts- First A8 outer cv joint and part of drive shaft, coupled to an A4 diesel shaft and cv joint. Second A8 outer cv and part of shaft joined to a golf diesel shaft and modified cv
This has been a lot of work, ensuring all parts fit correctly without compromise, the shafts have been machined for an interference fit then welded before being turned back down on the lathe.
I then moved onto the front radiator, I was going to utilise the A8's but it's to high even when sitting at 20 degrees, so with a lot of searching I think I've found one as big as possible for the slot available it's a VW t4 transporter 2.4 diesel, I'll purchase a complete unit next week.
Next in line:- the handbrake, I stripped down the A8's centre console to have a look to see if it would fit afterall, good news, under all that wood and padding is a normal size arm.
So I set about making a mounting bracket to suite it to the Mr2, it's almost finished, I'll post some pictures of it when I've connected the gear linkage and handbrake cables
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hey dangerous
coming along nicely buddy.when you reckon you will have the engine in and all sorted,,, my dad used to build cars like this putting v8s in cars etc and making all the running gear etc.the list is endless,but as ive said before i know how much a hard job these conversions can be so hats off to you mate,going to be a great conversion when all built etc :)
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Engine is in, Audi A8 front and back subrames are in, loads done ,but still loads to do
D
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Been away from the car for a while, with man flu, christmas duties and work.
Although it doesn't look too much, I've made some more progress
1, the new hanbrake set up is completed. I was able to use the Audi's configuration afterall and it works a treat with handbrake (Mr2 switch), cable all OEM. The hanbrake sits next to the drivers bum support as in the 430, the Audi's centre console will provide some of the moulding when I make a new one.
2, New front end radiator area- This was a bit of an unknown as I had no reference, the Audi rad was just wrong, outlets impossible to work with, auto inlets, fan temp switch etc. So I started looking on the net for a replacement, Sports Alumium rads were £300+ so that idea was ditched. Luckily radiator suppliers show a drawing of every radiator, I looked at around 200 before coming across the T4 VW transporter 2.5tdi rad, so £60 later I'm working with it on the car.
I looked at the Mr2 radiator mount metalwork and decided to just cut it all away, I'd tried fitting the new rad here and there but, something was always in the way!
Now with a fresh area I started to fab up new fan, radiator and condenser mounts, I'm very happy with the end result, the new radiator has around twice the cooling volume of the Mr2 one.
The condenser will be hidden from view as it's pretty tatty, a new one is around £220, I'm not prepared to spend that much on one. The US can supply for £100 but shipping and taxes bump it up to a total of £250!
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And the radiator, the hoses will sit on the lower plates at the front for support and extra cooling.
I'll be pipe bending next weekend, main hoses, heater matrix and petrol tank filler pipe from the rear.
I've fabricated a new power steering centre mount, I'll also have some new hoses made up to make up more petrol tank space.
Preliminary measurements of the tank size may give me a front holdal area for a small weekend bag ;)
D
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Got back from Eygpt last week and unfortunately brought back a pesky stomach bug aswell, it's knocked me sideways!
I've only managed to do the new pipework from the engine to the radiator and heater matrix, but at least thats basically finished now.
D
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hope you feel better soon dange and at least you have finished one job,one jobs better than none lol
gonna be a top job finished mate :)
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Work has been crazy giving me little time to concentrate on my home projects.
All I've managed to do is fit a towbar and electrics to the Audi for Stoneleigh (what a nightmare, the back and drivers side had to be stripped down to fit the towbar and Audi towing control module with electrics, not happy >:()
And during the evenings I've fabricated a fuel cell template. I'm using the original toyota fuel pump with sender unit, the Audi and Toyota pressures and flows are pretty close, if it doesn't work I'll fit an external pump. I'm also going to copy the swirl pot from the toyota tank. The fill tube will run from the DNA desired position to the front of the car using two return stop valves, the diameter of the pipe will be at least 34mm for a descent flow at the petrol forecourt.
Here's the template, it's been in out of the car countless times for a snug fit.
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Does this mean you will be trailering your build to Stoneleigh?
Just a thought, but i seem to recall reading somewhere that the Supra fuel pump fits in place of the mr2 pump and gives a higher pressure. Might be a cost effective option if you need more output.
Look forward to meeting you at Stoneleigh.
Beany ;D
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Cheers for the info. I'll start looking ;D
D
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Ticked most of the boxes this week, picked up all the tig consumables, Ali sheeting and a cheap sheet metal bender
Today I took apart the Mr2 tank so I could see the design of the fill resevoir for the pump, it's simple but ingenious.
Cut the Ali using the templates.
I'm out tonight, so if I'm up for it I'll start welding the new tank together, ready for fuel flow testing tomorrow.
I'll video the test, as it will show what I'm aiming to achieve.
I had a look on ebay for fuel pumps and it seems they do direct replacements for a bunch of toyotas as a single unit
http://cgi.ebay.co.uk/NEW-TOYOTA-MR2-SUPRA-CELICA-255-LPH-UPRATED-FUEL-PUMP-/380108602214?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item58803cfb66
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OMG Near miss!
I was testing the toyota fuel pump which was submirsed in a couple of gallons of fuel when a spark proceeded to set the pump, bucket and me alight, I was working on the bench, so trying not to freak out, I took the pump and bucket outside of the workshop. I then addressed my gloves and fleece which were burning, I took off my gloves then patted the fleece. Now it was time to sort out the pump, I got the garden hose and gently sprayed the surrounding area, this put the pump out. Next was the bucket of fuel, I got some large blocks (which were next to it) and created a wall, next I just sprayed the blocks, edge of the bucket and floor, about half an hour later the fuel had burnt off.
I gathered myself and realised how lucky I was. I could have lost everything, but the only damage in the workshop was a singed pvc window frame, melted blinds and angle grinder and a slightly charred workbench. Outside, well the bucket is no more and the pump is out of the project.
I was able to carry out a test (before the fire) and confirm that the toyota mr2 pump assembly is not feasible- so back on ebay for a compatible part.
Today I started to weld up the fuel cell, the base and sides are on, now I can see how much room I've actually got for the intank fuel pump assembly
D
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good youre OK D!!
sounds like the sort of thing that happens to me, ;D
MADMAN
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Glad your ok D
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Been away from the car for a while, had a break over easter, but finished off the new fuel tank today.
I checked the capacity of the tank and it comes in at a lovely 64ltrs (14.4gallons), very happy, should see a range of 280miles between fills at 20mpg. I'll mock up some fuel and breather lines so I can test the engine later
NB. The blue pipe is just to stop the water leaking from the tube, btw the non return valve works a treat, I nicked it from the toyota tank, the passat pump and sender unit are sitting on top of the tank, the pump twist & locks on the base of the tank
Next I'm on the gear cable, a new supplier has sent me a sample and it's perfect.
Straight after I'm on the firewall. I need to put the roof back on so I can see my working area around the engine as I also need to fabricate a sealed flap for the dipstick and filler cap.
I'm having a weekend at Stoneleigh, so can't see much work going on over the next two weeks, maybe it's time to take a working holiday to get things moving ;D
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tank looks great mate and its coming on nicely,yeah buddy a working holiday sometimes does the trick and its amazing how much you can get done,prob see you at stoneleigh buddy and looking forward to seeing some great cars
:) :) :)
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Ahh the inspiration of Stoneleigh ;D
First let me say I enjoyed stoneleigh and can't wait to be there with a car
I've been busy on the car, and can report some more work has been done
First the firewall, this meant putting all the roof and trim bits back on the car for measurements, then loads of cutting grinding and welding to obtain a real snug foul free fit, the primered frame shows 'open areas' this will be the easy access engine panels, the top plate will be bolted down ali, oil check and filling will be courtesy of a couple of flaps in the ali panel.
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/firewallframewithinallthesurroundingtrim.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/firewallframewithroofetcinplace.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/Firewallreadytoplateup.jpg)
The front inspection/access panel is where I've got two options, i) another ali plate OR dare I say a polycarbonate panel to show off the V8, hmmm, yet to decide
Next, continue with the suspension, as you may all be aware I'm trying to make the car OEM for many parts, so I've made a conversion block which takes the standard Mr2 strut and marries it up to the Audi bottom wishbone, this works suprisingly well, the strut sits dead centre, I'll still use the GAZ struts as they are adjustable. A similar block will be utilised for the back, I haven't completed this yet as the engineering supplies shop is shut for the bank holiday weekend, I need a couple of M12 fine thread bolts.
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/mcphersonstrutconversionblockfinished.jpg)
And finally today I've carried out a primary check on the lathe for the fabrication of my new flywheel, a dual mass one is sitting in it for clearance checks.
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/Gettinglathesetupfornewsolidlightweightflywheel.jpg)
oh and I've changed the way I upload pictures, hopefully this'll give a better viewing experience
D
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Hey,
I have a queastion...
I have a Lexus LS 400 4L engine... 260 HP... 8cyl. ( which belongs to my 97 year old grandpa... he can't drive any more sinse 2 months) (!)...
Can the engine be used for a build like te 4thirty? or a 5cudo? Are these type of lexus used in any kit build?
Kind regards,
Dick
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Hey D.
Awesome work,
the suspension block conversion etc. could do away with the spacers, making it possible for places like AUSTRALIA who can not use spacers to be able to build DNA cars legally ;) ;) could be a money spinner in the making ;) ;)
Look forward to seeing completed project.
MADMAN 8)
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hey dangerous
looking good buddy its gonna be one of those extra mile jobs when done.v8 spyder will sound awesome..you have put some craft and graft into this build and it will show...
im with madman cant wait to see it done..........
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The ls400/430 is a beaitiful engine, very quiet and strong. There's a LS website that is dedicated to modifications, including a twin turbo 400. Unfortunately it's a rather large engine and would make fitting it into the Mr2 more difficult than the Audi v8, there's also the added expense of a conversion plate for the gearbox for starters.
It's not impossible but I would stay with the Audi option, purely because most of the parts are available 'off the shelf' and a couple of projects have or are being completed.
D
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Nice work. This is now getting interesting. Keep the posts comming :) :) We like!
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Hey Dangerrous,
Thanx fot the info. It is indeed a lovely engine lot of power. Too bad she is so big, fat and heavy. The LS 400 is not a really fast car... though it is a lovely car to drive.. its like driving a big ship (compared to my volvo s40 II 2.0 turbo diesel lol). It is for sale now... but don't think I'll sell it soon due to the sky high petrol price (and 300000 km).. so I'm also on the lookout for options to give the car a second life... do something cool with it.. hehe (maybe I can sell it to Superreplicas to make a RR phantom out of it LOL)
Can you give me the link of the LS website you where talking about?
Love your build! Lot of skill!!
Best,
Dick
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I owned a ls400 for 8 years, I just didn't want to get rid of it, I was also thinking of using the engine, but a few measurements persueded me otherwise!
here's the turbo link
http://www.soarerworld.com/forum/showthread.php?t=105
I've picked up the profiled blank and machined the back for the speed sensor ring and ring gear. It's now been turned around to machine for the pressure and clutch plate, I'm only running 0.02mm out as I've dialed it in, face to face it's 100% true.
Should have the basics done by tommorrow.
Pictures to follow, I've tallied up the cost and it's around £110 (£90 for the profile blank) Machined flywheels seem to run at around £280 and that's without the extras ie sensor ring and ring gear.
(I love saving money, I'm just tight!)
D
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Thanx ror the link Dangerrous! Awesome! Allso found some vids on youtube.. the turbo's / superchargers turn the ls 400 into a beast!
Can't wait to see your new pics.
Kind regards,
Dick
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It's been a busy few days on the lathe, I've modelled the flywheel on Paul and TVR engineering's individual designs
First I had to clean up the 25kg slab of billet steel, I'd already cut the front of the flywheel
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/firststagecut.jpg)
Next the cutting of the back, here's where I took all the weight off the flywheel
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/backofflywheel-1.jpg)
Here's the swarf from all the cutting, bit of a bird's nest
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/Swarffromtheflywheel.jpg)
Next it's the first cut to make way for the pressure plate, you can see the front of the flywheel.
I machined up a tight fitting bush to keep everthing central, that's what you can see in the middle of the flywheel
(http://i8.photobucket.com/albums/a13/dangerrous/kit%20car%20pictures/frontofflywheelfirststagecutouts.jpg)
Next to polish the cut outs then drill and tap the flywheel.
