Delco-Moraine deletion - production guinea pig.

[Sparky]

The hammer? Yup, that's a keeper.

[Sparky]

Long day today.  Took it slowly to validate Ian's process, and document for myself.  Got as far as I could under the bonnet without the new brackets, which hopefully will arrive in just a few days.  First dumped the pressure then drained system via one of the bleeds, and mopped up much of the remainder with the Mityvac.  Best to keep a bunch of rags underneath too.  Then pulled all fuses to the system.  ABS warning light on!  Then pulled the relays and light went out.

Resultant jar of brake slime.

Pump and accumulator next.

Then, the dreaded brake pedal.  Pushrod clevis pin nice and easy, but getting the pedal off for drilling is nasty.  Probably best to take the seat out but I'm very bendy and managed to get it out in the Lotus position.  Getting it back in though - not at all nice, 18 minutes of contortions, and I ran right out of expletives.  More on order for tomorrow.  Access to the pedal pivot shaft split pin is via the fusebox aperture.  Lining up for a replacement pin needs a bit of patience too.  Very long-nosed pliers invaluable here.  Template made up for drilling.  Ian's spec calls for approx. 3mm of meat between pedal leading edge and new hole; I got 2.78mm.  OK, as none of the stress is in that direction.  I drilled the hole at 9mm, then relieved it with a circular file until the pin was a snug, but free fit.  In the last pic, you can just see the edge of the fabled heater valve.

And then these arrived!  Tonight I shall dream of shiny new brackets. And limbo-dancing under a steering wheel.

Thanks to Chris (wookie) who pointed and took photos for me.

[Sparky]

Started the day on the front pipes, cut, dress, flare, add unions in preparation for pipes from proportioning valve.

This is THE tool for pipe flaring.

Sorted pipes and unions from master, ready to tailor for Proportioning valve once I get the brackets.

And relocated receiver/drier to the other side of the GRP, to avoid interference with master.  Also need to shift a bank of fuses to accommodate servo.

Dressed bottom of valve, removing flash that would interfere with banjo seals.

Changed the tail at front of manifold ready for 3/8 vacuum pipe.  This will provide contingency engine vacuum in the unlikely event of system failure.

New vacuum pump.  Slightly different to the one Ian used, and will need a different approach to mounting, but I'll work it out.

Mounting lugs removed to facilitate placement in current vacuum pump recess.

Boot floor heaven: held in by one bolt, which came out easily.  I can only imagine Bazza's been at it.  Of course that means I'll have to sort it out later.

Fuse/relay box near battery removed and ignition.switched live feed soldered in (red wire); this will route via engine bay to vacuum pump recess.

Also noticed this crushed capillary.  It's the one that feeds the heater controls.  spliced in new capillary.

So far so good!  But I'm gagging for those brackets.

Now, pop quiz (if anybody's stuck with this).  Identify the cables (green/white & black, i think) to the left of the red connectors, and what they're powering.

 

 

Edited May 11, 2018 by Sparky

[Barrykearley]

Looking bloody amazing. Nice work.

Im currently shopping and ticking bits off. I can’t wait to be doing this on mine.

[Steve V8]

54 minutes ago, Sparky said:

Now, pop quiz (if anybody's stuck with this).  Identify the cables (green/white & black, i think) to the left of the red connectors, and what they're powering.

Newly installed W/M/F Exotics direct remote emergency call wiring.

In the event of an emergency the nearest Exotics engineer is automatically called, the system is then cleverly reverse wired back through the fan relay sucking as much hot air back in as possible causing the radiator to boil. On arrival this allows said Exotics engineer to pull bottom hose and enjoy a piping hot cuppa tea and a chat before diagnosing problem.

[Sparky]

Uncanny!

[Sparky]

To explain the wiring:  engine idle is erratic and likes 2000RPM.  Exhaust back pressure valve (EBPV) isolated.  Throttle jack (TJ) still present, but TJ solenoid missing.  TJ wiring plugged into EBPV solenoid.  I could see the TJ cam acting on the throttle.  ECU throwing Code 26.  EBPV solenoid wiring is now used to power an electric chargecooler pump.  Lovely.

[Sparky]

Mocking up the proportioning valve.

Pretty much on hold now, awaiting several items.  I will be visiting Ian in Margate on Friday to pick up the brackets.  We'll probably take the opportunity to schedule in an Exotics, Inc. strategy meeting, which will render me incapable of driving home.  Fortunately the Margate branch Penthouse Suite is at my disposal.  I might even bring a companion.

Ian, I suggest some fresh straw in the shed in case Barry decides to attend.

[Barrykearley]

My postman’s gonna hate me this week.

i simply can’t wait to get going on this

[Sparky]

Glorious day for working on the drive!  Today I fitted 6 metres of new 3/8" servo pipe, and found plenty of existing engine vacuum problems.  

T junction branches off to the inlet manifold to provide contingency engine vacuum.

Ready for routing into the boot.

