Lancia Beta Forum

Well this is my Beta, it’s a 2 litre IE HPE registered in 1982, which is my Track/Road Car, although everything I seem to be doing to it, is turning it more into a pure track car only.
I thought this would be a good idea to have a on-going blog on the car so not only others can see what I am currently doing to the car but also what’s happened to the car, and what can be done; it also acts as a record of things i've done for myself.
I’m not sure how the forum will cope with so many pictures, so if it becomes a problem I will upload pics. to my flickr page and add links. Please feel free to chip in with any comments, suggestions and idea’s at anytime, but don’t be too nasty. ;)

I was originally looking at getting a fulvia coupe or sedan to use with some type of motorsport intended, but then this HPE came up on ebay as a “running” example needing TLC at Bath, 10 miles from me. I asked for some pics. And a week later became the owner of a £99 HPE around September 2006.
It wasn’t until I arrived to pick it up that I found the owner was Gary Stretton, editor of Classics Monthly. He was going to have ago at restoring the car but ended up selling it due to having too many projects on the go. I told him what my plans were for the car, and he told me to keep him updated, which will lead onto later on. Somehow, I’m sure it was with some type of black magic that he started the car and with it popping and bagging drove it onto the trailer. From that moment the car didn’t run again for roughly a year. Electrics!

From many, many, posts on the old betaboyz forum you may remember me asking plenty of questions regarding the electrics, to the point that at one time I could tell you which colour a wire was out of the loom and what it did from memory. I’m starting to forget now, I’m taking that as a positive as I havn’t had a problem with electrics since I replaced the whole engine loom, and ignition related wires, as well as distributor, coil, ignition amplifier, igntion barrel, airflow meter, while removing a digiplex loom that had been bodged to “work” without the digiplex unit and may have had an immobiliser previously fitted.

When I got it back home, my first job was to start stripping the car of weight, removing most of the interior and bumpers front and back, its suprising how much those wrap around bumpers weigh! This was a job that was further continued at Wiltshire College as I was currently on my 2nd Year of a National Diploma in Motorsport and became a project car for me and three friends to use for coursework etc…
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMAG2040.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMAG2045.jpg)
Here it’s pictured being taken to Lackham College, it then was moved to a purpose built facility for the motorsport side of the college at Castle Combe racing ciruit, where I carried on for another two years completing a Foundation Degree in Motorsport Engineering. The car wasn’t in there as long as I was I’m pleased to say, overall I think it was only in there a maximum of a year, but while it was in there had some of the following jobs seen to:
The subframe had quite a substantial crack right near the gearbox mount which had cracked due to a poor weld at the last attempt of welding a previous crack up. So this was welded up and then I put a sleeve over the top also welded to help transfer the load a bit more evenly.
(http://i135.photobucket.com/albums/q152/lanciamad_album/212.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF53491.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF53521.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF53531.jpg)
The front valance came off to be cleaned up, luckily it turned out to be JUST surface rust as well as many areas over the bonnet and wings.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF48671.jpg)
The door strips came off so each hole was filled in as well as the holes for the rear bumper, and many other areas were tidied up so it was at least passable at an MOT.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00005.jpg)
One side of the transverse arms were bent just a tadd, so a good condition cross member was fitted in its place.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00041.jpg)
As well as this, betaboyz springs front and back were fitted, as well as polyurethane bushes in the front. (I didn’t have time to fit the rear at the time). I will put a specification of the car at the end.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00026.jpg)

As a mini project for college, I had the main hoop (B pillar) made and bent by merlinmotorsport so this is ready to go in the car at some point in the future from garage to car.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00079.jpg)
I cant remember what else had been done, but you can imagine it was a full strip down of everything and then rebuild, so you could say I started with a solid shell, with poor bodywork and built it up from there.
With various other jobs completed it past its first MOT with me, March 2008, and naturally it had to go on track. I was unsure whether I would have the car ready in time so couldn’t book the Lancia Motor Club track day at Goodwood but two weeks later decided to go down and watch anyway. The day before, the head gasket went, but from what I could tell it was only minimal water leaking into one of the cylinders and I decided to brave it. I arrived without problems although watching the odd puff of white smoke along the way, and then the unexpected happened that I could go on track at the end of the day for a session as car numbers had dropped due to weather, so it was rude not to.
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_2613225_7832.jpg)
The car went fine, although started to drink water on the journey home and had to make three unplanned stops to fill her up on the near 100-mile journey back.

So it was off with the head, and I was correct, head gasket had gone. I had a spare IE head at home so I took this to be skimmed at a cost of £10, rebuilt the head up at college and bought a new head gasket set for around £60 plus a timing belt £10, so didn’t cost me that much, it was something I hadn’t challenged before, and the best bit is its still going strong.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF3038.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF3048.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF3053.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00169.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00170.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00167.jpg)

After this, I had the bodywork redone in some places and a professional respray by a local company to me.
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_3292189_2219.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_3233003_4665.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_3403038_1971.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_3458785_2284.jpg)

I then did my first proper track day at Castle Combe Circuit in November 2008, and got it a bit sideways around camp corner on one of my laps in the first session, followed by another 5 cars doing the same within half an hour, that was certainly slippery. One of my favourite pics of the car I must say and I’d like to say I held it like that all around the corner but that would be a lie.
(http://i135.photobucket.com/albums/q152/lanciamad_album/n719035572_5040793_5631.jpg)
The car went faultless all day, not needing any oil, water etc… ending up doing 8 sessions of 15mins each, roughly 80 laps, nearing 100 miles of combe.

Classics monthly magazine then got in contact with me and wanted to do a 5 page spread, as i had originally bought the car from the main editor Garry Stretton, and found it a project with great interest, and an example that not all 19 year olds (at the time) drive around in corsa’s with ironing boards fitted to the roof.
(http://i135.photobucket.com/albums/q152/lanciamad_album/2585_139151400572_719035572_6239660.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/2585_139151405572_719035572_6239661.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/2585_139151410572_719035572_6239662.jpg)

In march 2009 i then got on Goodwood again for a full day this time, although i only went out 5 times during the day, due to it being so many cars booked, and do prefer to go back to the paddock to check the car over than in the que. Thanks to Tony Harrison for this great photo of the car on the day.
(http://i135.photobucket.com/albums/q152/lanciamad_album/2585_139120740572_719035572_6238671.jpg)

Since then i have been doing a few modifications for the rest of the year.
Some new copper brake lines for the whole car was made by myself as well as the goodridge brake lines fitted, this is now with high boiling dot 4 brake fluid as well as a bit of red paint.
(http://i135.photobucket.com/albums/q152/lanciamad_album/2882_175340010572_719035572_6802180.jpg)