Once it's finished I'll send it to be balanced with the clutch assembly
D
nb, it weighs in at 6kg
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Another good weekend's work, I've now finished the flywheel
http://www.youtube.com/watch?v=dWzZcZh6PlQ
And also completed the conversion blocks for the rear struts
http://www.youtube.com/watch?v=GeLZ8AXs-wI
Hope this makes the build a little more interesting
D
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NICE VIDS! it sure gives an extra dimension to your thread! Love it and very educative!
Keep them comming!
Are you going to put a genuine exhaust on ? You prob know MacGyvers build on madmechanics.com... he just fitted his ferrari f430 exhaust... man oww man that sounds sexy!!
http://www.youtube.com/watch?v=hzVNhyOp40c&feature=player_embedded
Imagine that on your V8! hehe
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unfortunately it's not practical in my build, as I've already looked into it
D
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Although not much going on the car I'm just in the process of having my exhaust parts made at ccr and Ben at Shark performance is readying my transformed OEM ECU for dispatch.
Once I've built up the exhaust I'll connect up the electrics and fuel lines ready to start it up.
After confirmation of life I'll tear it down to the chassis send of parts for powdercoating, spray the chassis then build her back up including actually permanently fitting the two year old kit, now I'm getting excited!
This has and still is a long build (nothing to do with the kit)
D
ps made a template,the exhaust will be slightly different.
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hey great vid dangerous love the craftmanship and idea of the mock exhaust..
great buld mate
:)
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Finally got the gear shifter cables and I've actually finished the gear mods
Although I had originally fabricated the linkage I couldn't confirm gear lever throw for a 'quick shift' set up and to work with the Ferrari h gate.
Unfortunately when I built it up with the cables there was to much travel 1st to 2nd or 3rd to 4th etc so I had to redo the linkage. A few calcs later and some alterations and it's all done.
(http://i8.photobucket.com/albums/a13/dangerrous/finshedgearselector.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/finishedgearshifter.jpg)
I've just dry fitted the rear clip to get the positioning of the exhaust, this will take some time to complete.
D
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Still playing around with a few bits, I've now repaired the rear clip and mounted it on the car, I've also worked on the Mr2 doors to fit the outer dna panels. I've fitted the panels to assure the exhaust exits in the correct place. While I was 'adjusting the doors I also trial fitted the door cards, anyone notice that they're not a true perfect fit unlike the outer panels, I had to trim mr2 door a little more than the video suggests.
Anyway I've made another exhaust template further to my discussion with CCR, although I am questioning the need for two large silencers
Here's a vid of the new mock up
http://www.youtube.com/watch?v=aF-Lo2GFtxM
This is a vid of the gt40 V8 set up, WAY TOO LOUD for everyday use
http://www.youtube.com/watch?v=5qfGB0Ofc8s
http://www.youtube.com/watch?v=CAOqx_FqueM&feature=related
And a vid of the ABZ engine in a lotus (the holy grail of Audi V8 conversion and my inspiration)
The engine has a VEMS ecu and 300cc injectors
http://www.youtube.com/watch?v=581rF3HhKAM
D
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I'm in AWE dangerrous, this is going to be the mother of all 430 spyders. Keep up the great work ;D
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I've had a busy time lately, Just landed a cracking new job (this has taken a fair amount of my 'spare' time)
The exhaust components have arrived ;D But would you believe it, the welding supplies shop is stock taking this weekend, so I can't get me tig bits :(
(http://i8.photobucket.com/albums/a13/dangerrous/Exhaustcomponents.jpg)
While I was waiting for the exhaust I decided to take Beemamans door locks one stage further
I've put the toyota locks in the doors, I drilled a 23mm hole through the grp and they're a perfect 'looks like they should have always been there' fit
(http://i8.photobucket.com/albums/a13/dangerrous/mr2lockindoorpanel1.jpg)
The backing plate allows me to remove the locks for service and spraying
(http://i8.photobucket.com/albums/a13/dangerrous/Doorlockplate.jpg)
There's an extension which links the door lock to the mechanism via a nylon bush preventing any rattles.
(http://i8.photobucket.com/albums/a13/dangerrous/doorlockextensionbush.jpg)
I'm using a non-primer bonding mastic which is specifically designed for the automotive industry, I've also used it on the petrol tank mounts, at £26 a tube it's expensive but has proved itself
Both doors are done and the locks work, another bitsy job completed.
I should be on the exhaust next week, it's a good weekends worth of work
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Top job d
I'd of done that but it was an afterthought and skins were already fitted.looks good though mate another modification that sands out.
:)
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Still working on the exhaust, going together well but just no room to manoeuvre, It's rather large and is proving to be a snug fit, the guys at osprey have really proved their weight in gold for quality and after sales support, it's cost about £1000 to do, better than the £2500 quoted by my local specialist, and I'm enjoying it.
Pictures to follow maybe Sunday
D
Just an add on note, new job and Christmas shopping is taking me away from project, I'll post when back on it
Darren
NB.
Back on the car, namely exhaust,
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Time for a little update, the exhaust is still not completely finished 'cause I ran out of tig gas doh!
But I've just put a vid on youtube, every single part had to be built up apart from the silencer, I've polished the bits as I've gone along.
http://www.youtube.com/watch?v=K4j7NB9Py_g
gives an idea of how it fits in the mr2 and how I've made use of the extra room in the kit.
D
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Looking great so far dangerrous
You know when someone is serious about their build when they produce a jig specifically for their tail pipes, LOL :D
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Finally finished the exhaust, really happy with result, hope it sounds good!
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0218.jpg)
View of either side from the top
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0220.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0219.jpg)
The exhaust box is held in place by a pair of sliding brackets, this will allow me to carry out any final adjustments when the kit is permanently fitted to the car in 2014 ;D Got a feeling I'll retire before I finish this!
Here's the guide I used from the Ferrari owner's club, these guys pay £60 to 'chrome' up their tips with stainless steel covers
(http://i8.photobucket.com/albums/a13/dangerrous/css-ex2.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/css-ex4.jpg)
Just a foot note, I'll be wiring in the new upgraded ecu next week for testing, Ben at shark performance needs to check all his modifications allow the engine to run in sports mode; that's increased bhp (around 20bhp), immobiliser bypass, sharper throttle response and a ghost signal fooling the gearbox limp mode.
If the ecu modds are successful it'll be a big leap in the build and the first OEM ecu re-write of it's kind (that I know of) for the ABZ engine.
The later fly by wire Audi V8 is another story
This could open up a new market for the V8/01X gearbox combo, especially for the Lambo guys, remember it'll be a plug and play ecu, no need for ANY alterations to the engine wiring or sensors. Fingers crossed :)
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Time for a little update, no ecu yet so I've done a little more suspension work
The video below is for the lower cross member
http://www.youtube.com/watch?v=IJrQHqphHpg
Next on the bill is the rear anti rollbar, the audi and Mr2 one's were not compatible with my current set up, the video below hopefully explains what I need to do and how I'm going to do it
http://www.youtube.com/watch?v=hC-flfhE0SQ
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Hi d
Great work buddy you remind me of mcgyver off mad mechanics.
It takes skill to do the work that you both do.most of us can build these kits due to the ease that DNA have made them but to put in another engine and fabricate all those parts etc takes more than skill.my dad used to be the same.he made one of those ghostbusters cars into a monster truck with a jaguar v8 engine.took him years on and off then before it was painted someone wanted the engine and he scrapped it.
Anyway d great vids and info keep them coming top work
:)
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Good job!!! i ADMIRE YOUR WORK!!!
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Another step forward on the project, this time it's the antiroll bar
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0231.jpg)
All parts will be sent for shot blasting and powder coating
Here's a vid of the setup explained and installed
http://www.youtube.com/watch?v=9RzxaBd-t9c
A little extra work on the fuel tank next...
D
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Great videos Dangerrous, it did look like the anti-rollbar was very close to the gear linkage, but fantastic work in the design and fabrication fella
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all clear around that area
D
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Top job d as always buddy.great craftsmanship and detail.I think should be call the extra mile.
:)
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Nice to see your still at it :-) 3 year mark coming up soon.. however I can't really say anything as my Lambo's been even longer.. lol Keep it up fella great pioneering work !
Steve
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Gotta laugh, I said I'd have it done in 6 months. :D
Things are moving forward, all these little 'later' jobs are getting done now while I wait for the ecu (still being tested )
Still love the look of the lambo, and would have done the same work if I'd gone for one of them.
Mcgyver seems to love every hurdle he comes up to on his project and exceeds with every step.
I'd love to see how the extra mile project is going, there's a lotus/360 project on extreme which seems to have stopped aswell.
Rest assured the car will be finished, when I don't know, let's see how the summer turns out
D
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The extra mile project is going slowly as i spoke to the guy today he said it should be running soon he as had to develop lots of one off parts cables etc etc to get it up and running now just some electronics and the base car will be ready for a kit
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Another week another job done...
I've fabricated the new header tank for the V8:
(http://i8.photobucket.com/albums/a13/dangerrous/headertank.jpg)
Here's a vid of the the header tank design, size and location
http://www.youtube.com/watch?v=pC6GJQrX4ys
D
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After 2 YEARS I'm finally getting my ECU back, :o ;D
The chip upgrades have been done, tested and confirmed running with new software!!!!!!!!!
I've been looking at various parts of the project, one being an electric roof, I gonna be bugging a 430 owner at detling, I need to see EVERY movement of it folding away and raising back up, cheers in advance for that.
Next is the dash, I have a unique advantage that the Audi engine gives me extra readouts ie. oil temperature and battery volts, the fuel gauge's signal is via the VW fuel sender
I have an appointment to see a backyard specialist in middlesex, he can produce one off dialbacks, and although 'cheap' I'm still looking at £250 for this with little extras included.
So here's a picture of the actual 430 dash (not mine)
(http://i8.photobucket.com/albums/a13/dangerrous/ferrariinstrmentcluster.jpg)
Here's one in a 430 with the carbon surround
(http://i8.photobucket.com/albums/a13/dangerrous/f430gauges.jpg)
Here's my collection
(http://i8.photobucket.com/albums/a13/dangerrous/collectionofinstrumentclusters.jpg)
I might be able to copy the fuel led display although it's not 100% yet, maplin do a led 10step led and driver on 0-12v
(http://i8.photobucket.com/albums/a13/dangerrous/ledbar.jpg)
so plenty to be getting on with
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D,
I think you should re-name your build.
"The Extra Extra Mile" should do it. :P
Excellent work as always, but hurry up and get it done already. I need to see it, hear it and be jealous of it. lol
Keep the updates coming mate.
Beany. ;D
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totaly correct beany its gonna go more than the extra mile.
got to be the most technical and advanced 430 spyder build on here.
keep up the good work :)
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Popped down to GAZ suspension and ordered my new struts:- around £600 (cash) all in, they're going to give me a set of springs to try. This is just to get a feel for the stiffness of the car as a starting point, turn around for the struts is about 4 weeks
Also went to a dialback/gauge specialist in Middlesex, he's going to print a Ferrari set of dial backs to fit the Audi/Mr2 combo, he also offered the more modern 'blacked out LCD look' of the 458 :o. The gauges light up when the ignition is switched on, with the predominent yellow rev counter staring at you in the middle :-\
-
I had the ECU back two weeks ago and most of my time has been spent sorting out the inputs and outputs from the Audi and Toyota.
Unfortunately I've had to sort the immobiliser myself (long boring story), the upshot of this is the engine will retain it's original immobilser from the Audi. I spent most of the morning taking out the Audi ignition barrel, electrics and Immobiliser ECU which is totally independent from any system, once out of the car I 'frigged' it with the neccessary inputs and tested- it works ;D
Now I can actually finish off the engine ECU wiring to the Toyota components, I've even moved my secondary computer with all my workshop manuals etc to my garage because I have to keep constantly referring to the wiring schematics of the Audi.
That's about it for the next few weeks, as we're at Stoneleigh then an 80's weekender.