 

I decided not to use the UP5X vacuum pump, opting instead for the UP32 (like Ian's) which is a better fit into the boot recess.  The UP5X will go into the next conversion subject which is an SE, so the pump will have to live somewhere else.  So I'm awaiting the replacement pump, and the brackets.

Meanwhile, translator time.  Very badly worn bearings, also tie rod joints.  The cable joints are in excellent condition.  I'd forgotten that this car was my guinea pig for quick-release cable joints; they've held up incredibly well.

Margate beckons...

[Chillidoggy]

After an operation to remove a metal splinter from his pointing finger, Margate Exotic's paramedic would like to like to assure everyone that Sparky's going to pull through.

 

[Sparky]

For a while there it was touch and go, but Shan's bedside manner (and that nurse outfit) pulled me through.  Ultimately, it was only a small prick.

[Sparky]

Here's what all the fuss was about:  brackets for servo and proportioning valve, and new pushrod.

Spent virtually all day iteratively fitting (and fettling) new bracket, servo, master cylinder and proportioning valve.  There's a lot of work involved in getting pedal dimensions/travel correct , and especially fabricating the brake pipes from/to the proportioning valve.  These require the utmost care.  Ian warned me that a significant amount of kunifer might be sacrificed, and he was correct.  I managed to cross-thread a union into the Wilwood valve, and this turned out to be irretrievable.  Down to me and all part of the learning curve!  Also, I had to cut the pushrod down by several mm to achieve desired pedal specification.  This is a complex conversion that requires significant care and planning, and not for the faint of heart!

[Barrykearley]

Really looking forward to the putting back together phase now 

[Chillidoggy]

Yes, it’s a complicated job, and anyone attempting it must be technically competent. The brake pipework in particular is enough to try the patience of a saint. I spent hours and hours researching and thinking about it before I even ordered any new parts, none of which are obsolete.

I’m personally recommending Sparky for doing the job, as it has to be carried out correctly.

I’m keen to see how Dragan’s car turns out, hopefully we may see it on test at the end of this week?

[Barrykearley]

I’m most looking forward to ensuring the pedal and pushrods are set right - my body is going to hate me

[Sparky]

It was all going so well...

Unfortunately the pump is a lemon.  It's leaking like a sieve and must be replaced.  It's now a toss-up between waiting for a replacement or using the UP5X I have, which will be a more problematic fit.  I'm also unhappy about the manifold, which comes with awful stock seals, so I shall change these for something more airtight.  Shame; I was so close...

[rizla603104]

So near and  yet so far.... tomorrow’s another day. 

[Sparky]

Awaiting some bits including a replacement pump, I got on with some other stuff.  Rebuilt the translator and put together a new tie rod.  Gearchange is lovely.  All balljoints are now quick-release.

Two NRVs had failed, and have been replaced.  Guess it's time to start checking these as part of any service.

Awaiting UP32 pump replacement, I decided to test-fit a UP5X.  We thought it wouldn't fit, but it does - horizontally AND vertically.  Worth remembering for any future conversions.

It's the aesthetics that take the time...

[Barrykearley]

Looks great chap.

its somewhat tiring fettling and getting it nice. I can only imagine the hell Ian went through getting the bracket right. 

Ive simply given up for the day - come back from walking dog whilst danny was at swimming, picked up the exhaust - and I simply haven’t got the energy to drag my sorry ass to the garage.

 

[Sparky]

Forgot to say - wasn't happy with the free play at the pedal, so ground a 14mm spanner wafer thin and performed another 6 Lotus positions.  Surprisingly I can still feed myself. 

[rizla603104]

All good stuff chaps! Can’t wait to read the results in a week or so

[Barrykearley]

22 minutes ago, Sparky said:

Forgot to say - wasn't happy with the free play at the pedal, so ground a 14mm spanner wafer thin and performed another 6 Lotus positions.  Surprisingly I can still feed myself. 

Ahh - I have a thin spanner just for that locking nut - a normal one will not fit.

i found with the pedal insitu - you could rotate the rod on the thread and adjust “in situ under the steering wheel in the Lotus position” and then pop back into the slot and whack the retaining pin in. There’s a whole lot of movement in the servo actuator. Then nip up the locking nut.

it does really help to have another car to compare the pedal with on the free play. 

10 minutes ago, rizla603104 said:

All good stuff chaps! Can’t wait to read the results in a week or so

A week?? Feck that - I might have given up for tonight - but the war will commence in the morning. I’ll be road testing by lunchtime 

Just spent 40 minutes sat in the hot tub with the youngest - she seemed a little sad and needed some Dad time - my body almost feels repaired !! Get a hot tub @Sparky - even my finger look clean 😂

[Sparky]

Remember Christine?  The silver High Wing?  I'm off to see her tomorrow.  She seems reluctant to let me rip her apart again, and has dropped some coolant in protest.

[Barrykearley]

Has she developed frontal or rear incontinence ??

nice three row upgrade in the offing