I got myself some dunlop track tyres which improves handling and grip a million times compared to my plastic road tyres i've got on it at the moment, two still from when I bought the car!
(http://i135.photobucket.com/albums/q152/lanciamad_album/2585_136790095572_719035572_6173750.jpg)

I have fitted some adjustable spax in the front, which has made it REALLY stiff now, and i'll be looking forward to using these in anger and getting the best balance for grip.
(http://i135.photobucket.com/albums/q152/lanciamad_album/2882_175342020572_719035572_6802260.jpg)

Since Goodwood track day I have done two sessions at Action days at Castle Combe, will be at Curborough this Sunday and have just booked to do another all day track day at Castle Combe in late November, let me know if your interested, (all cars welcome).
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC_0148-vi.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/classicaction363.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/classicaction336.jpg)
At the last action day ;D me giving it the beans out of quarry corner. To me and the cars credit we kept a caged up track prepared ford anglia a distance behind all session, unsure what was under the bonnet of that one.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF7709.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF7711.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF7708.jpg)

Back to the car, I have also recently fitted grooved/drilled front discs mated with Tarox pads, and new pads and discs on the rear, as well as a new handbrake cable from the betaboyz this year. ;)
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0122.jpg)

So that I can control cooling before the standard fan kicks in, I have a secondary fan fitted to a manual switch on the centre console which controls the temperature bang on for what I want.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF5790.jpg)

Some recent work that has been done over the last couple of weeks includes the exhaust having the chop, as of course it was still the original length for when bumpers were fitted, this has now been reduced to the length of the fog light and comes straight out of the silencer which I think looks a lot smarter.
From this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0174.jpg)
To this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0180.jpg)

I have also made myself tackle these rear bushes that I kept putting off, to find they were reasonably simple to replace in the end, I managed to get the old one’s out with a vice not even connected to a bench and a claw hammer! So here’s them fitted. Only one I have left to fit is the bush situated in the hub as I cant get the bolt undone at home, that’s on there tight.
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0178.jpg)

As well as Spax in the front, I have now fitted some in the rear and its certainly a revelation, car seems to stick to the road like never before (on smooth surfaces) and the suspension is certainly much harder than before. I’ll be having them on fully hard for track use, and from what I’ve seen the only movement is in the top mounts and the sidewall of the tyre.

I hope it didn’t take you as long to read as it did to write :D, I will write in a more detailed manner as I work through things now, it was just the bulk of history I had to skim through. Car specification to follow.

Next projects, are fitment of an Ansa manifold and solid strut top mounts!

This is the exhaust manifold I bought from HFStuart. :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/Picture064.jpg)(http://i135.photobucket.com/albums/q152/lanciamad_album/Picture067.jpg)
I got to work with the wire brush and then sanded it down further with wet and dry.
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0197.jpg)
After doing this I blow torched the whole manifold dry and then sprayed it with black manifold paint.
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0205.jpg)(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0203.jpg)
Once this had dried I got to work on wrapping it all up in heat wrap, I ended up using almost all of a 10m roll of the stuff and held it in place with metal cable ties.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF8655.jpg)(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF8656.jpg)
Next job will be the fitting after Curborough.

Car Specification:

Engine:
Standard 8 Valve 2 Litre Fuel Injected 122BHP
Gearbox:
Standard 2.0 IE Gearbox
Exhaust
Ansa 4-Branch Manifold
Shortened Tailpipe
Front Suspension:
Adjustable Spax inserts
Betaboyz lowering/Uprated Springs
Polyurethane bushes
Rear Suspension:
Adjustable Spax inserts
Betaboyz lowering/Uprated Springs
Polyurethane bushes
Strut brace
Brakes:
Goodridge stainless steel brakes lines
Dot 4 Racing fluid
Front:
Drilled/Grooved Discs
Tarox Pads
Rear:
Standard Disc
Standard Pad
Other:
Bumpers removed front and rear
Interior stripped
Bucket seats
Harnesses
Bonnet pins
Secondary Fan
Track tyres for track use only – Dunlop currently
Cone K & N Air Filter

What a post Marcus !

Great stuff and quite inspiring for those whose road car projects are lagging a touch  ;)

How would you rate the Betaboyz springs for road use ?

Glad you like the post Stuart :), hopefully others will to and i'll keep it updated as and when jobs are done.
I cant comment fully on this as i havn't driven a beta with the standard spring, but have been in one. I have a picture of mine and a 1600 HPE nose to tail and the difference in height is really not that noticeable. I've had mine in now for 3k miles plus and are still as new. On the driving matter i found they are stiffer but with a standard shock absorber your find not much difference in the ride other than roll slightly reduced.

Yes, very nice post.
But, regarding your back box - the odd angle i mean, from your photos it appears that it has been welded, as the pipe connecting it to the middle box goes off at a sharp angle.
If it was unmolested (just guessing it has been messed with) then it is adjustable via the olive and rear hanger.
The hangers do tend to get distorted though and need re-bending to get them back where they were originally but the box tucks away nicely under the rear corner and should not "dangle" as yours does.
Lancia put the cutout in the rear valance for a reason.

Cutting it was inevitable though as you have no bumpers - how many times did you smash your shins?

Anyway nice post, does it sound different with the Ansa?
   

Oh i forgot - how did you end up with the traverse link damage?
Trolley jack?

The transverse links were like that when i bought the car, and by the looks of the tyre that was on there people were driving around like that! :( Yeh i presume some type of trolley jack did it.
Ansa hasn't been fitted yet, and suprisingly although the exhaust looked long as original, it didn't stick out too much. When people said about possibly tripping on it, i just said why would you need to be that close to my car. :D
Regarding the silencer, the new shortened version is a new old stock silencer which hasn't been messed with (and was the same as what came off), i did adjust it further after that picture was taken and the car is raised to the third notch on axle stands.

The middle section of the exhaust was vibrating on the underside of the car at just above idle speed, which annoyed me; so i took it all apart again ::) adjusted it a lot better like it should be, but now this means the tailpipe sticks out at a bit of an angle :-\
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00705.jpg)
Think i'll buy some new rubber exhaust hangers as the original one's are clearly stretched and it seems to be a looseing battle to get it looking right. It all has to come off to fit the ansa anyway ;)
Of course this is the main reason why a HPE is the perfect track toy :D
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00703.jpg)

Car looked great at Curborough, well impressed.

Geoff

Thanks Geoff :)
Had great fun, car did me proud as usual with no problems other than the exhaust rubbing on something when at speed around one of the corners; total mileage for the day was 270 miles there and back for me not including the 15 laps round Curborough.
Was really impressed with the brakes and suspension on such a short twisty track. Seemed to be able to brake a lot later and with the shocks on fully hard there wasn't much forward momentum when hard on the brakes.
(http://i135.photobucket.com/albums/q152/lanciamad_album/4027775082_c0f7352ab7.jpg)
Picture taken by Tony, some great one's as usual 8)
Here's some in car video's, two clockwise on shorter track and one anti-clockwise on longer track:
http://www.youtube.com/watch?v=9vCDCh8JbFg
http://www.youtube.com/watch?v=VLZA3OTT6tg
http://www.youtube.com/watch?v=WjIt2ovXcj4
Sound is awful due to cheap camera and vibration.