D
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:'( :'( :'( :'(
1) workshop computer kept crashing, took almost whole weekend to load new Electronic workshop manual updates for the Audi wiring schematics
2) Updates DIDN'T correct errors in manual
3) Unable to get into ECU via OBD connection, this wire definition is missing from schematics
4) computer keeps crashing if on for longer than an hour
5) irratic outputs from ecu ie fuel pump relay 0v supply from ecu, efi relay inturrpted 0v signal. ALL earth connections have been checked and rewired twice by two different people aswell as 12volt supply
6) Vag-com diagnosis error codes on TCU give low voltage warning, yet the immobiliser shares the exact path in power measured at 13.4v for both terminal plugs and has no DTc's
After two weekends of wiring up, a crashing computer, OBD problems and square eyes from staring at wiring schematics......
i)I've purchased another workshop desktop
ii)Decided to bite the bullet and go VEMS (versatile engine management)
And if that's not frustrating enough the coilovers are missing the Toyota top mount swivel plates from the original struts, I just hope they have forgotten to give them to me from the dispatch dept at GaZ, or this could be more hassle if they've been 'mislaid'
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sorry to hear all the probs d
when they happen buddy they happen all together..
hopefully they have just left them at base like you say.
you will get there buddy chin up :)
your doing an awesome build mate...
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Likewise D, sorry to hear about the set backs.
If Gaz have missplaced your top mounts, mine should be available soon, as my coilovers should be arriving at the end of the week and come with pillowball, camber adjustable top mounts front and rear.
You are welcome to them if you need them.
Battle on through the problems mate and keep smiling.
Beany ;D
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Phoned GAZ, they were going to call me for the same reason. The storeman was on holiday last week, when he went through the usual paperwork today he queried my SECOND parcel, as it was still on the shelf ;D
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Phoned GAZ, they were going to call me for the same reason. The storeman was on holiday last week, when he went through the usual paperwork today he queried my SECOND parcel, as it was still on the shelf ;D
I'm glad you got some good news Darren, sounds like you have been having some fun, let me know if you need anything to sort out your computer. Keep up the great work fella ;)
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Cheers I will
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I've made the plunge and started a purchase bundle with VEMS for the ecu
And i've tried my new Dampers on the car. This is the first time the mr2 has sat on it's wheels (Audi) in 3 years!
(http://i8.photobucket.com/albums/a13/dangerrous/finallyMR2onitsownwheels.jpg)
Sneaky shot of the front damper
(http://i8.photobucket.com/albums/a13/dangerrous/reargazshocksinstalledfirstfix.jpg)
Another sneaky one of the rears
(http://i8.photobucket.com/albums/a13/dangerrous/frontgazshocksinstalledfirstfix.jpg)
I haven't adjusted them yet, this is a side view
(http://i8.photobucket.com/albums/a13/dangerrous/Sittinglowww.jpg)
Can't be arsed to do anymore, More work next weekend
D
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Hey Dangerrous, this is going to be faster than the real thing!
Brillo.
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A little teaser update....
The Vems ecu is wired up and running in 've rich mode' (basically first start and run map)
After some tweaking and checking bits and pieces the v8 burst into life and OMG!!!!!! The throttle response is amazing, the sound has to believed, it's not like a v8 at all it has a deep raspy sound like a TUBI system.
So happy that after over 3 years my engine is alive again and the results are only what I could have dreamed of ;D ;D ;D ;D ;D
More tweaking later then the video to show off this monster
later's
D
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Brilliant news D,
I'm chuffed to f*** for you. Can't wait for the video to see how she sounds.
By your initial reaction, pretty damn good I'm thinking?
So what wheels are you having?
Looking forward to some more updates.
Hop to it! :P
Beany ;D
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Hi d
Really happy it's turned out better than you expected buddy :)
You've put some serious work into that car and it shows.some great fabrication and detail.
A true credit to your skills and craftsmanship d
Can't wait to see and hear the car done :) :)
Keep the good work and pics coming
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are you sure that youre axels are strong enough ?
i've put an Audi V8 4.2l in an diablo and have broke theme 2 times ! you can't imagine how much power those engine's have :o
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This setup is tried and tested, the late 01X gearbox is more than strong enough, the drive shafts are the original A8 rears and 20tdi's, again no problems there.
D
This is a bit of mashup between the Audi A8 and mr2, the Mr2 chassis sits on A8 cross members and suspension, the drive train is pure Audi, ALL the Mr2 drive train is sitting in a scrap heap outside the workshop
-
So what wheels are you having?
Looking forward to some more updates.
Hop to it! :P
Beany ;D
Well due to the suspension modifications my pdc is VAG or mercedes, there are some nice wheels coming out, but to be honest I love the diamond cut 458 wheels, so may start searching for this style, I've got a couple of good wheel suppliers local to me, so fingers crossed
D
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Little opps!
All this testing has kicked out the starter, A tooth on the flywheel broke and lodged itself in the starter sprocket, this in turn ripped the starter apart.
Sorry no vid as above has stopped play :(
I've started to strip the car down for powdercoating and getting the chassis ready for prep and paint, guess I've got no choice on the engine compartment colour, as Ferrari do theirs Satin Black
Gonna be busy in the coming weeks, I'll be taking a few weeks leave to get this part of the rebuild done quickly
Finally moving forward with the build ;D
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While I'm stripping down the chassis for paint, I thought I'd give you an idea of the throttle response and sound of my ABZ v8 engine, the following video is exactly what I've been raving on about, the exhaust is slightly different due to my own configuration, remember this is a V8!
http://www.youtube.com/watch?v=TBbQV3ZRZgY
D
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That sounds awesome ;) An 80's URQ (Quattro) with 4x4 and ABZ power, nice! Looking forward to hearing your motor roar mate.
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What do you do if you start to run out of room.... well...
(http://i8.photobucket.com/albums/a13/dangerrous/tentforspace.jpg)
£40 of ebay, once finished with, just chuck it ;D
D
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£40 for that garage, that's cheap.
I don't know how you've managed to build what you have so far in that crummy tent? Lol.
Beany ;D
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Be sure and ask MADMAN for help when you need to take the tent down - he's the expert...
Dove US
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Be sure and ask MADMAN for help when you need to take the tent down - he's the expert...
Dove US
Sure am ;D
-
:D :D :D
-
Essex DNA chapter ,now open with free camping ;D
-
complete with DNA kit bed fully installed ;)
-
I'm off this week, so making good headway with build.
I've stripped the car to 'chassis' stage for paint, some wiring is still connected cause I don't need to remove it from the cockpit
(http://i8.photobucket.com/albums/a13/dangerrous/frontviewchassisreadyforpaintprep.jpg)
I've finally welded in the new fire wall (this will also increase structural rigidity) and filled in the gaps
(http://i8.photobucket.com/albums/a13/dangerrous/firewallcompletereadyforpaint.jpg)
The rear is completely empty and also ready for prep to paint, I'll do it as per Ferrari, satin matt black
(http://i8.photobucket.com/albums/a13/dangerrous/rearviewchassisreadytoprepforpaint.jpg)
I've also done all the minor bits to both subframes, these plus all other components are going down to the powder coaters tomorrow.
The engine will be cleaned back to Aluminium and the rocker covers are off to be anodised cherry red
The cars' colour has been chosen and all will be revealed when the chassis is painted
D
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Top job d
Can't wait to see it painted and the parts going back on.this is the way cars should be built.from the ground up :) going to be wicked buddy :) :)
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Great to see some more progress D.
Full on paint job on this one then, it's gonna be awesome.
Can't wait.
Beany ;D
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Are you going to be doing the paint yourself D? Can't believe you have stripped her down to bare bones, that's a proper job mate, I would have masked her up, haha
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Yep, I've been around the crash repair business all my life, Dad had his own business etc...
If you look at some of the garage photos you'll see the extraction system, this minimises paint dust laying on the car and keeps the air clean by recirculating through a filter bank and returning clean air into the garage.
Stocked up on ancillories yesterday, cost £245, this will bring me upto primer stage for the car
Powder coaters have got all my parts- £290
Suprise of the day was a visit to Audi I have some rusty bolts with offset adjuster plate washers, nothing special £15 EACH!! X4
D
-
D, are you still going with metallic black?
-
nope
-
Fingers crossed for red chrome :D
(http://www.fyeah-cars.com/data/media/1/ferrari_f430_x_red_chrome.jpg)
-
Wow, that looks cool!
Yes Madman, you've got me, I said a red car looks cool. Lol.
Beany ;D
-
:-X I said nowt!
I wonder if they do a Yellow chrome? (that would be cool) or would that be gold :-\ back at you your Lordship ;D
MADMAN 8)
-
Been away for a while, caught an inner ear virus which took me out of action for a number of weeks with vertigo then had to make up time/money with following weekend work blah blah.....
Anyway I've finally put some paint on the car, the front and rear sections are painted 'as per Ferrari' spec boring ol' satin black.
The cabin is epoxy etched ready for actual colour of car, just need to spend some time masking up the black -boring-
(http://i8.photobucket.com/albums/a13/dangerrous/Cabinectchedreadyforpaint.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/Frontchassishoodpainted.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/Rearenginebaypainted.jpg)
Masking up next weekend, possibly painting Sunday
D
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Glad to see you back D.
This is gonna be like a brand new car stripping it back that far for paint. But with the amount of work and attention you put into your engine conversion I'm not surprised you'd go to such lengths.
Looking forward to seeing more updates, now you're back on your feet.
Beany ;D
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Looking good d
Feels great when the paint goes on :)
-
Cheers
It does feel good to actually see some paint on it, although most of it will be hidden when the car is complete! ;D
-
That red chrome would be so f*****g epic!
-
Well it's been 3 and a half years but here you go
(http://i8.photobucket.com/albums/a13/dangerrous/frontleftchassissprayed.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/frontrightchassissprayed.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/Rearrightchassissprayed.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/rearleftchassissprayed.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/cockpitdone-1.jpg)
nuff said
D
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You can't go wrong with red D :) Looking very, very nice mate
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Excellent job D!
Your talents know no bounds. It's so annoying, lol. :P
Yes it's been a long haul, but it will so be worth it. I can't wait to see it all finished.
Beany ;D
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Great colour choice D, (kept it quiet.) This will definatly be worth the wait 8)
MADMAN
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Looks good d you can't beat a full stripdown and rebuild and a fresh coat of jam :)
I have to say there's been some great builds on here but yours is far the most technical and first class of them all
You have done a great job of the car you should be proud and of course it's red so a great colour too :)
My dn8 is going to be red buddy so looks like madmans getting his way lol :)
-
Just a small point. Is anyone going to tell Dangerous he's forgotten to put the panels on, or are we just going to wait till he turns up at the next show and point it out to him then?
Brillo. :D
-
Epic Job Daz! ;D
Now crack on-I want to see the finished car! LOL!
-
Cheers guys, Shame this part of the job won't be seen when the cars' got it's clothes on ;D
Last technical job will be the electric roof.
I think the general census of opinion is that every DNA uk build is of high quality, everyone's build has it's own identity 8)
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Cheers guys, Shame this part of the job won't be seen when the cars' got it's clothes on ;D
Last technical job will be the electric roof.
I think the general census of opinion is that every DNA uk build is of high quality, everyone's build has it's own identity 8)
Ahh!!! Electric roof, 8) I Want one too. I hope you can perfect it, put me down for one.
MADMAN 8)
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Had a lazy holiday, been playing around with car so here's an update
http://www.youtube.com/watch?v=OTdbU-hIVsI
http://www.youtube.com/watch?v=gU-vMild3-c&feature=youtu.be
party on....
D
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Outstanding work D.
I take it you will not he bothering with the dummy engine and will simply be able to see the Audi V8 in all it's glory through the engine glass.
Can't wait to see it completed and to see how you get on with the electric roof.
Keep those updates coming.
Beany ;D
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Hi d
Great videos as always buddy :) as I've said before I've not seen someone do and fabricate what you have done.it reminds me of my dad as he is the same.he can make or do anything.
You can't beat a stripdown paintjob and rebuild like yours.gonna be the best build to grace this forum and there's been some great builds.
Keep the info and pics coming we look forward to them :)
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Electric roof is always on my mind, the Mr2 one is sitting in my lounge so I keep looking at it getting a feel for the mechanism and how to sort out the rear fins.
Due to the actual position of the engine in the Mr2 and the kit design, I will still need to lay the engine cover ontop, the engine detail is just for cleanliness and finding oil leaks, ie. the rockerbox gaskets were letting by and the sump gasket is sweating a little oil.
Cheers for the comments, they keep me going when the enthusiasm is a little on the low side.
D
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Can't wait to see this ripping up the tarmac round here D.. I like the idea of the dust covers disguising the original calipers, great work as always mate.
