Another rust combat

[proffighter]

Originally Posted by chrisbalich

Very cool, Roland. Thank you.
I'm always looking to expand my tool collection and this looks much more precise than a press-brake or just jamming something in my vise.

it's a Swissmade Gressel, one of the tool companies here in Switzerland and well-known allover Europe. There is no better one if you need a vice, especially those for the work bench but also machine vices. Very expensive but last longer than your life.

[LJ851]

Originally Posted by proffighter

it's a Swissmade Gressel, one of the tool companies here in Switzerland and well-known allover Europe. There is no better one if you need a vice, especially those for the work bench but also machine vices. Very expensive but last longer than your life.

Roland,
I’ve been looking for a quality benchtop bender like this for a while now. All I have previously found are the Asian universal benders but they don’t appear very well made. Looking at Gressel’s line of HB benders it appears yours is a HB10 ? Is this correct?

Thanks !

[proffighter]

Originally Posted by LJ851

Roland,
I’ve been looking for a quality benchtop bender like this for a while now. All I have previously found are the Asian universal benders but they don’t appear very well made. Looking at Gressel’s line of HB benders it appears yours is a HB10 ? Is this correct?

Thanks !

Yes, it's a HB10. I worked also with HB14and HB20. The 20 is what I would buy but the price...

[proffighter]

Today I was able to proceed with the fan. I could borrow the tool to set the rivets. After a few Test rivets I set the "real ones". To have a good solid fixation to hit the rivets, I made an massive aluminum counter part as seat for the hub.






It went easier than I expected. Looks quite nice. Only 3-4 hits with the tool and done



And of course test fit to check how it looks, I like it.



The hub is an aluminum replacement. Nice made BUT the rivets needed are not 72° as stock but 90°. No issue so far, but I expect if someone sells replacement which need different hardware, he should inform. For this reason I have now a lot of both versions

When I want to check the amount of shims needed I fitted a new belt. Bought according parts catalogue 710mm but it's way to long. Checked the old one: 700mm?? How this can be? Checked other suppliers like PP, FVD, all the same. 710mm. The only thing left is the Smartracing pulley on the crankshaft, I thought it's the same diameter than stock, but have no stock one to measure... However it is like it is, have to buy a 700mm.

[pkabush]

Not sure this will help but, I just went through a similar issue with my belt not fitting after installing a different fan.
It turned out that the fan wasn’t sliding all the way onto the alternator shaft. I re-installed my original fan and everything worked fine.
Your parts are looking amazing as usual. Must be nice to be so close to the finish line.

[proffighter]

Originally Posted by pkabush

Not sure this will help but, I just went through a similar issue with my belt not fitting after installing a different fan.
It turned out that the fan wasn’t sliding all the way onto the alternator shaft. I re-installed my original fan and everything worked fine.
Your parts are looking amazing as usual. Must be nice to be so close to the finish line.

Thanks for input. But I had the shorter belt with the stock fan hub as well. so issue is not caused by the custom part. I also checked the alignement (housing pushed forward to transmission side). Fan is also all the way onto shaft (can see through the holes it's touching the big shim behind the woodruff key). so left only to check the diameter of crank pulley.

... Thanks, but close to finish? Not at all (unfortunately or not ) Thousand of things still in my mind. You'll see

[proffighter]

It's been a while since last post... However, after I had to glue most of the cork insulation once again as they fell off after a while (dammit self-adhesive quality) it had no motivation there for a while. Now I started to fit the aluminum coated tissue. Unfortunately the one I had 20 years ago was not available anymore, thick and solid but very good to drape. All samples I received where stiff almost like cardboard, impossible to glue in there without wrinkles. At the end I bought the least bad. To have at the beginning a little feeling of success, I started at the top. Went out not bad. Still have to cover the edges, but this I will do as last.

[gsmith660]

I like that

[krasuskyp]

Great to see you back here again Roland - and - that you're still havin at it! Lookin good... keep on pluggin away,,,

[proffighter]

Such a time consuming thing, so only little (but at least some) progress

[proffighter]

last update before vacation



The tissue us less flexible and drapable as desired. Therefore I had to make smaller pieces. Left over area in the middle will probably not possible in one piece, at least two I guess. But first I am off for two weeks :-)

[proffighter]

While I regularly continue, I don't do regarding posting... However here a little teaser about wiring harness (I made all new). Pictures are a bit older, more current will follow soon

[proffighter]

Long time ago (check my thread "another EFI conversion") I mounted a BMC airbox and made air tubing from Filter to turbo out of PE-HD tubes. No issues since, but When remounted the box, I noticed the inlet diameter of box seems smaller than stock. So I measured and found about 80mm against almost 100mm of stock airbox... Furhter I disassembled the BMC CDA box to check the surface size of the cone shaped filter. it's not easy to check surface due the wave shape of filter material l left this out and just looked at surface as it would be flat. So BMC Box seems a little smaller than stock...

So easy decision: A bigger box has to be fitted. I bought the same CDA Box but bigger version. In- and outlet 100mm. I did not measured surface yet, but quit bigger than stock for sure.

So beside the box, I have to make the whole tubing new. before it was also 90mm reduced to 75mm after 90degrees elbow before BOV connection (and the bottleneck of less than 80mm at box in and out). Now it will start 110mm at box with little 3D-printed adapter (red), reduced to 90mm until after the BOV. Also I made an additional clamp (nothing like on the market) out of SS to take off some weight from the box. Progress so far:

[proffighter]

Because of the bigger measurements of the new air box I needed to replace the Filter bracket (still the K-Jetronic piece) with a new. Made it out of hight strength aluminum, anodized in black. So a little weight saving too








BTW: the stock bracket was drilled already (you know me, don't you :-) )

[fourblades]

Great work as always!

I like the bigger airbox.

Glad to see you back posting.

John

[proffighter]

Originally Posted by fourblades

Great work as always!

I like the bigger airbox.

Glad to see you back posting.

John

Thank you!

Me too likes box

[proffighter]

Today I finished the whole inlet tubing from air box to turbo. First I shorten the silicone reduction hose. Easy to do with sharp cutter on the lathe.







PE-HD tubes "welded" using frying pan




Test fit before final cut's to adjust space between the two pieces where reduction hose will be

final version fits like wanted

[proffighter]

hmm test fit picture lost... so here it is:

[proffighter]

Today I startd with making engine wire harness. To get the right lengths of the cable I made kind of Connector bracket to get the correct position of them similar to engine is car. So it's easier to route the cables and test-fit before mounting pins.





Note: As you can see here, I still will use the spacer to lower the engine. Made this to get the B6 intercooler under the wing. The 965 intercooler is not that thick, so no issue for it. Regardless I like the idea of the lower engine (lower center of gravitiy)

[proffighter]

I just saw that I never posted pics of the finished engine bay heat and noise isolation, so here they are