Jobs to do before Castle Combe on the 28th November:

Replace damaged fuel pipe
Replace fuel filter
Spanner check rear suspension
Fit ansa manifold
Adjust exhaust system accordingly
Check all hoses and fluids in engine bay
Change induction system

First, I tackled the most important job, the fuel pipe. I noticed that before Curborough, one of the pipes looked like it was under pressure, as it had become slightly kinked and as a result was starting to wear. It wasn’t leaking and looked like it was only the outside wall, so I taped it up as a bit of an insurance policy and it didn’t cause any problems.

I then got to work in removing the fuel tank. Firstly disconnecting the three wires for the fuel tank sender unit:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00720.jpg)

Then the other relevant pipes (Easy when you don’t have an interior):
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00721.jpg)

Fuel tank drops down easily with the trolley jack:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00722.jpg)

The offending ½” fuel pipe (Tank to pump):
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00723.jpg)

The new pipe I bought is braided so should be a slightly better quality and will help prevent the kinking that occurred with the rubber one:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00724.jpg)

I decided to replace the fuel filter while I had the tank out, its still the original from when I got the car, and not knowing the age, fitting a new one cant be a bad thing. This is the old filter and the filter to engine pipe that seemed to squirt out a bit of fuel under the jubilee clip before anywhere else, so I replaced this pipe also:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00728.jpg)

Here is the new filter fitted in bracket, bit rusty but still doing its job (Cleaning and painting things will be a job for the winter):
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00727.jpg)

All pipes connected back up again, quick test of any leaks and the pump working, then fuel tank re-fitted:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00732.jpg)

I then tackled fitting the ansa manifold. When raising the front of the car, I was pleasantly surprised that the rear wheel also lifts quite happily off the ground at the same time, when being jacked by the rear of the front subframe:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00726.jpg)

Once the car was raised as high as possible on axle stands, the whole exhaust system was removed, leaving the front section. This was a much easier task removing than fitting the ansa. With this removed I attempted to fit the ansa, finding that I needed to disconnect the front anti-roll bar for the manifold to go up through; with this disconnected from the wishbone and loosened from the mounting on the subframe, it just squeezed through, also with some wriggling to get it past the steering rack. At this point, the idea of keeping it as clean as possible had gone out of  the window. After some strange angles and various lengths of sockets, extensions and spanners I managed to get it on tight, even though 2 or 3 of the nuts looked physically impossible to do up when initially looked at; and here it is fitted:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00725.jpg)
With this now on, I fitted the rest of the exhaust to the best I can do for now. Its not at the perfect angle nor position but does its job.

With these jobs done, a more rewarding and cleaner job was tackling the induction system. With the hose loosened off I removed the large flat air box and am replacing it with a cone K & N filter. I started off with a new paper element of which I then replaced for a K & N panel filter, but I honestly noticed no difference and if there is an improvement it would be at higher rev’s as the car seemed more responsive at lower revs with the standard paper element! For now it sits quite nicely on top of the engine but not exactly the most ideal spot for cold air (Cold air feed pipe to be fitted):
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00730.jpg)
I didn’t quite realise how big it was until it arrived but JUST fits under the bonnet in that position; but at least you can see the engine unlike the eye saw of an air box. Due to the filter being of 76mm ID and the air flow flange OD being 68mm, two aluminium joiners and a red reducer pipe does the job nicely, and I think looks quite smart, if not a bit boy racey (o dear). Ideally I’ll probably fit it in the inner wing near the alternator away from heat when I get some more pipe/hose; but the perfect location would be on the nearside inner wing with a direct cold air feed; only problem being that the battery is in the way. Move battery to boot, hmmmm, another job on the future list.

All pipe connected again, initial start up created lots of steam with various moisture, oil and dirt burning off.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00733.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00735.jpg)
The hose pipe was on standby as I was told by a friend his heat wrap caught alight when some oil dropped onto it. This is what it looked like after having the engine running for 15mins and fully upto temperature:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00736.jpg)
Apart from a slight blow at one of the joints (just needs to be slid further down) everything seems fine, and there seems to be noticeably less back pressure at idle from the exhaust.

Can you not extend or relocate the pipe with the cone K+N on the end of it well away from the point more or less directly above the exhaust manifold?  I know you have heatwrap round the manifolds but that don't fix a hot engine bay!

I did this on my Hawks, they have a very hot engine bay regardless of what you do with the manifolds.  I plumbed the tube through a side panel of the engine bay to an area where it was protected from the wheels and any water spray or rain, where it could draw in colder air.  Defo made a difference!

But you should be commended regardless for flying the Beta flag !  Great stuff :-)

not sure about that cone filter idea I think (and this is just a personal opinion) that performance air filters are 99% mumbo jumbo you'd never feel the difference as it is so small (might sound faster with a cone as it will be noisier). The standard box seems to draw air from a fairly cool spot so I can't see there being a major improvement even if the cone is relocated (aside from easy plug access I suppose). If you are still running injection the air flow meter on L jetronic will in itself be a limiting factor not a high performance idea! no coincidence I think that later performance lancias used IAW with pressure sensors instead

  ;) Not only near enough above the manifold but also resting on the engine and top water rail :o Hopefully get this sorted before the track day, just need to measure what length/size/angle tube and hose i need. Saying that, the original air box is near enough in the same place as it is at the moment with the inlet being directly in front of the radiator :-\
I agree there is minimal improvement if any with the cone filter (Manufacturers spend thousands on researching it of course), but does allow me to relocate it to a cooler area, and colder air will make a bit of a difference (in theory).
Don't know about flying the flag, but if it influences and inspires new and current owners to work on their cars and make use of them, then that'll do for me :)

Follow your heart ;) ::)
Well I did a bit more on the car today, the exhaust was blowing at the front section to middle section joint, so with various twisting managed to slide it down a bit further; a hammer might have been involved also. As well as this I spent some time getting the rear silencer hanging correctly, this was the best outcome i could get (Its straight and level anyway):
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00742.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00740.jpg)
With this done, i set-up our other camera for when I took the car for a test drive, and the sound quality is much improved on the other camera: http://www.youtube.com/watch?v=C33wrTUp07Q
Everything went fine with the final moisture being burnt off by the manifold. It does seem to be quite slug-ish from low revs though, whether this is down to the ansa creating less back pressure or the filter sucking in hot air i'm unsure, i'll fit the k & n panel filter again and see; until i can relocate the cone. Seems to go better than before anywhere above 4000 rpm 8)