-
Come on d we need some more videos of this amazing build :)
Gonna look great built buddy :)
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Hey D,
how about this for you?
full F430 soft top with all you need to convert to electric roof, on ebay item no. 17096365087
if anyone could make it work, you can, just a tad expensive
MADMAN 8)
-
http://www.ebay.co.uk/itm/Convertible-Roof-Ferrari-F430-F-430-4-3-V8-490HP-Parts-F430-/170963650870?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item27ce3a4936
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Time for a little pictorial update
Front caliper covers done, Wheels are clear on both locks
(http://i8.photobucket.com/albums/a13/dangerrous/frontviewfrontcaliper1.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/topviewfrontcaliper.jpg)
This shows what's behind the wheel, the caliper covers were a really tight fit, there should be more space for the new wheels
(http://i8.photobucket.com/albums/a13/dangerrous/barefrontsuspensionandcaliper.jpg)
And the rear
(http://i8.photobucket.com/albums/a13/dangerrous/offsidebearsuspensionwithcaliper.jpg)
(http://i8.photobucket.com/albums/a13/dangerrous/nearsiderearsuspensionwithcaliper.jpg)
moving along nice and slowly
Air con pipes all done up to the engine bay
Been looking around at wheels again, these are Audi R8 replacements, a definite possibility
(http://i8.photobucket.com/albums/a13/dangerrous/wheels.jpg)
D
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Bootiful ;D
-
Very Nice D!
Liking those wheels, a lot.
Beany ;D
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top job d as always buddy..
looking nice just wait till its painted and complete the fun you will have :) :)
-
Just........ :o :o
;)
-
re-routed the rear brake lines today, wasn't happy with my first run, I'll protect them with heatshrink to look OEM, also started to sort out the stainless brake hoses, the Audi/Toyota ABS will also be part of next week's tasks, although I'm on call from Friday so might not get into the garage :(
-
As an added note regarding wheels-
The Audi A8 wheels are 17" but have large tyres. I've looked at a wheel size conversion chart and can confirm that 20" rims will fit my chassis due to the A8 suspension set up, the current Audi rims are foul free, I'll load a video later to show the ARC of travel on the front.
Here's just one site that I've used
http://www.miata.net/garage/tirecalc.html
D
-
If 20's will fit, it has to be on 20's!
Like I always say, someone has to do it first and I think you pretty much have the ultimate first when it comes to the 430 Spider. ;D
Beany ;D
-
Just a quick vid to show movement on Arc and wheel clearance.
http://www.youtube.com/watch?v=0sPsefJNZmQ&feature=youtu.be
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Just a quick vid to show movement on Arc and wheel clearance.
http://www.youtube.com/watch?v=0sPsefJNZmQ&feature=youtu.be
Nice work there my friend!-will look great on 20'' wheels. ;)
-
Great work as always d
You will have loads of fun when this is done :)
-
finished running the new brake lines with stainless braided hoses. A Job I absolutely hated! Tested and all fine
now onto wiring up the Audi ABS sensors, easy Sunday afternoon jobby :)
Next the clutch hydraulic pipe
-
This build is turning out superb!! :)
-
Hey Splne1,
Long time no post.
Have you been overseas?
Good to see you back, how's your build going?
Reply in your thread mate, so we don't side track from Dangerous' awesome build.
Beany ;D
-
:o :o :o sh*t now that is one quality build sir!
simply amazing, looks like factory.
nice job ;)
-
More work done over the past few weekends (Been on call so car has come second)
Finally finished all the fluid/pipe transfers from the front to the back, all brake lines now full and working with fresh fluid
Fuel tank lines done including the filler and breather
(http://i8.photobucket.com/albums/a13/dangerrous/Antisurgefuelbreather_zps39388787.jpg)
Here's two videos explaining the fluid/air/brake lines
http://www.youtube.com/watch?v=jW2pBXVpDko&feature=youtu.be
https://www.youtube.com/watch?v=moez5LIyh9g
An added note on Ali cleaning, to remove the cruddy old oxide layer I'll be using Motar/brick cleaner, this MUST be washed of with detergent and water otherwise the acidic solution will continue to eat the Ali
Here's a test piece that I had laying about
(http://i8.photobucket.com/albums/a13/dangerrous/AggressiveAluminiumcleaningsolution_zps9cc87349.jpg)
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Looking good. Great work.
-
It's been a busy weekend with getting ready for two weeks in Gran Canaria etc, I wanted to shift all the engine bits to the powder coaters for when I'm away, but the engine has soooo many parts to strip off. I had to make a crank bolt removal tool and extend the knuckle bar to 5 foot to get it off!
Here's my improvised tool
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0014_zps73f12f26.jpg)
Had to do the same on my VW transporter van, these bolts are really torqued up!
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0013_zps1321a125.jpg)
I'm about 60% through the strip down
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0018_zps742b39c1.jpg)
Although the cam belt was changed around 10,000 miles ago, none of the idlers were renewed, every single one is noisy, the oil seals are okay but for the sake of a few quid I'll put new ones in. With the engine being on the trolley, all these jobs are relatively straight forward ;D
-
Gonna look real good D.
Will be nice to come back from holiday to all those freshly coated parts. Is the colour scheme gonna match the car?
Look forward to seeing the results.
Beany ;D
-
The colour code will be as per ferrari engine
-
Hey Darren,
after chatting with you at Stoneleigh I just had to visit your V8 DNA build and my god, you're one talented man. Can't wait to see the finished article.
Regards
Paul
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Speechless! An absolute work of art mate.
-
err? hope you don't think the 'ferrari' pictures were my v8, they were just to give an Idea of colour scheme.
If not cheers guys, I'm still polishing the ali bits on the engine
D
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Well time for a timely update.
The engine has been a long process what with waiting for bits, and work. I'm very pleased with the result.
The engine has had new rocker gaskets, cambelt, idlers, inlet maniforld gaskets, nuts and bolts all parts powder coated etc....
(http://i8.photobucket.com/albums/a13/dangerrous/cleanengine_zps2d04cfc5.jpg) (http://s8.photobucket.com/user/dangerrous/media/cleanengine_zps2d04cfc5.jpg.html)
Click on the photo for a short vid
(http://i8.photobucket.com/albums/a13/dangerrous/th_cleanedupenginecolour_zps959d7476.jpg) (http://i8.photobucket.com/albums/a13/dangerrous/cleanedupenginecolour_zps959d7476.mp4)
(http://i8.photobucket.com/albums/a13/dangerrous/cleanedupgearbox_zps9c81ebd6.jpg) (http://s8.photobucket.com/user/dangerrous/media/cleanedupgearbox_zps9c81ebd6.jpg.html)
Still got some work to do on the engine, but you get the idea
D
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Certainly looking the part. Well worth all the effort, very impressive mate!
-
This is looking fantastic, can wait to see this all running.
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Oh dear rudy's getting ideas!!! Get it on the road first mate!! ;D
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Great job d
Love it when everything's cleaned up and repainted.makes the job more like brand new
Keep the pics coming buddy.
I've said it before this is the best build that's been on here.everything first class and the skill needed is far superior to anyone's ive seen :)
Brilliant
-
Wow, that's the dog's b's. When are they being installed?
-
I'm impressed to Beema, And I'm known for being a picky b*****d! Though there are a lot of builds going on that will look great at the shows next year! Having spoken with the guys at newark and I may end up staying a dna owner after all! They certainly dont let the grass grow.
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:o stunning D absolutely stunning 8)
-
You need to know, I am following you
Closely
:D
Bloody awesome
-
I guess all that remains is for some smarty to make an all wheel drive version!
:D
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Still working on the ol' beast, Here's a little update via a vid. getting close to firing it up again
http://www.youtube.com/watch?v=GcJHPMyXVU8&feature=youtu.be
D
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:o if I had 10 percent of your engineering skills I'd be a very happy man well done its going to be an amazing car D
-
:o if I had 10 percent of your engineering skills I'd be a very happy man well done its going to be an amazing car D
Not just Amazing it will be the Ultimate replica, keep up the Fantastic work D
MADMAN 8)
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As ive said before the best DNA ever built. No one has the balls or skills to ever do this themselves.
Car looks and will be as new as ever possible. Ile be drooling over it that's for sure at the shows
Well done d its amazing.
You need a first class paint job on that when its ready to justify all your hard work.
-
Can't wait to hear the engine on this beast. Really will be an amazing car when finished. Nice work matey
-
Little update, not much done as I've been on call but..
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0036_zps64987389.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0036_zps64987389.jpg.html)
I've also done a vid to explain a little more
http://www.youtube.com/watch?v=RRHtk-vIjic&feature=youtu.be
Cheers
D
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Agree totally with earlier comments.......This is going to be the ULTIMATE car! :)
-
Watched the vid just now - completely awesome. Seriously beautiful work.
-
Well done dangerous great build love the vids subscribed to YouTube brill ;D
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cheers, all comments appreciated
D
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No comment from me mate as I'm sat here with my mouth open slobbering! ;D
love it love it love it..........
-
....and here is me panicking over my exhaust brackets!! ;D ;D ;D loving your work..
Paul
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As I've said before dangerous is the most talented guy on here and his knowledge and work is first class.
That's not saying everyone can not build cars as there's tons of people on here building first class jobs and have built first class cars in past its just dangerous has built something I believe no one else would ever do.
Quality and skill all rolled into one makes the best DNA car ever :)
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All I can say is " simply the best "
As a fellow motor head I'm so jealous.
Firstly on what this is going to be like when done and secondly on the skills that you have.
This is by far the ultimate of ultimates.
I'm a fussy bugger when it comes to detail, but this is something else.
Well done and cannot wait to see this beautiful monster one day.
Are you going to have all the engine on show through the rear deck glass.
It's a work of art.
-
Quality all the way D.
Absolutely incredible.
Beany ;D
-
Unfortunately the rear glass also shows the soft top, the engine cover serves a dual purpose of the illusion of a Ferrari engine and covering the Toyota designed folded roof.
D
-
Either way it will look fantastic. :)
-
With your engineering skills I'm surprised its not having a genuine ferrari electric folding roof lol ;D
-
I will be having an electric folding roof, but on the Toyota framework
D
-
I should have known well if any one can do it it's you pal ;)
-
I will be having an electric folding roof, but on the Toyota framework
D
Hurry up D and work out how to do the electric roof, that will be the icing on the cake and I would willingly chop my car up to fit one ;D
MADMAN 8)
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It's DIY time again, the guys at Vems wanted to upgrade my stepper chip outside of the ecu in a separate box- complicated! So I thought I'd have a go myself, I've taken the stepper chip off the board(this is a 4 way independent solid state switching transistor usually used for low power stepper dc motors, hence 'stepper chip') and wired the four 5vdc logic signals to some fast switching 3amp mosfets with schotty fast switching flyback diodes for protection. A basic mosfet is quite a delicate transistor and therefore doesn't like voltage spikes, the solenoids will spike at around 200v when turned off , the idea of the diode is that it puts that voltage in an ever decreasing loop through the solenoid protecting the little ol mosfet from popping it's innards
All tested, just need to put it back in it's box
(http://i8.photobucket.com/albums/a13/dangerrous/stepperremovedfetswithflybackinstalled_zps18317ac8.jpg) (http://s8.photobucket.com/user/dangerrous/media/stepperremovedfetswithflybackinstalled_zps18317ac8.jpg.html)
Getting closer to firing it up again :)
-
I don't know what you just said, but it has to be good. Lol.
Getting closer to startup?
Beany ;D
-
Yes, agree........you lost me too! :) You've certainly got some great skills and your finished car will truly be the dogs!
-
nor do I :D
-
Well here's the first quick vid of the car running in rich cycle (protection mode before being dyno run for tuning)
Now to set up the dash so it talks to the audi engine
http://www.youtube.com/watch?v=YS06mgc-nlY&feature=youtu.be
cheers
D
-
Nice work d
That looks like a brand new car.going to be great finished :)
-
What a motor what an engineer enough said ;D
-
Congrats D.
Really coming together nicely now, one more major milestone.
I take it Mrs Dangerous isn't too keen on being a film star. Lol
Great work mate.
Beany ;D
-
She came over to watch the grand prix, and caught me still tweaking away in the garage ;D
-
Well done mate. I bet that put a smile on your face when you heard it fire up.
Excellent work and skill. That says it all.
