Delco-Moraine deletion - production guinea pig.

[Sparky]

Jeez, I hope it's not a rad.

[Barrykearley]

2 minutes ago, Sparky said:

Jeez, I hope it's not a rad.

Never done one - is it hard 🤣💪

[Sparky]

Got the new TPS today, on and adjusted.  Now everything except the braking system is finished.  There's one brake pipe I'm not happy with, so I'll remake that.  Still waiting for the replacement vac pump.  Having a baaad time getting the washers I need for the final hydraulic fit; hopefully that will be resolved tomorrow.  A Farmyard fix may be imminent...

[Barrykearley]

6 minutes ago, Sparky said:

 A Farmyard fix may be imminent...

You know it makes sense 👍

[Sparky]

Must...resist...

[Barrykearley]

Trust me - come to the light @Sparky

[Sparky]

Figure out the lamp driver and I'll admit you're my father.

[Barrykearley]

Yes son - it’s now all sorted. 

Thats our little secret

[Sparky]

The Farce is strong in you, Darth Tractor.

[Sparky]

Lamp driver sorted out, thanks to Barry!  This overrides the low pressure warning light that was problematic.

I've been struggling to get copper washers for the proportioning valve outlets.  They have a critical OD of 12.75mm.  Ian had good access to get these fabricated; unfortunately I do not.  So today I gave up, whipped out a file, and made them myself from standard washers.  90 minutes of non-stop fettling, and my fingers are agony.  But, sorted!  I've altered a part spec, reducing the specified banjo bolts from 20mm to 18mm to accommodate the thinner washers, and relieved the valve slightly, enabling me to get the rake I need on the pipe unions.  As soon as the banjo bolts arrive, I'll have a brake pedal.  Reminder to self:  anneal washers.

Replacement vac pump arrived, and works just peachy, so I cut and filed the mounting lugs to enable fitting in the recess with appropriate brackets - again.  Lovely to get most of it back together again.  Another slight deviation from Ian's fit: - a 4-way plug for the vacuum electrics.

This one will get the ultimate test once finished, as it's due an MoT next week...

[Barrykearley]

9 minutes ago, Sparky said:

This one will get the ultimate test once finished, as it's due an MoT next week

And this is another critical stage IMHO. I am practical and competent - however in my previous employment I instigated a buddy check system on many critical path issues. It really helps to have another eye cast over such works. Setting up the wilwood valve can be done on the road - but 5 minutes on an MOT roller and you know everything is right and proper.

looking forward to seeing it finished chap 👍

[Sparky]

Bazza, have you gone 60/40?  And are they stock brakes?

[Barrykearley]

Yes - I’ve got it set at 60/40 presently. It’s standard brembo front and rear. Running green stuffs in there and slotted discs. All of that was on the car when I got it.

the greenstuffs are much much better when they are hot

[Sparky]

She flies!  Banjo bolts just 2mm shorter were a great help.  I had a couple of slight weeps on the new unions under servo pressure, but they seem sorted now.  I won't be signing it off for a few days yet, during which I'll be testing the brakes in diverse scenarios and looking for issues/leaks.  The new vacuum system is well sealed; the original Lotus stuff leaked a lot!  Sorted that out and we now have a decent vac system overall.  Numerous vacuum repairs, a new TPS, throttle jack deletion and sorting out some wiring have resolved a very erratic idle, and the engine now runs beautifully.

The brakes feel excellent, and inspire so much more confidence than the awful Delco-Moraine system.  Let UAT commence...

[rizla603104]

Looks like the original cover fits well too. Great work. 

[Barrykearley]

The cover needs a slight trim - but yes it fits. 

Get driving @Sparky it’s a brilliant setup - I for one am well impresssed

[Sparky]

I did a fair amount around the local area - braking hard from 30-40MPH.  Finally settled on 7 turns out for the Wilwood and 19Hg vacuum.  I'll get it on the rollers on Tuesday hopefully.  Then I'll see how it brakes at higher speeds.  Looking forward to giving this one its legs now it's running so nicely.

[Barrykearley]

And what do you reckon then @Sparky?  

The braking is fantastic with a servo conversion brembo isn’t it? Even with the dire greenstuff pads on mine - it’s bloody amazing - a proper full on transformation. What is the best is the confidence when you press that pedal it will work, be consistent and stop in far far less time

[Sparky]

Wonderful pedal!  First time I've enjoyed driving an S4 (apologies to owners but I'd never have a car with the DM setup).  I'm cautiously optimistic; time will tell...

[Barrykearley]

My S4 was the first DM car I’ve had - it’s just fine. The S4s was dire and properly dangerous. I put this down to the solenoids sitting over time and not being used as it was fine with the fuses pulled. 

Its critical the brakes work and consistently - I absolutely love the set up now. It’s easily maintained, parts availability will be superb and it’s a nice servo setup as frankly abs doesn’t belong on a Sportscar.

 

[Chillidoggy]

I have my Wilwood at five turns for the moment but I need to bed the new Mintex M1144 pads in first, so haven’t settled on a pressure as yet. I’ve set it up to 21” vacuum, I could come down a bit from there, reckon it might be better with slightly less assistance. Definitely interested to learn how you get on for a comparison.

[CarBuff]

The older, non-ABS Esprits (with the external vacuum pump) were designed to run the brake servos with a minimum of 18" vacuum, so that is a good setting to aim for.

[Barrykearley]

12 minutes ago, Chillidoggy said:

I have my Wilwood at five turns for the moment but I need to bed the new Mintex M1144 pads in first, so haven’t settled on a pressure as yet. I’ve set it up to 21” vacuum, I could come down a bit from there, reckon it might be better with slightly less assistance. Definitely interested to learn how you get on for a comparison.

Don’t think my greenstuff lumps of damp oak help comparisons presently. Yes I think I’m at 23, but I’m not convinced the gauge is accurate either as I fettled it to zero It. The brakes are without question superb - but yes possibly too much assistance presently. As it is - I’m happy and don’t want to adjust just yet without checking what the vac is accurately 

[Chillidoggy]

18 minutes ago, Barrykearley said:

Don’t think my greenstuff lumps of damp oak help comparisons presently. Yes I think I’m at 23, but I’m not convinced the gauge is accurate either as I fettled it to zero It. The brakes are without question superb - but yes possibly too much assistance presently. As it is - I’m happy and don’t want to adjust just yet without checking what the vac is accurately 

Time for a new gauge?

[Barrykearley]

Yes - I will check it though - but believe it needs replacement. Doesn’t change the fact the brakes are sublime