Not much to report... this postal strike seems to be slowing me down with various pipe/hose for the relocation of the filter in the post from fleebay. I did have a look at the butterfly, and the throttle cable needed a bit of adjustment as it wouldn't fully open without a bit of force on the pedal. that was probably the reason. ;)
A job that wasn't important but has annoyed me for a while was this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00743.jpg)
90% of what you see was purely down to the screw underneath the grill rusting and then the water running down and staining the valance.
Quick rub down, primer and spray and looking presentable again :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00745.jpg)

Managed to have a go at relocating the filter with various items arriving in the post, so its gone from this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00730.jpg)
To this now:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00758.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00759.jpg)
It does fit quite snuggly just under the black brace bar which is a bonus, but i'd like to get a better angle and fit where the new sections fits the original hose.

if you are aiming for track use could you not fit main/dip/side outer lights then use the vacant inner bowl as a grille with a tube shaped enclosure behind it to fit the cone I'm thinking n/s would be best as it would have a shorter hose run maybe you could use the o/s for an oil cooler?? 

Oil cooler sounds good to me ;) over the O/S would make sense being so close to the oil filter as well, although according to the gauge it never reads past half way in the green, i'm sure it would benefit from one though. Do the monecarlo's have an oil cooler fitted just out of interest, and I presume a sandwich plate is required for the extra two hoses ???
My future plan is to relocate the battery inside the car, so as you say the air filter can go in the n/s inner wing which has a cold air feed from the gap in the front valance. I'd just need a 180 degree pipe from the air flow, or chop the "elephant trunk" hose so that the air flow meter was straight in line and a 90 degree hose down to the filter.
Funnily enough the car has perfect weight distribution with me in the car, side to side. Any suggestions where the battery would be best ??? Boot, behind passenger seat maybe ??? Negative ground from battery should be alright connected to the chassis as long as its substantial shouldn't it ???

volumex has oil cooler and larger radiator same as air con versions of normal beta

Update time ;D
After a good day out at the NEC classic car show on saturday, I also bought some more things for the car, suprise suprise ::) as well as a few unexpected items i'll be testing out  :-X (Watch this space)
This is what I bought; a pair of rear polyurethane strut top mounts:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00766.jpg)
Due to the piston rod type of the spax units, the round file came out so there fit:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00767.jpg)
Quick sand down (Already shot blasted) then primered:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00768.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00769.jpg)
Only spray can with enough paint in it was gold, so here's a front and rear shot:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00772.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00771.jpg)
And strut put back together again:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00773.jpg)
Comparison shots for you, before and after:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00770.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00774.jpg)
Quick bounce up and down in the car, and there visibly stiffer but by no means rock solid, another successful project by Mark ;)
More from me tomorrow i expect :P

There is....
New territory for me today, never had a look nor worked on the gear linkage inside the car, to find there's not much to it :D Plastic centre console removed (less weight again) and gear knob.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00781.jpg)
Nut and bolt removed underneath:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00782.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00783.jpg)
Unit removed:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00784.jpg)
This revealed the sound proofing etc... which i removed and chipped away (More weight loss), just a bit of surface rust revealed:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00785.jpg)
Quick rub down with a sand block then primered:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00788.jpg)
Sprayed up in gloss black:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00789.jpg)

I then sanded the floor down ready for painting:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00790.jpg)
and primered:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00791.jpg)
Primer to Aluminio code, 620:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00792.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00793.jpg)
Drivers side done:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00794.jpg)
Passenger side primered and sprayed:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00795.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00796.jpg)
If I have some time tomorrow, it'll be relocation of the electric window switches, refit modified centre console piece and refit standard gear linkage, for now ::)

Had a go at relocating the electric window switches over the last couple of days. Luckily i had a spare metal plate for the fog light switches, so i cut the ends to get rid of the holes and trimmed the bottom a bit, so the switches will fit nicely in the perfect sized cut outs originally for fog light switches.
I mated both together then MIG welded (Neat enough for something you won't see :D) them together, pic. of the front and sprayed up:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00797.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00798.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00799.jpg)
Dummy fit to see what it would look like:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00800.jpg)
Refitted the gear linkage:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00801.jpg)
Centre console got a further chopping, refitted and all wires connected:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00803.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00802.jpg)
ECU fitted correctly ??? Previously was just wedged on the back piece of the console which no longer exists, but found the correct bracket now, also wiring tidied up:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00804.jpg)
Mats cleaned and fitted, job done :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00805.jpg)

Everybody likes stickers :) well you've got to be childish sometimes:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00806.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00807-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00808.jpg)
Just need some betaboyz's one's now ;)
I thought i'd better take some more pics. so i know what i'm looking for in the garage when I get around to building the uprated engine :D
Head Gasket Set:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00809.jpg)
Head I expect to be using as it has already had some work done to it:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00810.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00811.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00812.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00813.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00814.jpg)(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00815.jpg)
I don't know what car it has actually come from so if anyone knows ??? that would be great. Due to the amount of work already done to it i expect i'll use it over the, head on the car now, the head that was on the car before the head gasket went, oh and the 131 head in the garage. ::) Only problem with it is this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00816.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00817.jpg)
Is this critical ??? I'm hoping its just something for you to locate the head onto the block easier, i cant remember :-\

The camshafts i'll be using are the very scarce Fiat Strada 130 items, which i managed to track down eventually and not too bad a price, and £70 off the advertised price wasn't bad either, i want to keep the standard distributor/igntion setup for now, so these were my only option as Guy Croft doesn't sell any for the IE, and his prices are not an option for me anyway:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00818.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00819.jpg)
Valve Springs i'll be using are made by a company called Iskenderian, and i've been told that they will cover me upto an impressive 9,000 rpm :o:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00820.jpg)
For valves, i've bought some oversize stainless valves which are 41.5mm intake and 37mm exhaust, but looking in the haynes manual it says the 2 litre has an intake of 41.6-42mm ??? So i'll have to check that when i build the head. I've been told, "These can run in your head with the stock seats cut out for the valve diameter and still leaves a proper minimum between the contact face and the edge of the seat." so shouldn't be too much of a problem:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00821.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00823.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00822.jpg)

I have a pair of 130tc for my vx you'll have to do a 'how to' on changing the cams over so that I'll know what I'm doing later ;) 