-
She came over to watch the grand prix, and caught me still tweaking away in the garage ;D
I used to get caught tweaking a LOT when I was a kid
;)
-
She came over to watch the grand prix, and caught me still tweaking away in the garage ;D
I used to get caught tweaking a LOT when I was a kid
;)
LOL! ;D
-
Quick update
1) car is basically now a rolling shell, all the suspension is done. I had to rework one of the driveshafts, think I had a blonde moment ::)
2) engine runs better after some tweeking BUT I'm not happy with the exhaust note- so I'm redesigning from the cats back
3) Landed a new job at the brand new port just over 2 miles from home, this means tonnes more time on the car and a significant payrise,
Should be getting the car/engine dyno'ed end of this year, looking for about 300-330bhp.
I'll post some pics and vid when I've redone the exhaust
D
-
Sounds great mate. The torque should really be something too.
What was the 'squeeziest' or most challenging part of shoehorning the v8 into the space .... So far?
-
The space isn't too bad, I've got used to everything being tight, To be honest I think I've got more accessibility than in the real 430 :)
-
Wow!
But then there's never any need for access to a 430 engine bay - I hear they never break down or need servicing
;)
-
hello !!
not sure if I had asked here? I think there was another fourm like this one so my apologies... ;D
but where do you get these kits !!
I have a Ferrari 360
but I would like to Build a Scuderia ;)
anyone have some links? or contact information
thanks !!!
some great builds and pics !!, as a owner there really darn close !!!!! unless you got up in the car
be hard to tell !!!
but daily driving yea hard to beat !!!
-
I think you may catch the attention of the moderator as you've block posted on the extreme site aswell. Naughty
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hello !!
not sure if I had asked here? I think there was another fourm like this one so my apologies... ;D
but where do you get these kits !!
I have a Ferrari 360
but I would like to Build a Scuderia ;)
anyone have some links? or contact information
thanks !!!
some great builds and pics !!, as a owner there really darn close !!!!! unless you got up in the car
be hard to tell !!!
but daily driving yea hard to beat !!!
Contact DNA direct if you are serious about buying a kit? These are the best kits on the market so they will put you right. Just google DNA automotive in Birmingham for contact details. :)
-
A up D,
have you got any further with the electric roof? I,m dying for you to do your magic on that especially if you allow me to pick your brains and follow suit with my car
First class work as always, cant wait to see your finished car at shows
Regards MADMAN
-
Not yet Steve, I'm concentrating on the engine and all it's ancillaries, mainly water flow to keep it cool and redesign of the exhaust for a better sound.
Keep you posted on the roof, I need to fit the kit then chop some bits off the weld some bits on then .....
D
-
Not yet Steve, I'm concentrating on the engine and all it's ancillaries, mainly water flow to keep it cool and redesign of the exhaust for a better sound.
Keep you posted on the roof, I need to fit the kit then chop some bits off the weld some bits on then .....
D
Cheers M8,
keep up the First class work, your an inspiration to us all ( enough pi--ing up your back now ;))
MADMAN 8)
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Not yet Steve, I'm concentrating on the engine and all it's ancillaries, mainly water flow to keep it cool and redesign of the exhaust for a better sound.
Keep you posted on the roof, I need to fit the kit then chop some bits off the weld some bits on then .....
D
If i may ask... Why did you not choose for a oem exhaust? What is it that you dont like about the note?
I am going to put in cam shafts with a more agressive profile for my build in combination with a lighter fly wheel and oem exhaust... It should make my engine sound more zippy and grouwling hehe
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The exhaust note from the osprey muffler is too boomy, and not tight enough. I've just finished installing the new muffler from Longlife, it's a completely different design and sounds better although I haven't had the chance to rev it up.
Re the ferrari exhaust, I just don't have the room for it and there were too many obstructions to run the pipes.
D
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Just a quick update
First of all thanks to Chris (Crossy) for getting me out of the Sh*t for parts
I'm now in instrument cluster mode- I've got to use the original Toyota ECU as an interface for the instrument cluster to get it to show temperature, ignition, handbrake, fuel, ABS, oil pressure, etc... the ECU sends engine readings to the dash via a canbus hi-low path and also switches it to read mode once the ecu confirms that the engine is running, just tacho and fuel gauge left to do. I've purchased a functional generator and Automotive oscilloscope to generate and observe signal data, the VEMS ecu can be programmed to send signals to fool the Toyota ecu, so shouldn't be too hard to get everything working. Once the cluster has all it's outputs I can rebuild it to mimic the 430 dash, I'm moving the speedo to the right and putting the coolant temp, oil temp and amp meter to the left. The Toyota dials plug into the circuit board, even the milometer plugs into the lcd driver so moving stuff around will be a breeze, I've got a spare dash to chop up to make the necessary 'adjustments' once I've got the Toyota dash components working I'll look into a digital fuel meter, although room may be an issue for this one.
I now have a new muffler on the car from longlife, It's a refined sound, is it the one I want? not sure. I may look into designing my own, Helmholtz theory is knocking around in the background.
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Can't wait to see what you come up with great work as usual your one hell of an engineer
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Just a quick update
First of all thanks to Chris (Crossy) for getting me out of the Sh*t for parts
I'm now in instrument cluster mode- I've got to use the original Toyota ECU as an interface for the instrument cluster to get it to show temperature, ignition, handbrake, fuel, ABS, oil pressure, etc... the ECU sends engine readings to the dash via a canbus hi-low path and also switches it to read mode once the ecu confirms that the engine is running, just tacho and fuel gauge left to do. I've purchased a functional generator and Automotive oscilloscope to generate and observe signal data, the VEMS ecu can be programmed to send signals to fool the Toyota ecu, so shouldn't be too hard to get everything working. Once the cluster has all it's outputs I can rebuild it to mimic the 430 dash, I'm moving the speedo to the right and putting the coolant temp, oil temp and amp meter to the left. The Toyota dials plug into the circuit board, even the milometer plugs into the lcd driver so moving stuff around will be a breeze, I've got a spare dash to chop up to make the necessary 'adjustments' once I've got the Toyota dash components working I'll look into a digital fuel meter, although room may be an issue for this one.
I now have a new muffler on the car from longlife, It's a refined sound, is it the one I want? not sure. I may look into designing my own, Helmholtz theory is knocking around in the background.
Yeah, I ran this through Google translate and even that couldn't determine what language you're speaking, D.
Lol.
It all sounds good and I just know the end result is going to be amazing.
How about a sound clip of the new silencer?
Beany ;D
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The exhaust is a completely different design, the tail pipes now look wrong due to the exhaust gas flow. I'll post a vid tomorrow.
D
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Well as promised , here's a short video clip of the exhaust note with the longlife muffler, I'll redo the tail pipes when the rear clip is back on.
http://www.youtube.com/watch?v=4d9oZf5_Zi0
I've also fitted the new ramair air filter.
My main task is to get the dash sorted, then I can really move on to new tasks.
D
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Nice sound mate! Can't wait to see the dash conversion! :) :)
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Sounds fantastic.
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;D all the hard work is really paying off sounds fantastic D
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Well it's been a busy one! I've got a new job, I've waited 5 years for this. I started 5 weeks ago and caught the Christmas & New year rota on, in the mean time I've received a few new diagnostic toys to enable me to sort out the Toyota instrument cluster so I'm back to where you boys are with a normal car ;D
The Toyota data link system is all back and running with the Vems ecu piggy backed onto the Toyota engine ecu. I can now start swapping the dials around to roughly mimic the Ferrari instrument cluster
Anyway here's a vid of the signal testing
enjoy
http://www.youtube.com/watch?v=NYtyfWndGLU
D
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:o whow didn't understand much but any engineering company whould be lucky to have a man with your skills glad you've got your dream job dangerous you deserve it love your build it's the ultimate build thread amazed ;D
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Wow!!! Insane skill on the cluster!! You seriously take it to the next level!
About the exhaust: heve you thought about just using oem tips?? The tips alone give it that round, hollow, zippy note...
Ps: Congrats with the job!!
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I'll have a look at the exhaust sometime in the future, I might just go and buy a used 430 system.
D
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I'll have a look at the exhaust sometime in the future, I might just go and buy a used 430 system.
D
Ow ok! I thought you don't have enough space in the rear to fot one,so that is why i sugested just the tips.... I think an oem system seriously helps when hearing it on Macgyvers car...
You allready installed a lighter fly wheel right?? Did you notice much diffference in sound before and after? More zippyness?
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Still not sure on the exhaust, that's sometime in the future.
I made the flywheel to my own specs, billet steel, strong but light. I guess it's no different to what's available but only cost me £90.
D
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Hey Dan,
I am buying a set of these DRL switchback lights for my build... Was eondering if you are also interested... Not looking for a profit if i can buy more i can reduce the price...let me know...
(http://i1113.photobucket.com/albums/k507/Dman1409/F83FDAE4-73B4-4EDA-80AC-77FCBFDF03FA.png) (http://s1113.photobucket.com/user/Dman1409/media/F83FDAE4-73B4-4EDA-80AC-77FCBFDF03FA.png.html)
Cheers
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I'm way off buying anything like that, but cheers anyway
D
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Well it's been a long while since a post due to other priorities at the weekends. I'm now sorted and should get back on track after my holiday to Egypt next Sunday.
I'm still on the dash and I've really dragged this part out, but the dials are all done including the lcd odometer display, and I've also sorted the digital fuel gauge
Just to clarify what I've been playing with:
The digital fuel display has had me scratching my head for a while, but once I'd finally made up a bread board (demo) circuit I found that the Toyota voltage signals to the analogue gauge weren't compatible with the digital one, so I've rewired the fuel sender and dash for an independent digital circuit.
Moving the speedo was just a matter of some cutting and glueing,
The sixteen pin lcd odometer display was another cut and glue affair, I've soldered the sixteen pin socket off the board for ease of final construction
Two new gauges curtesy of ebay have given me oil temp and volts, the Ferrari dash shows oil pressure instead of volts but my engine isn't wired up for that output, so volts it is
I'm pleased with the result, the main thing being that the speedo is now on the correct side
(http://i8.photobucket.com/albums/a13/dangerrous/Replicadashwithdialsincorrectplace1_zps69e8aa0b.jpg) (http://s8.photobucket.com/user/dangerrous/media/Replicadashwithdialsincorrectplace1_zps69e8aa0b.jpg.html)
There's still plenty of rewiring to do, the led warning lights are yet to be lifted off the board and relocated under the three dials on the left.
I've got a seven segment led to show what gear I'm in, that's going at the top of the tacho gauge. The dummy multimedia display will show the word 'Road'
(http://i8.photobucket.com/albums/a13/dangerrous/Replicadashwithcircuitboardandextrawiring_zps3c8ea197.jpg) (http://s8.photobucket.com/user/dangerrous/media/Replicadashwithcircuitboardandextrawiring_zps3c8ea197.jpg.html)
My next post will show all the bits together before it goes off to have a new Ferrari dial back
D
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Wow. I wish I was as clever with these things as you are. Amazing work.
This car is going to be better than the real thing by far.
Looking forward to seeing more posts as the build continues.
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:o awesome your one very gifted builder this will be the ultimate build allways look forward to your updates :)
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Time for another update, I've finally finished the instrument cluster circuitry. I'll take the cluster to reap automotive in the next few weeks, he'll produce a new dial back for it.
https://www.youtube.com/watch?v=C_eWXLphCUQ&list=UUQy19its5YFKl4-3Ouv3aUQ
;D
D
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Dangerous
Good looking job. I would have liked something like this on the Furrari but given Merc electrics I'll keep it simple and stay with just the decals, and a set for Cal.
Have you ever used a Picaxe microprocessor. I'm doing a few stand alone bits for the Furrari. Nothing to interface with Merc circuits.
M
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Nope, but the raspberry is another open source processor, I'm an Arduino kinda guy ;D
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Dangerrous. Thems is hard to program. The Picaxe is writen in Basic and the boot sector is built in. Much easier. Can run four program's at the same time independent of each other but will talk to each other if need be,
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Dangerous, this is simply awesome. I so love reading your updates. Detail, detail. I wish I had your skills.
I thought I did a good job with my dials, but these are simply fantastic.
Great work.
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Has it been that long since I posted on this page that I get an automated warning message :o
I've been away from the car for ages, (excuse time!) one- bought a new road car that needed loads doing to it (VW Phaeton)
Two- another new job, same type just a lot closer to home, but more hours.
I'm going over niggling stuff at the moment, these are the PITA jobs that I just didn't want to do i.e.
The temperature gauge worked in reverse (foo par on my account) and the resistance range from the temperature sensor was just wrong, I hooked up the TIS (Toyota Information System) and started mucking about with variable pots and fixed value resistors, the ABZ audi engine has two sensors, one for the ecu and a second for the instrument cluster, the Toyota uses one sensor for the ecu which then, via the bus line, informs the combination meter the engine's temperature. I found that the audi instrument cluster has it's own resistor range, but the audi ecu sensor was a perfect match for the Toyota ecu, £8 later, range issue sorted. Next job was to sort out the temperature gauge, with the help of the MR2 workshop manual I was able to identify North/South for both windings, it was just a matter of swapping the correct wires.
Next job was to sort out the clutch master cylinder, the Toyota has a bore size of 5/8, the clutch would only fully engage with the pedal on the floor, this just felt uncomfortable. I ordered a 3/4 bore motorsport master cylinder off ebay and fabricated a converter plate to take the new master cylinder, then I reworked the plunger rod from 5/16" unf thread to the Toyota's M8, and made a threaded sleeve to take the Toyota's fork end clevis.
I've put the quick shift gear lever back in and the throttle cable will go in tomorrow, I've reworked the Audi accelerator ball joint and now have an 8mm socket with an M8 thread to bring the Audi and Toyota together, all parts are still OEM.
Pictures to follow when those jobs are completed
D
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Come on fella.. We want news / pics..... this build is nearly taking as long as my Murci !! lol
;D
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I'm on it ;D
getting the car ready for wheel alignment and dyno testing to map up VEMS ecu
D
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OH mama!
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A little update on some progress
New Clutch master cylinder, this matches up with the larger Audi slave cylinder
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0242_zpsshij3kcd.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0242_zpsshij3kcd.jpg.html)
Alternator rebuilt with new bearings, rectifier and split ring, the original bearings were worn out so I though I'd replace all serviceable parts.
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0241_zpsxfmhoh3d.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0241_zpsxfmhoh3d.jpg.html)
D
In the process of upgrading the standard fuel pump from fuel performance ltd, they sent the wrong one
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0244_zpswzq5xk8n.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0244_zpswzq5xk8n.jpg.html)
The exhaust brackets are finished, shouldn't go anywhere now
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0243_zpsjeexsbe7.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0243_zpsjeexsbe7.jpg.html)
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getting there "D" going to be one hell of a car when completed
MADMAN 8)
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Cheers Steve, I may turn up at Stoneleigh with the car, it'll just be with the kit bonded on but at least I'll be there with a car ;D
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I cant wait 8)
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wish i was going to be there as well looking really good D
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Mixing civil duties with car, but ...
Had a nice walbro 255ltr/hr fuel pump delivered with fitting kit, would have liked a direct replacement pump for the bosch one but it works
next, I had to alter a few bits of wiring to take a standard mr2 instrument cluster for the dyno tuning, I'm going to redo the other one cause I'm not happy with the fragility (if that's a word) of the wiring on the modified instrument cluster.
I've picked up a new towing dolly and ancillaries to move the chassis around on the road,
Next a total move of stuff from the garage to the workshop, the car now sits in the garage waiting to go for a laser wheel alignment. I actually drove it for the first time in 6 years from the workshop to the garage, I had to adjust the short shift cables a little, but the clutch pedal is perfect.
A little back story.. when I fabricated the drive shafts one side sat in the cv joint a little too far so I redid it, this was a few years ago, testing the bite of the clutch I tore the join apart, as you can see from the picture there's no evidence of a weld, I'm puzzled.
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0248_zpsr6w0t5mc.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0248_zpsr6w0t5mc.jpg.html)
I machined the two parts again and pushed a dowel into either end so it would be aligned for the weld, you can see the machined dowel pushed into one part of the drive shaft, I just need to cut it and then bring the two parts together.
I welded the driveshaft on the lathe so I could check that it ran true after each weld; adjusting if necessary. I also purchased a fresh set of 7018 (low hydrogen/high tensile steel) rods. One fillet and four caps later the driveshaft was finished
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0249_zpskoxp4zfb.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0249_zpskoxp4zfb.jpg.html)
just need to take some time off work to progress to the next point :)
D
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Took the car down to have 4wheel alignment, surprisingly enough it wasn't too far out with me using a spirit level and a bit of string ;D
Preliminary dyno/remap penciled in for 31st March
D
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Hey D! Good to see you are still on your project!
Love your guage cluster!!
I found some nice guage cluster face on ebay.. I dont know if you allready have it, but i thought it mightbe interestingfor you... Below is the link
https://www.ebay.it/itm/181960442948
Cheers!
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thanks for the link, I'm having some dial backs made up by a local specialist if he's still around.
D
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My time is currently split between two cars, kit car and road car :(
I'd like to concentrate on the DNA more but VW's can be a PITA
Anyway...
Sorted out the drive shafts, I wasn't happy with a possible tear under power so I've reinforced them
https://www.youtube.com/watch?v=25eIN1-h5rw&feature=youtu.be
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0039_zpssuoewgbe.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0039_zpssuoewgbe.jpg.html)
And now they're back on the car, the alternator is also sorted, turns out it was grabbed by customs for some reason.
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The extra mass in the middle of the shaft should also give smoother ride as it damps out any harmonics in the shaft..
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Well progress is being made, I've sorted all the bits and pieces out to get me on the track, I had to hire the whole race track because my car didn't fall into any recognised category, ouch!
We started the engine and noticed it was running a little rough, it seemed that there was a little hiccup with no7 cylinder, either the ecu had blown a MOSFET or the ignition amplifier had gone down on bank7
I tried various bits- new plugs and a new COP, but the problem is further back along the supply line
So I just ran the car around the track all day trying to break something, seems to be all good, no problems with coolant temperature (24deg c today), drive shafts, clutch, gear change, suspension, the grip on my old hard tyres was interesting to say the least. Very happy with sway bars around the corners, the car sits dead flat.
Just need to repair no7 somewhere, then I can really thrash it on the dyno ;D
https://youtu.be/HTIHrO6iP4I
My mate took the video, so apologies as it was his first time (although youtube fix did an excellent job)
Darren
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My god :D
I want one :( fantastic Darren
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WOW its been a long build but WOW
cant wait to see it in the flesh
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Huge milestone D, excellent to see mate well done.
Chris.
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cheers guys, it's fast and drives well. Shame cylinder 7 wasn't powering up. Next is the dyno in a couple of weeks or so...
D
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Well done D ,great to see the car out of the garage and coming to life ,another step closer hope to see you at stoneliegh next year with your car Jd
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Hi D! Where are you located? I'm doing a road trip to the uk this weekend to visit a couple of builders and hunt for oem parts for my build... I'm arriving in new castle on friday, then indrive down to Durham to visit JD, then on the way down to collchester i visit a parts dealer, saturday morning i go to eurospares to pick up more parts...and hang around in the area.. Sunday afternoon i drive down to dover to get the ferry back to Duinkerken..then drive back to holland..
Depending on where you are located i'd love to come over and see your build in the flesh... At least, If you are ok with that?
Cheers!
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you will drive right past me, more than welcome to have a look, I'm currently fabricating a 430 exhaust
D
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Still on the long road to building this PITA, I've now completed the F430 exhaust muffler replicating the Ferrari box innards
I'll let the youtube video do the talking
https://www.youtube.com/watch?v=t6Fhsn7P0do&feature=youtu.be
cheers
Darren
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Hi Darren
love the video on YouTube. Keep up the good work. looking forward to meeting you at Stoneleigh next year in the car take care.
8) 8) John James
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you will drive right past me, more than welcome to have a look, I'm currently fabricating a 430 exhaust
D
Hey Darren! I've seen your message too late! It wont be very long before i visit the UK again for more parts... Are you located in essex!? In the halstead / Colchester area?
Great job on the exhaust btw!!
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10 minutes away from the Dartford bridge, you would have gone over it to get onto the M20 for the dover crossing
D
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Finally got the engine setup for mapping, it was done by a uk programmer whilst on a break from a job in Germany, this guy really knows the heart of the vems ecu, he just needs to do a little more tweaking and I can book it in for a map.
Even at this stage he's adopted the running characteristics of the Ferrari engine, ie. fast idle then slow transition to normal idle after a 0% throttle period.
I'm a happy bunny at the mo ;D
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Great to see some progress buddy :), another step closer ,jd
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Finally got the engine setup for mapping, it was done by a uk programmer whilst on a break from a job in Germany, this guy really knows the heart of the vems ecu, he just needs to do a little more tweaking and I can book it in for a map.
Even at this stage he's adopted the running characteristics of the Ferrari engine, ie. fast idle then slow transition to normal idle after a 0% throttle period.
I'm a happy bunny at the mo ;D
Do you have a video on that? Id love to see more on that!
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no vid, it was streamed live on youtube for the programmer to observe the results of his changes then deleted.
D
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Got the car down to the tuners today, engine finally sorted ;D
https://www.youtube.com/watch?v=EJeQSuejAh8&feature=youtu.be
next-body
D
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Great news buddy ,does this mean it's actually time to get the body on now :) jd
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yep ;D ;D ;D
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Another update
I've been doing some moving around and tidying up, the car is now back in the workshop ;D
I've uploaded a video showing some of the bits I'm doing on the car, click if you're interested
a) exhaust wrap
b) starting to offer up kit
c) front wheel track width and why I've spent sooo much time putting on the A8 suspension
https://www.youtube.com/watch?v=f7j21Ip3AU4&feature=youtu.be
enjoy
D
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Another update
I've been doing some moving around and tidying up, the car is now back in the workshop ;D
I've uploaded a video showing some of the bits I'm doing on the car, click if you're interested
a) exhaust wrap
b) starting to offer up kit
c) front wheel track width and why I've spent sooo much time putting on the A8 suspension
https://www.youtube.com/watch?v=f7j21Ip3AU4&feature=youtu.be
enjoy
D
Looking forward to seeing this completed D
MADMAN 8)
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lovely video mate - nicely done.
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Wow D iv just got a tinglein feeling seeing it looking like a Ferrari now and it's not even my car ,you must be over the moon mate , jd
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Does this help?
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0004_zpsxfzmrzwq.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0004_zpsxfzmrzwq.jpg.html)
Just Measuring up the wheels front- 20" 8j et55 back 20" 9.5j et45 but I'll take it to a wheel supplier to have a proper measure up when the kit is bonded on
D
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Just finished off the washer bottle relocation, the video shows how I did it. I think I've done it like most of the builds completed here
https://www.youtube.com/watch?v=y9g-HUtdhcA&feature=youtu.be
Still at it.....
Currently redoing the rear tail pipes... hope this is done by tomorrow.
Next I've got to rewire the air con outside the ecu with all the safety protocols still in place. I'm part way there thanks to the mr2 wiring schematics.
D
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Just finished watching the naked car lapping the track. 7 years of graft, very impressive!!
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this thing is going to be a missile!
... a "guided" one I hope :D
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we worked out that the car was down by 65hp on the track.
D
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Feels a bit like Déjà vu, Exhaust tail pipe fabrication
I made a jig for the new tail pipes, lifted up the car and levelled it up.
They were incredibly cheap, I was considering another set, although they were top quality and a lot more money
(http://i8.photobucket.com/albums/a13/dangerrous/exhaust%20tip_zps0qqvqxlk.jpg) (http://s8.photobucket.com/user/dangerrous/media/exhaust%20tip_zps0qqvqxlk.jpg.html)
I cut and shut the tail pipes so they mimicked the Ferrari style staggered tip design.
Then started to work my way back to the silencer.....
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0011_zpscm5gqpae.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0011_zpscm5gqpae.jpg.html)
The pipes are now done and now exit the body
top view
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0012_zps8qtylrbr.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0012_zps8qtylrbr.jpg.html)
side view
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0013_zpsugrj4tc0.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0013_zpsugrj4tc0.jpg.html)
I can now move onto the next task of wiring up the air con :)
D
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looking good D. should be completed for this coming season ;) ;)
MADMAN 8)
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Love the pipes D.
Very nice work, it just looks class.
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Really nice. Love this attention to detail and a relatively straightforward process, though not without its challenges I'm sure!
I spent weeks trying to find a pair of oval tailpipes for my 93 Porsche turbo build. Originals were unavailable unless I bought the muffler. Not having a lazy $3100 I embarked on the journey of discovery. $80 was a better deal and they were an exact aesthetic copy. Stainless too :)
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OMG.. Well done fella, looks like your cracking on with her... We must have two of the longest builds ever.. lol :-)
Keep at it..