When I get around to doing it, will do. ;) Got to stop working on the car and projects first then i'm sure i'll lock myself in the shed one day and it'll be done, hopefully :)
Well its been a whole 4 days since I updated :o :D (I have way too much time on my hands atm) so here's the latest.
When at the NEC, some items i wasn't expecting was presented to me by Mark, these included, some new "prototypes" for me to try out. The first is a new gearbox shock, the second the engine shock and thirdly a short shift gearchange kit. The gearbox shock I took away with me, the engine shock still needs some adjustment so that'll be one for the future and the short shift gearchange kit just needed some final details, you may have seen it at the NEC on the saturday ???
This is the gearbox shock:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00776-1.jpg)
And fitted:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00780-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00779.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9392.jpg)
When I took the original off, it was a bit of suprise to find it was effectively doing nothing other than acting as a pivot as there was no compression what so ever, i presume there should be at least some. In comparison this is rock solid, but the car feels no different to drive on the road and i've done 100 miles already with it. The "testing" will be this saturday when its put through a whole days work out on Castle Combe at a track day. Hopefully it'll help through the chicanes, and i'll take it apart to see if any wear has occurred.
Last weekend i popped down to Mark's to pick up the short shift gear linkage which is now completed; we fitted it there but due to the awful weather, didn't bother getting it adjusted properly. It was fine, but finding 5th and reverse was a bit of a nightmare. This i'm pretty sure is down to the rest of the linkage having the original bushes which are worn. (New bushes on the shopping list)
As a temporary measure I have sorted the linkage now so all the gears can be found, as I will explain in a min. (I'm not going to be able to chase after the magical 119 mph without 5th!)
Here's the new bit:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00782-1.jpg)
Notice that the stem is now straight to further reduce the movement for 2nd and 4th, and Mark tells me there is also less movement for 1st, 3rd and 5th as well, regarding this.
Effectively the movement has been reduced by changing the pivot point; a spacer has been added and of course if the gear lever moves up, so does the point at which the bearing carrier attaches, see pics:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00783-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00784-1.jpg)
Sprayed gold:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00785-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00786.jpg)

Fitting; remove the nut nearest the handbrake and loosen the two nuts bulkhead end, this will allow you to pivot it enough:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00787.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00788-1.jpg)
Now you have access to where it attaches to the linkage, remove the nut, then remove the bolt. (The bolt is threaded into the linkage as well as held by the nut)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9383.jpg)
Remove the 2 x 10mm bolts holding the bearing carrier down and the whole unit will lift out.
Place aluminium spacer on the unit, due to the length of bolt required now, you will need to get some longer one's as the originals are too short, Mark supplied me with these allen head type bolts:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00791-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9379.jpg)
Tighten hub carrier down:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9378.jpg)
This leaves you with the linkage to connect up, washer you see pictured behind head of the bolt is unnecessary but when fitting the linkage don't forget to put the really thin washer in between the block and the linkage; I tightened the bolt first then refitted the nut but there's nothing stopping you from doing both at the same time:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9381.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9382.jpg)
As I was having an issue with getting 5th and reverse, I found that by packing a few washers under the point it mounts near the bulkhead on the passenger side it pivotted it enough so i can get all gears now due to the poor condition of the linkage bushes. 5th and 3rd were so close it took the easier route all the time into 3rd; anyway, i put it into 5th gear, then tightened the nut nearest the handbrake then the two near the bulkhead:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9386.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9385.jpg)
Job done :) Just awaiting my "racing :D" gear knob now.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9389.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9388.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9387.jpg)

With regard to the suspension, adjustable camber front and rear is something which would be ideal. General setup for the road to save the tyres and a more aggresive negative camber set up for the track, so i'm going to be trying out a few things ;D
The rear transverse arms are currently, one solid and one adjustable as original. My idea is to have two adjustable arms so that not only toe can be adjusted but also however much or little camber you may require.
So i've come up with this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9396.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9398.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9399.jpg)
Essentially it is a threaded piece of mild steel tube with a wall thickness of 2mm. At one end it has a left handed thread and the other a right handed thread. This means that when on the car, no parts or bolts will need removal and the tube can be adjusted while on the car for the aquired suspension setup. To attach this tube to the car, is done with the use of rod ends/rose joints, which simply thread into the tube and are locked in place with a half nut.
When fitted I will use the spacers shown below, (2 for each rose joint) as well as a Nylon spacer which should keep the rod and rose joint far enough away from the strut body and rear cross member.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9400.jpg)
Pictured below you can see the top arm wound fully in either end giving a "hole to hole" measurement of 550mm which is very similar to the original setup while the arm below is wound out so that there is enough of the rose joint threaded into the tube, but still gives a "hole to hole" measurement of 580mm, which hopefully should be more than enough; even to satisfy me :D.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9401.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9402.jpg)
With regard to the front setup, I have some new bolts and eccentric bushes coming in the post, then it'll be down to how i'm going to fit them, and what level of camber they can produce; i'm sure i'll keep you all updated! ;D

Sorry, but I don't see how raising the gear lever base would effect the pivot point.
surely the pivot point is the same only higher.

Maybe so Geoff; sorry my mistake. The actual point which the linkage meets the rod is the same, I suppose it is due to the extended length of the rod, less movement is therefore needed to operate the gears. Mark would be able to confirm.

I took a not too dissimilar route with the Gamma (I cut two inches off the top)
much less travel and more precise, although saying that if you miss a gear it
can be more difficult trying to engage it a second time.

Geoff

New gear knob, from this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9387.jpg)
to this:
(http://i135.photobucket.com/albums/q152/lanciamad_album/1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/11.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/12.jpg)
Eccentric bushes came today, so had a quick go at fitting them to some spare front strut bodies, needed to enlarge the hole to 16mm diameter but initial signs look good :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/14.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/15.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/16.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/17.jpg)
Concentration is now on sorting the car out for the track day this saturday, just needs a fluids/pressure check, then brim her with fuel which should just about be enough for the day. Weather doesn't look promising but if its dry then i'm quietly confident i'll be able to keep up with some more modern equipment (http://www.freesmileys.org/smileys/smiley-rolleyes010.gif) (http://www.freesmileys.org/smileys.php) I'm aiming for a 1:35 min lap round combe (in the dry), only because it would match the slowest car running in the castle combe saloon championship  :D and a standard powered 27 year old car matching that, would make me ;D to say the least. "apparently" I have 4 or 5 seconds to take off my laptime so it may have to wait till next year, when all the suspension changes have been added.
As ever i'll post up how I got on, some pics. and fingers crossed some decent in car footage  :)