Steve
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just to put it in prospective
£19.99 per side for these:
(http://i8.photobucket.com/albums/a13/dangerrous/exhaust%20tip_zps0qqvqxlk.jpg) (http://s8.photobucket.com/user/dangerrous/media/exhaust%20tip_zps0qqvqxlk.jpg.html)
£149.90 per set for these:
(http://i8.photobucket.com/albums/a13/dangerrous/ferrari%20tips_zpssaq0uu2r.jpg) (http://s8.photobucket.com/user/dangerrous/media/ferrari%20tips_zpssaq0uu2r.jpg.html)
No brainer after counting the cash
D
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Another task ticked off the list- Aircon
Here's a vid of the work I had to do to get cold air out of the blower
https://www.youtube.com/watch?v=RRzkB7k2BhY&feature=youtu.be
Next task is bonding the kit and looking at the roof
D
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Another great video Darren car is looking really good, don't really understand all the technical stuff, but I can now see why air con is quite expensive to having in a car.
What an eye opener can't wait to see you at Stoneleigh.
Looking forward to your next video, and engine sounds amazing take care JJ
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Has it been that long since I posted to get a warning :o
Well now I'm on the body, the rear clip is done the doors are ready to be bonded, the front clip is also ready, but I'm going to look at revising the door hinges.....
https://www.youtube.com/watch?v=M7cU3l1TsWA
cheers
Darren
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Another update on the car, I've now completed the basic fabrication on the passengers door and the final opening is now acceptable..
watch the vid and have a look at the cutting frenzy to get the result I wanted ;D
https://www.youtube.com/watch?v=X-3ADKsm9jU&feature=youtu.be
cheers
Darren
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Spectacular work mate. She's a keeper
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I'm so far behind on building a 430 that there's loads of documented info on personal builds. Fabrication is my thing, putting the kit on the body isn't, I know that there's a few more obstacles to overcome along the way, but I hope I can sort them out my way if possible, I always refer to build diaries to see if there's an easier way to do stuff.
D
Every now and then I start up the car, I get a lovely tingle inside when I hear the exhaust note, believe me this is what really keeps me going ;D
D
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Oh I get it :)))) there are just some things that are unbeatable. Knowing you have that engine is certainly up there! Knowing too, that you're building a second-to-none vehicle, that will be a head turner and a jaw dropper is pretty sweet too :)
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Fantastic and ground breaking work.
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Both doors now done, next week I'll have a look at bonding the doors and front end on. I'm going to tig the cuts in the doors, the mig is just to fierce for the thin metal.
D
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Well this is a test of my patience!
I've been messing around with the bonnet, trying to get it to fit without any major adjustments.
First I had to get the mount holes for the hinges correct, Surprisingly DNA don't give any measurements but do for the back, anyway the third attempt worked a charm, I used chemfix to block the drilled holes, this is stronger than FG and wood, plus it expands ever so slightly as it goes off to form a very good repair.
Next I put the Renault trafic bump stops on the scuttle panel (these are on pretty much any Renault commercial vehicle, even on one side of the new 2014 model), not happy with the positon I moved them out for greater adjustment. Then I put the hinge point bump stops in, again I did a little work, this time on the bonnet, again for greater amount of adjustment.
The wing supports were addressed, I slotted the holes so I could adjust them when ever...
With all the work done and several hours adjusting here there...... I couldn't get it perfect.
I went back to square one, I let the front clip sit naturally and lifted the front to where it seemed to feel more balanced for the weight, the side supports were completely loosened off. I then let the bonnet just lay of the bump stops, it was very close, infact the only real problem seemed to be the front nose wanting to sit up slightly, I could use the hinges to pull it down.
Next job was the latch, using the given measurements I drilled the holes in the scuttle panel only to find I had no adjustment, so I rewelded the bonnet catch bracket in a lower position I could then move the catch up and down till perfect, I also fitted a 3x50mm plate behind the scuttle panel for extra rigidity, I'll replace the spacer washers with some solid machined ali spacers for a better look.
The bump stop holes in the bonnet will be reinforced with 42mm core plugs.
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0074_zps8dtx5bgc.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0074_zps8dtx5bgc.jpg.html)
The countersunk stainless bolts will remain on show, I don't want to chance any cracking around this area
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0075_zpsqoytewhd.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0075_zpsqoytewhd.jpg.html)
This is the bonnet in position, My wing supports aren't bolted in position so there's a 3mm drop in this area
(http://i8.photobucket.com/albums/a13/dangerrous/FILE0076_zpsouyg1r8q.jpg) (http://s8.photobucket.com/user/dangerrous/media/FILE0076_zpsouyg1r8q.jpg.html)
Finally a shaky ol' vid showing what I've done
https://www.youtube.com/watch?v=eg0SKItf9qg&feature=youtu.be
D
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Well done D.
It took me a very long and frustrating day to get my bonnet/front clip arrangement setup. The main problem I had was getting enough 'tension' when the bonnet was stowed so the scuttle bump stops were under enough pressure to stop bonnet bounce when hitting bumps while keeping all aligned. We've got cobbles I could try this on ;D
I had to move my scuttle stops too, and I had a period where I thought I'd never get the bonnet/clip aligned, then suddenly - then finally all dropped into place.
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I'm sure you've already got this - remember to dowel-key the hinges/bonnet/wings once you're happy with the alignment. It's helped my bodyshop maintain a datum.
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Once I've repaired the bonnet I'll dowel pin everywhere
D
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Hey D , it's been quite a while since iv been on the forum, it's great to see you cracking on mate she's looking fab, not to far away from the finish line now , jd
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Cheers John, won't be long before I take her down to the wheel specialist for a fitting.
D
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Away on holiday in Egypt, back on Tuesday, refreshed and ready to get back on track with the car😁
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Still cracking on with the car, the crazy weather had delayed getting back to working on the car, so the first job was looking into getting the workshop warm with a higher calibre heating system. I've installed commercial fan heaters these are 3.3kw and required a dedicated electrical circuit, they're awesome!
I hit a stumbling block with the bottom window scuttle trim, I've copied the sides with some perforated sheet, it seems to work
Next to the door skins, these required fibreglassed surrounds for the altered hinges.
With that all done, I fabricated the top supports and then fitted the door skins
(https://www.pixelsbin.com/images/2018/03/18/fibreglassed-hinge-seal-cupsc5ebe7c198e39edb.md.jpg) (https://www.pixelsbin.com/image/AoGiB)
(https://www.pixelsbin.com/images/2018/03/18/drivers-door-top-support-1bb3708e4856c9d64.md.jpg) (https://www.pixelsbin.com/image/AoEp1)
(https://www.pixelsbin.com/images/2018/03/18/passengers-door-top-supportc49967586ffee553.md.jpg) (https://www.pixelsbin.com/image/Aol6J)
here's a video to help explain
https://www.youtube.com/watch?v=-MNQnP644M0&feature=youtu.be
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Just watched your video
Coming on nicely now ;D
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Nice to see some 360's and 430's in production. It's been a bit quiet recently.
OXO
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Moving things along, I've completed the scuttle window trim panel, and started to address the gap between the front clip and bumper, it's a bit of a PITA because I have to keep taking the bumper off to work on it section by section, not easy when it's just me.
here's a vid showing some of the work
https://www.youtube.com/watch?v=nkBcDpk8HNs&feature=youtu.be
cheers
Darren
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Just posting a few photos as 'working progress' with some items
I'd bonded the rear deck to the frame, but had to take it off again. Photo will show why
I had purchased the windscreen cheese cutter kit for £10 off ebay, let me say that the wire supplied is pretty much useless. Luckily a windscreen fitter was around the corner fitting a new screen, he gave me a a couple of metres of square stainless wire, I cannot recommend this stuff enough, not one snap and it tore through the poly adhesive.
About 6 years ago, I approached Brian and Roland at Stoneleigh, for ideas on how to increase the air flow through the engine bay to take care of the heat produced by the v8, I asked if the 5cudo rear panel would fit, they were unsure, but as ever they were very accommodating, a rear panel was laid up for me and I collected it a month later, the panel has been sat in the corner of a room ever since, until now!
Another panel that's been niggling at me is the rear diffuser, I don't require the exhaust cut out and felt it spoiled the look of it, so I've repaired it with a gelcoat and fibreglass
I've also finished dressing up the bumper to get the clean look I was after.
These are just teaser photos, I've still got to finish the boot lid and light cluster on the rear panel. Prep the rear diffuser for polyester blocking. The bumper and front panel are finished.
The door skins are all dressed up to the rear quarter and front wing for both sides, door gaps are sorted, the wing to A pillar is all blended in
I've lowered the trim line on the rear quarter by the Pininfarina badge, I referenced some photos in my library which seemed to show the panel join to be about 5mm lower.
Having some me time has really progressed the car along nicely, although there's still loads to do :(
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Coming along nicely
More pics please :)
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If your going to that extreme
I would make the rear bumper detachable, and not part of the rear of the car..
One - for access later
Two - you will have a proper gap, which looks right
For the time it will take you (at this stage) it would be silly not too, IMHO
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I don't need to make the bumper detachable for any access, with the rear diffuser removed my engine and gearbox can drop down and slide out, I designed it that way years ago
If I were to separate the rear bumper from the rear panel I would also have to make up a support frame like the Extreme kit. The work I have carried out is primarily for function, and ascetics second, the rear vent on the scudo panel allows for greater air flow.
Speaking to Barry at Stoneleigh, I liked where he was coming from, I might carry out some more mods to the front of the car, luckily this will not interfere with my current panel work.
D
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Yes I understand what your saying, but one of the things I get told at shows from ‘on lookers’ is that because the rear bumper isn’t a separate piece to the back of the car, it’s an instant recognition for the car being a replica...!
Personally? If I was in your shoes and doing doing everything your doing, it would be a small addition to make a large difference..
IMHO
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Hi d
Great work as always buddy :) I do think lee is right it’s s good idea to do as it can make it look more authentic but also if you ever damaged the rear you could have another done and moulded before fitting to car so in case of damage it’s not s rear end just a bumper replacement? I accidentally smashed my 458 into booth and the fry was wrecked.but had to replace the whole frt end again and paint doors etc but if it was seperate I’d just had s bumper
Keep up the good work buddy
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More updates to the finicky work being carried out.
The diffuser is now ready for paint ;D
The Scuderia decklid has a slightly different shape to the F1 roadster, I have had to make a new rear section to be integrated into the DNA decklid, this was done by making a mould on the car with a 3mm gap all around, the Scuderia has a large gap along the rear shut line to the engine bay, here I laid a 10mm spacer to achieve the correct look. The picture is as it's just come out of the mould
Next the revised light position and sculptured contour around them. To assure correct alignment I squared up the car and used the Formica to act as a refence plain, then with plasticine I stuck the light to the Formica and bonded them in place from the rear using the original fibreglassed cup as a holder, I'll fabricate some top mounts for the other studs off the light.
I'm back to work on Tuesday, unfortunately work on the car will slow down again, but this month has broke the back of this job and I'm onto new stuff, all be it about 10years behind eveyone else :D
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Had a long week off work and I've been full on with the car, the rear panel conversion is finally finished
here's a vid of the progress,
https://www.youtube.com/watch?v=PUeJKBwadFM&t=19s
and a couple of summary photos
cheers
Darren
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Looking good Darren
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Looking good Darren
A great attention to detail mate.
Did you not fancy making the rear bumper detachable, whilst you were doing all this work?
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I did look at the possibility of making it two panels, but concentrated my work elsewhere. Brian and Roland suggested either having a signwriter paint in the panel separation lines or pinstriping the panel lines back when I purchased the kit.
D
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I had a good sign writer around last year to do mine, as I hate the white inside the line.
He spent all day at the house trying different ways to get it right, but because the line isn’t 100% in width and depth, if you paint it, it looks shocking..
Luckily he only did it in paint that took a fair few hours to dry, so we managed to get it all off before it all dried on.
Needless to say, we decided, after nearly a full dad this wasn’t a way forward for my car....
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Now moving forward with the kit install, good to be putting things back on
Cleaned up the already once glued rear decklid frame, reprimered the freshly painted underside of the decklid
Got out the mastic gun and glued it back in place again
Also getting on with cutting the vents out of the rear panel
Now to leave it until the weekend, thick Polyurethane adhesive takes time to go off and cure
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Looking good d finally your into the body and your doing a great job mate :) soon be sending it for paint mate :)
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Hey Wayne,
Great to catch up with you at Stoneleigh
D
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Ditto buddy will stay over next year and hopefully have a car with me :)
Keep them vids coming buddy
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Done with the bodywork for a while, moving onto the next puzzle, possibly the electric roof
I've been doing a fair amount of work and head scratching, here's the limited amount of progress so far.....
https://www.youtube.com/watch?v=VVQ7RIydea0&feature=youtu.be
cheers
Darren
Enzodesign did look into the electric roof back in the early days, they gave up pretty quickly just after getting the rear decklid to lift up.
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If anyone can get it done buddy it’s you.keep up the good work and the vids :)
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Looking forward to seeing this done, last step to a perfect replica 8)
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What’s your plan for the Z flaps??
They will need to be moved too before the roof can be popped up?
Are you automating the lifting of the latches too that sit on the middle of the deck, so the two rear roof sections can hook into the deck?
(Or did I miss that but on the video?)
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What a job you’ve taken on.
With regards to position sensing I would go with an arduino and load cells. ( limits as well if you need them) so you don’t overload any part of the process and break something if you have a jamb.
I looked at something like this for my 4thirty. I could figure out about as far as you’ve got but couldn’t figure out the roof bit. Gave up and bought a West Coast.
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Hi Lee, there won't be any centre latches, the tail fins will act a bit like a 6 series roof mechanism
z flaps will probably be controlled by a servo, there's one in the video on the roof, I just didn't reference it because I've just done controls work with it for feasibility, I've bought a step down transformer 12- ranging from 6 to 4.0v, A mini servo should fit the job.
The Arduino will control most of the roof automation, I'll partner it with a digital I/O board to increase the number of inputs, current load sensors will be separate, I'll have them just trip the power. Most limit switches will be a diode return path set up to reduce the wiring in the system.
Please bear in mind, there's going to be a fair amount of things not working out before I get any real progress. I'm only a man in a shed ;D
Darren
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I think I would go for the Arduino Mega as this will cut down (by one) the amount of boards you have. Should make fault finding easier. Remember you can feed an Arduino 12v and get 5 out.
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Fair play mate..!
Well done and can’t wait to see this in motion.
Your doing an amazing job and keep it up ;D
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If you use a Mega you could also drive an LCD screen showing the status of the roof, just like the one in the Furrari.
Why? Because you can.
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The first piece of the puzzle done, the electric decklid
https://www.youtube.com/watch?v=zwlDB-nd258&feature=youtu.be
Darren
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Slowly going through the roof automation.
The decklid flap automation is complete, here's a vid of one side put together and how I plan to control the up and down limits
https://www.youtube.com/watch?v=D7Xetmh96KE&feature=youtu.be
cheers
Darren
next the roof going up and down ( got a week off for this one)
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Another update regarding the electric roof
the swing flaps are finished and put aside, the main electric drive to raise and lower the front roof is complete, I've used 'of the shelf linear actuators and the rest is fabricated.
The drive operates via a 12mm bright steel bar connecting the roof and the actuator arms through the body's structure, the idea is to be able to remove the 'automation and still be able to manually operate the roof.
works a treat
https://www.youtube.com/watch?v=5Rly169iElg&feature=youtu.be
next to balance the automatic deck struts and then the rear buttresses of the convertible roof
cheers
Darren
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looking good Drren 8)
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Cheers, I'd actually fabricated all the brackets before, only to find that they fouled on the outer weather strip of the roof when folded, but pleased that the roof now operates, need to fill the actuators with gearbox oil to quieten them down. I'll be balancing the struts today.
Darren
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Continuation of roof work, revisited some of my previous work, as I wasn't happy with the fluidity of the roof movement. I used hex bits and sleeve to obtain a better, stronger connection between the roof and drive
Next I balanced the inline linear decklid actuators
https://www.youtube.com/watch?v=Qt_wme6JdXk&feature=youtu.be
With those bits now sorted I moved onto the decklid catches, I wanted to improve the way the cable was attached, so I've fabricated a better end on the release lever (not unlike a brake lever) for the ferrule, I'll do the same with the pull down latch
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Cracking on with the roof mechanism, I've now finished the decklid latch system
https://www.youtube.com/watch?v=piurVbCvg44&feature=youtu.be
Next I'm on the the rear buttresses
Cheers
Darren
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Fantastic work Darren, cant wait to see car finished and working
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I've been continuing to work on the roof, unfortunately I've hit a problem that has stopped me in my tracks.
The rear buttresses need to fold in and turn upside down to tuck away. First I don't have the room for the mechanics (raw mechanism made up, then removed, I had to repair the cut aways on the seatbelt brace when I installed the acme screw feeds and then removed them!)
So I'm back to having to manually fold them away.
My problem is that I sold my roof about 4years ago with the fibre glass panels, so here I am making new ones...
I placed a modelling clay 3mm spacer under the mould to allow for material when it sits in a pocket, the steel reinforcing also gives me something to weld to for the rear hook and strap bar, I'll show it done next week when I cast the other fibreglass part. I've fabricated a ladder type support for the rear window and mohair, this will be wrapped in tesa tape to soften it for the pocket.
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I think I have a pair of fibre glass bits for rear of hood
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Oh, if something doesn't look right with my inserts, I'll take you up on the offer to borrow yours as a measurement template and do them again. Thanks
D
Got to ask, how on earth have you got a spare set?
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Come on Darren, you don’t ask questions like that..!
The aladdin’s cave is there for a reason 👍🏻, and we are all thankful for it...
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:D
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Been catching up on diy since covid restrictions have been relaxed a little. So just done a couple of little jobs on the car.
My motor controllers have arrived from china, I can now control the electric decklid rams as desired, this has also meant that the pull close mechanisms are redundant, the rams do the job perfectly.
I had also received my little £4 12vdc solenoids for the rear buttress retainer brackets, these are now also controlled electrically, the stops will be made when the roof is complete.
So here's a vid showing the bits in action
https://www.youtube.com/watch?v=HyalwwTTUPg&t=27s
Cheers
Darren
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brilliant as usual 8)
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Mind boggling !
It's going to be amazing when it's finished. Can't wait.
OXO
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Time for another update, I've been working on the Mr2/Ferrari dial backs for the mr2 modified instrument cluster. I've used INKSCAPE to produce version 1.0
Because I've drawn the dial backs, every component of the drawing is configurable for a correct fit and alignment against the mr2 circuit board.
The lay method has been tried and tested by a youtuber called 'more molecules' I'll make a couple of changes to free up more colours, but it'll be basically the same.
very pleased with the result so far
Cheers
Darren
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the MR2 is the opposite way round D
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Hi Steve, that's why I sold my DNA dial back, I changed my mr2 instrument cluster to mimic the f430 instrument cluster around 5 years ago, the reworked circuit board now has the gauges, mil lights, and speedo closer to the f430 positions.
I've still got to do the fascia cover like yours, but that's some time off yet.
Darren
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here's the video of the work I did years ago
https://www.youtube.com/watch?v=C_eWXLphCUQ
cheers
Darren
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Hi,
Goodness me......... that's mind boggling !
OXO
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cheers, almost forgot I did that, first time I viewed the video in 6 years!
Darren
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I've had two weeks holiday and been able to crack on with the car, My next door neighbour's son has shown an interest in the build for his media studies, not sure what or if anything will come from it.
DNA f430 folding mirrors all done, refer to other post.
Next I'm on the body prep for it's first polyester primer filler coat, I'll get the heat gun out again and go over the car checking for air bubbles under or in the gel coat.
Will I finally get to throw some paint on it after 11 years? ;D
cheers
Darren
Added note, I'm also configuring a basic system to show what gear I'm in on the instrument cluster, I'm sort of copying this guy:
https://www.lancerregister.com/threads/arduino-gear-indicator.513766/
I'm looking to use a sixteen segment display for a true N and R, will post if I get anywhere with it
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wow, thats a lot of instrument panel work, great if you pull that off. Looking forward to seeing it.
I was feeling pleased with myself just getting a prancing horse logo lit up when selecting Race mode using the manettino!
https://www.youtube.com/watch?v=zmF2VPifNrM&t=4s (https://www.youtube.com/watch?v=zmF2VPifNrM&t=4s)
My medium term plan is to upgrade to indiglo plasma like Madman has done, replacing the horse with RACE, with an independent +ve feed. Moman has quoted or the work, I've used him before with the F360 replica. https://moman.pl/en/ (https://moman.pl/en/)
Keep up the good work.
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One thing I've been searching for is a company that's able to print custom dialbacks, looks like you've just introduced them, I've just emailed them, thanks. ;D
My Steering wheel is a bit of an issue for me, I want to keep both airbags, the trimmer has already confirmed that the passenger one can be kept, he'll use perforated stitching. Roland gave me a Ferrari centre badge (sticker) for the drivers airbag unit in place of the Toyota centre badge.
I purchased a thrustmaster f430 steering wheel, I'll have a play with that at some later stage, pity the wheel is too small and plastic for a direct replacement.
D
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Yes Moman are good, I loved the dials they made for my old F360 replica based on the Peugeot 406 Coupe, fabulously lit and gorgeous driving at night. You can specify what you want, theyre made extremely well: https://www.youtube.com/watch?v=Vq4gfkISoSw (https://www.youtube.com/watch?v=Vq4gfkISoSw)
With regards the 430 wheel mod, basically its a sandwich of your existing wheel, you dont use the sim wheel rim at all (https://i.postimg.cc/cC9GKY6G/Adapting-Thrustmaster-F430-to-Momo.jpg). They seem to fit best with a Momo ot Momo style wheel.
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I purchased the thrustmaster at least 5 years ago for £10 off ebay ( broken pedal ) I offered up the thrustmaster to the Toyota steering wheel and decided that the whole unit was just too small, I'll look into using the thrustmaster switchgear with the DNA sandwich plate at a later date
D
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Back to bodywork updates, I'm now finishing off the blending of the DNA rear clip into the Toyota outer sill and door slam panel, I've also addressed (for me) the bonnet hinge issue.
The hinge allows bonnet over travel when fully open, stressing the bonnet skin seam around the hinge area, I've reconfigured the hinge to stop vertically plumb with the catch also latching at the same angle.
Here's a video of the hinge etc...
https://www.youtube.com/watch?v=IdCZ5hYxqMg
cheers
Darren
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Paint prep is not my strong point, so it takes forever..... just getting ready to put polyester primer filler on the final panel, the rear clip.
Then block sand, then apply another coat, then block sand, then wet and dry to 600, then sealer, then primer.
The last step is to then wet dry the whole car removing any trace of scratches, orange peel, or blemishes.
The garage will be turned into a paint booth, giving it good clean, then covering the walls in polythene, and finally laying down polythene on the floor, I'll dampen the floor just before painting any colour on the car.
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looking good Darren, love the Scudo rear, you just need a Scudo front bumper to go with it
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Might play with a different bumper at a later date ;D
The rear is not really a scudo conversion, the light cluster panel is something Ferrari did on the standard car, I've seen a few pictures, this is what led me to the slightly altered back end. Again I may change the back end at a later date, to something like Lord Beany did on his, I just want to get it finished and enjoy it :)
The scudo bumper does look nice
D
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yeah I think bumper is loads better, if you decide you want one at a later date let me know 8)
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Hi Daran,
I’m just looking at adding my new wheel into my car very soon ;D
Can’t wait to see it on the car
Just the sticker to add, which I’ve had to buy from Ferrari (ouch not cheap at all)…!
Then the red switch can go back on.
(Obviously, the badge needs turning around the right way up :D )
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That looks very authentic, is it a genuine 430 rim?
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Well this has been a while ;D
I've not done anything with the car because I was fed up with it, I needed to do something else to take my mind off it, so I built a tilting car trailer for my 'hotted' up Saab 95 to go on track days. I've had my fun and now it's time to get back on the car.
The seats have always been an issue for me, various builds have gone different ways through the years, I wanted 430 looking seats but with adjustable headrests, I started looking at this part of the build around 10 years ago and never really solved it.
A fresh look and now I have the adjusted headrest frames for the trimmer.
Steve's original post regarding the rebuilding of the mr2 seat gave me some ideas to work from, got to thank him for that 8)
Here's a vid of the biuld as usual
https://youtu.be/YZHMs7OlYVU
D