Well I’ve got some pics. and video footage from camp corner, but no in car footage i’m afraid, Castle Combe’s policy, suction type camera mounts aren’t allowed; quite right really.
Unfortunately it wasn’t a trouble free day today :'(, but I still returned home under my own steam in a normal fashion, and happy with the cars overall effort; more on that later.
To start, what glorious weather we had yesterday morning. Rain! :( Just what you want, I think not. The day would be split by sessions of various driver skill level. I always go for the novice group on the basis it’s not the fastest car in the world, but i’m not the slowest driver (Well I like to think I am), I had 4 sessions, 20mins each. From around 2ish it would then become open pit lane so all can mix and “play”. I was going to fit the track tyres when I got there but it was so wet, I thought road tyres were only the way to go; how I was wrong. First thing was the sighting laps, 4 laps at around 50mph to get you used to the track and your car, I was struggling so much I was fighting to keep it on the track never mind behind the pace car. Considering all shocks were on fully soft and I was using road tyres, every corner even though I was doing maybe 30/40mph the back end was stepping out of shape; things didn’t look good for the rest of the day :o.
As soon as we came back in from the sighting laps, it was time to go out for my first session. Yet again I struggled through the session tail happy at every moment, managing a top speed of around 80mph down the straight, and on about lap 4 of the session under reasonably light braking the nearside rear locked up out of the blue spinning me 360 on the track, luckily with no-one around and plenty of distance away from anything which would damage the car. After completing the session, it was straight on with the track tyres, and what a difference. Even though you wouldn’t think it, I had something new for the day, some grip. :)
The track was still wet but there was much more grip. The back felt solid now, and it was now only understeer under acceleration, which I was much happier about. The rain stopped and the track started to dry out, this is where we get to the 4th session. As the track dried I was finding more grip and was starting to go quite well; a Porsche 944 and Caterham were no match for the HPE and were overtaken during the session, then here’s the BUT.
As I approached quarry corner (25% of all uk track day accidents happen at this corner!) the engine suddenly died, but managed to slow the car down enough under braking and going through the gears to get round and pull to the side of the track. As I waited to be towed back in, my initial thoughts were, is it a belt, has something let go engine wise, or is it fuel starvation. As soon as I got back to the paddock it seemed ok engine wise and all belts present and correct. As it was reading a quarter of a tank of petrol and the amber light flickered going through the chicanes I thought it was down to this. Held the air flow flap open, built fuel pressure up, turned her over and started first time. I went straight to circuit motors, you got it, right next to the circuit and put £20 of fuel in, job done i thought.
It then went to open pit and the track was almost fully dry, so I stiffened the suspension by 8 turns all round. The car was absolutely flying around that’s all I can say. I still overtook the 944 even though the driver was starting to become half decent and the track was dry, matching it for pace down the straights and much faster than him through the corners. After almost a lap of holding me up, he finally gave way. I say gave way, I mean had a drag race down the main straight to get past him; Italian horses won ;D.
Few laps later, and exactly the same happened again, turned out of the chicane and the engine just died, this time there was well over a half a tank of fuel so that ruled fuel starvation out, and being the same again I was confident it wasn’t belts, it wasn’t. I had no spark! Exactly what I didn’t want, like you do, we fitted a spare coil (2), ignition amplifier and distributor, no luck. Put all the original parts back on, then eventually noticed the yellow wire on the battery terminal wasn’t looking brilliant. Forced it into its connector and presto I had a spark! I’m guessing due to the forces being put through when cornering this was disconnecting the wire just enough to cut ignition while still looking as though it was connected. Tightened everything up, put the road wheels back on and drove home without a problem. The first time it happened I can only guess I knocked the wire or battery while playing with the air flow meter.
Generally I was pleased with the car, in the dry it handles superbly, not too differently to an impreza estate! Brakes seemed good for what they are, the quick shift is good, found all the gears with ease, and the gearbox shock seemed to help with cornering through the chicanes, so generally all positives for the day. Only criticism would be when reaching the limiter in 4th, changing to 5th is like hitting a brick wall, where trying to squeeze that last “19mph” is a struggle; I was told the maximum reading was around 108mph on the speedo.
Quotes of the day come from two friends, which were passengers:
Ben, “Its certainly got some grunt”
Mark, “It handles and brakes much better than I thought, it’s great fun I’m well impressed”
That’s far too much writing :-[, so here’s some pic’s:
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9403.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/1-1.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9424.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/3.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/4.jpg)
More pics. can be found here: http://www.flickr.com/photos/lanciamad/sets/72157622768683859/ (http://www.flickr.com/photos/lanciamad/sets/72157622768683859/)
and some video’s:
Castle Combe November 2009 Lancia Beta HPE McMillan Support (http://www.youtube.com/watch?v=_0kserzXSo0#)
Lancia Beta HPE Castle Combe November 2009 McMillan Cancer Support Track Day 28/11/09 (http://www.youtube.com/watch?v=1gEOqC6iP7A#)
Castle Combe McMillan Cancer Support Lancia Beta HPE November 2009 (http://www.youtube.com/watch?v=CTQya1NF9bQ#)

0-1 min20 secs, showing me on the parade laps of a rather wet Combe track :-\
Spiky at Combe Cancer Charity day (http://www.youtube.com/watch?v=-EJcWn7eyVs#)

Some of the best pics. from last saturday...
(http://i135.photobucket.com/albums/q152/lanciamad_album/100.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/101.jpg)
I was keeping up through the corners but the Impreza has the pace down the straights :-\, also me chasing down the 944...
(http://i135.photobucket.com/albums/q152/lanciamad_album/102.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/103.jpg)
This is why i'm after some negative camber on the front :o and this is with hard side-walled track tyres on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/104.jpg)
Its all part of the day :D...
(http://i135.photobucket.com/albums/q152/lanciamad_album/105.jpg)

Been a little while since an update so here goes....
As part of the on-going development of my idea of the ultimate track car, it was due the addition of a cut-off switch and while i'm at it, want to fit the battery in the boot on the nearside. 1. Weight will be moved onto the rear where its needed 2. This will give room in the engine bay for the filter to be moved into direct cold air flow.
First, I did some shopping. Battery cable x 2, Cut-off switch, Battery box, and various terminals...
(http://i135.photobucket.com/albums/q152/lanciamad_album/21-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/2-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/25.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/23.jpg)
I got to work with fitting the battery box, drilling two holes through the floor then hammerite'in and spraying to prevent the "R" word, as well as this i welded in a bracket to mount a third hole, seems to have done the job, you can shake the rear of the car by the battery box :P
(http://i135.photobucket.com/albums/q152/lanciamad_album/24.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/26.jpg)
With that done I trimmed down the cut-off switch with a hacksaw which luckily fitted perfectly in between the electric window switches…
(http://i135.photobucket.com/albums/q152/lanciamad_album/28.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/29.jpg)

While I was in a wiring mood, I replaced an unhealthy wire/connector and if you don’t know and don’t want to know what’s inside your fusebox look away now…  :o
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00794-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00795-1.jpg)
Cut-off switch fitted, but battery is still in the engine bay at the moment as its fully working, but when wired up in the boot, there’s some bad connection or earth problem going on where voltage seems to be around 8volts and when I lean against the seat or get in the car 12volts arrive :-\
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00819-1.jpg)
Changing subjects, this is the block I’ll probably be using if I do a full engine build…
(http://i135.photobucket.com/albums/q152/lanciamad_album/227.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/228.jpg)
Came out of an IE HPE some years ago, and has hardly had any use since it was last built by as I believe their know now, red mist racing at Street, Somerset. As far as I know, it has a brand new oil pump and shells, as the chap I bought it from was in the process of rebuilding it while his HPE eventually ended up in a scrap yard; it has also been bored out and has 84.6mm pistons fitted.
As well as this, I got bored one day so started fiberglass’in…
(http://i135.photobucket.com/albums/q152/lanciamad_album/215.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/216.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/217.jpg)
No idea how the final panel will turn out, but I’m going to give it a go and make it up as I go along basically. I’ve used kitchen foil as a backing, and then once the whole wings done I’ll go over it with filler, and then trim it up if it requires due to me using the outside of the wing as a mould.
And to finish the post off, it looks like the blog will have had a 1000 views by Xmas, ok 900 of them might be me, but it seems people are keeping a track of what I’m upto, or are drawn by the pretty pictures. :D Merry Xmas and Happy New Year to all.  ;D ;D ;D

Hi Marcus,

Hope you had a good Christmas and a happy new year to you and your family.

Could you tell me what it is that you are doing with the fibreglass work on the wing.

Cheers
Pete

Didn't have a bad christmas thanks, i've taken some time off from working on the car that has only given me time to find some more projects and work to do in the new year :D
With regards to the wing, I contacted a few local companies for a quote to produce some fibreglass wings, but was unsuccsessful. I literally went to Half*rds and bought a fiberglass kit and got to work leisurely when it was tipping down with rain one day. I've done a little bit more on it since the pic. you see, but overall thats taken about 5 hours in 4 different stages. The main intention is for a performance point of view, once i've made the wing i'll weigh it against the original to see what weight loss there is. Of course you won't have a issue with the "R" word ever again either. Once this wings done, i'll do the other side, plans after that is to then do the front valance and if I turn into a masterful fiberglasser have a go at doing the bonnet, which will just be a single skin with stregthening bars fibreglassed in underneath. If i'm pleased with the final result, I might make some more/spare, the cost to manufacture isn't that bad but it's terribly time consuming.
Hope you had a good xmas and have a great new year. 8)
Marcus.

due to the heavy rusting on early coupé wings fibre glass ones were widely available at the time if you wait a while or fish around a bit I'm sure you'll turn up a pair

http://www.honeybournemouldings.co.uk/frontwings.htm (http://www.honeybournemouldings.co.uk/frontwings.htm)

TA V much.

I have a pair on my Coupe 1600 and I could take one off and weigh it if you like. I could even compare it to a steel one I have spare to save you removing yours.

Guy Moerenhout Racing do polyester/fibre glass doors, bonnet and boot lid. http://www.abarth-gmr.be/new/parts.php?dzial=LANCIA%20BETA%20COUPE%20/%20MONTE%20CARLO (http://www.abarth-gmr.be/new/parts.php?dzial=LANCIA%20BETA%20COUPE%20/%20MONTE%20CARLO) - click the Parts tab. They're a bit pricey, especially with the exchange rate being so bad at the moment, but the website might give you some ideas about what can be achieved.

Cheers
Pete

If you could do a weigh comparison on the wings that would be useful to know :) I'll have a search around for what I can find. As I say, it was just a project I started due to the bad weather last month, something which will probably go on the back burners, now i've got some more projects/idea's :D
Latest update, i've got a new oil sump gasket for the other engine (think i've got all the gaskets I need now), a pair of adjustable transverse arms are in the post to me, so the rear end is now going to be fully adjustable camber and toe wise, and the latest project/headache, is bike throttle bodies which i've just bought on the cheap so will have to see if there going to be compatible, as well as a custom manifold that will be needed for them and the new engine management system that will be needed to run them :-\
And all this on top of some more general work, battery relocation into boot, the front negative camber suspension set-up, and building a shed for me to do most of the work in  :D I'll get some piccys done once i've gathered all the parts etc...

Battery relocation / Cut-off Switch is finally done, a lot of head scratching was done by 3, 4, more people, but I finally solved the problem, when thinking of a mini of all things. Due to me removing the earth cable from the gearbox, to into the rear of the car now mounted to the chassis, the earthing required from the engine/gearbox to chassis wasn't good enough causing :D electrical problems :D, i've run a wire from the gearbox to a nice shiny bit of the chassis and job done ;D
Here it is in the back, looking quite smart if I say so myself...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00829.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00830.jpg)
Just needs cable tieing and clips running along the inside of the car to make it look tidy. As a result, there's a battery sized amount of room in the engine bay to use for whatever in the future; oil cooler perhaps. The wiring due to the change is somewhat hectic, but currently works well and will-do for a short period. (I have plans). 1 shiny penny to whoever noticed I put the brake reservoir on the wrong way round :D (I only just noticed, makes no difference) The airflow meter is now hanging in mid air which isn't ideal, but seems to be held well enough by the hoses, and I won't need to make a bracket for it if I won't be using it, read on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00828.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00833.jpg)
The latest thing i've got my head into, is fitting throttle bodies from a bike to the car, this however is quite a project in itself. As well as this i'd like to run wasted-spark ignition, and have been told to expect around 150bhp using the standard engine if everything went to plan, something in the region of 180bhp+ on that engine I should be building sometime this year,  :).
I've got most of it planned in my head, and parts soon to be flooding in, whether I do anything with them will be a different story. Throttle bodies have arrived, from a Suzuki GSXR 750 08/09 bike, but have twin injectors and twin butterflys, whether this will be in my favour or not I plan to find out :P. To connect these to the engine, i'll be attempting to make a custom intake manifold from steel, with some rigid hose connecting both of them together. I'm going to go with megasquirt for the engine management system, reasonably priced and looks quite user friendly. Wasted-spark ignition will be taken from a Ford  :-X with a crank sensor fitted to a modified crank pulley with a trigger wheel mounted to it, i've got a MAP sensor coming from a Renault something :'( but the ECU has one built in anyway :) and an adjustable fuel pressure regulator for a celica.
The plan for the wiring, is to make a completely new loom for everything so if it doesn't all work out I can just bung all the original parts back on connect them upto the original loom and away we go. Before I waffle anymore, this is the only work i've done regarding all this...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00834.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00835.jpg)
Template of the manifold made out of paper, for me to make from 6mm steel. I could have just used a gasket and made it slightly bigger, but couldn't be bothered to go in the garage and find one. I'll do a mass pic. session once everything arrives.

Pics. as promised...
This is the bike throttle bodies, off a GSXR 750. They have rather big bore's and a twin butterfly / twin injectors configuration so whether i'll use these is a maybe atm.  :-\
(http://i135.photobucket.com/albums/q152/lanciamad_album/31.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/311.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/3-1.jpg)
Sump gasket
(http://i135.photobucket.com/albums/q152/lanciamad_album/39.jpg)
Adjustable fuel regulator, very bling :D
(http://i135.photobucket.com/albums/q152/lanciamad_album/38.jpg)
MAP sensor of a Renault but this is optional as there's already one on the ECU
(http://i135.photobucket.com/albums/q152/lanciamad_album/37.jpg)
Choice of coils and leads off a Ford
(http://i135.photobucket.com/albums/q152/lanciamad_album/36.jpg)
Megasquirt ECU
(http://i135.photobucket.com/albums/q152/lanciamad_album/4-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/41.jpg)
Started roughly cutting the intake manifold out of 6mm steel, its not that cold outside when your only using a hacksaw :) rest of it or at least some of it I hope to get done tomorrow.
(http://i135.photobucket.com/albums/q152/lanciamad_album/33.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/35.jpg)
Most of this work is going to have a reasonable set back, as i've suddenly had some inspiration to work on the project that should have been done before I even bought the beta :o
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00823-1.jpg)

With work coming to a stand still on the delta turbo, (waiting to get some parts), attention back onto the beta for a few hours. Went down to the local tyre place for 3 tyres for the delta turbo in the back, bloke said "are they in the Alfa" (http://www.smileyhut.com/confused/doh.gif) (http://www.smileyhut.com), well at least he got the right country. Next stop was M-tech, booked in on wednesday (20/1/10) for it to be rolling roaded ;D Have no idea what to expect power wise, so anything north of 100bhp and still in one piece will do for me lol Only modifications are cone k and n filter and four branch ansa exhaust manifold, we will see... as usual, pics, video and print out i'll post up, however good or bad the outcome. I did notice a fuel leak coming from the 4th injector when I got back home, so that'll need attention asap.
With the battery in the boot, I still had to tidy the two main wires running through the car, so some clips sprayed the same colour as the floor and self tappers and its looking like this now...
(http://i135.photobucket.com/albums/q152/lanciamad_album/53.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/54.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/55.jpg)
Still looking hectic but more wiring and the cut-off switch wires out of the way from the gear linkage and passenger footwell.
(http://i135.photobucket.com/albums/q152/lanciamad_album/57.jpg)
This week I was planning on just having the majority of metal cut for the intake manifold base, so I could get on with making it, but it now looks more likely a local metal work place will be cutting it out as long as there cheap enough. I've got to go in monday morning to see what they've come up with so far, so i've made a more accurate drawing for them to have a look at.
(http://i135.photobucket.com/albums/q152/lanciamad_album/58.jpg)
Then it's onto welding some tubes onto it at the right angle.

Took the template in for them to have a look at, said it should be ready by wednesday, cost about a tenner, bargain :).
Got to work on the fuel leak, fuel rail and injectors out...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00823-2.jpg)
This was the problem...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00825.jpg)
Bit of a mystery to how and why, as the only thing near it is the throttle cable that runs on the other side of the pipe, I can only put it down to age, or some wildlife that got peckish :D.
Managed to get the old pipe off eventually with some crimps and a mini grinder, replaced with a new piece of pipe and jubilee clips.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC008322.jpg)
Everything back together...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00833-2.jpg)
Wiring loom for the megasquirt came today, really pleased with it, all colour coded with where each wire goes printed on it, makes life a lot easier when I get around to wiring everything up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00834-2.jpg)
Next update will be wednesday night, hopefully with some interesting figures, really looking forward to finding out what it actually produces power and torque wise, if it can withstand my abusement i'm sure it'll cope with some rollers.
Figures to aim for, from 28 years ago:-
122 BHP
175NM of Torque

Interesting stuff! Did you think about using bike carbs at any point and completely doing away with the fi system?

One thing about the tb's and the megasquirt though,it would be relatively simple to add a turbo at some point!!.....A nice low useable 6psi application perhaps ;D

I'll pretent i didn't read that suggestion :P yeh it would be good to get a turbo fitted sometime in the future even if it would have to be quite a small one, but for now and the next two years, is this throttle body conversion (...on the cheap ;)) and then building one hell of an engine to compliment them, cheaply of course. I did think about bike carbs, apart from setting them up all equally they seemed a bit too easy to do for me, I just wanted to do something a bit more challenging and be able to control the fueling; also what it says on the rear will still be true, its fuel injected ;)
Well everythings gone wrong today basically, good news is only one thing with the car!  ;D
Started the car up in the drive, warming it up / demisting, the usual; and looks like my drivers side window switch has packed in :-\ no movement from the window and the switch only clicks to work in one direction so if anyone's got a spare going handy and you don't want much for it, give me a PM or email. Also the whole front water jet piece as the plastic ball for adjusting direction of spray just decided to fly out everytime you put the washers on. :(
Driving to M-tech for the rolling road, a new VW polo reversing out at speed from the dealership decides not to look and nearly takes the nearside out, lucky i was in 2nd and have a heavy right foot.
I get to there place to find no banner out and no-one around, ask there neighbours and they've moved to a new site on the business estate, sooo I go over there to find there newer and bigger premises of which there just moving everything into, so rolling road hasn't happened yet as they havn't got anything setup; to be fare to them they didn't have a contact number for me. Told me to ring them up in the morning and there hope to get it done tomorrow night. :-X
And to top it all off, went to collect my intake manifold base to find he hasn't done it yet, been too busy and one of the machines broke down so i've got to go in friday before 1pm and collect it now.
Rant over, I cleaned the car today not that you'd notice after 6 miles of wiltshires finest pot holes. ;D
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00836-1.jpg)

Well got it on the rollers in the end 8)
Not a brilliant start as on the way there it was coughing and spluttering everytime between 2-3k rpm not sure to why other than its running too rich, and still doing it now :(
Pic of it parked outside there old place...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9603.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9604.jpg)
They have since moved into there bigger premises...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00840.jpg)
Exhaust probe and strapped down...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00842.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00841.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00843-1.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00844.jpg)
Well it all went to plan, it did indeed achieve over 100bhp at the flywheel and most importantly is still in one piece :)
Figures taken from carfolio.com for this car...
122bhp @ 5500rpm
129ftlb @ 2800rpm
28 years on, using the original set up and with a head that i didn't check the shims before I fitted it, it produced *drum roll*...
108bhp @ 5400rpm
127ftlb @ 2500rpm
 ;D Rather pleased with the figures considering age as well as somethings not working properly between 2-3k rpm, still pulling like a train ;) Bloke that did it commented on how massive the ECU was and asked whether it was a bosch system. I told him what it was, and he was really impressed with the fuel ratio under acceleration saying that most older systems are awful and give you figures all over the place. Here's my engine speed vs air/fuel ratio as well as flywheel power...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9616.jpg)
Nice steady 12.3:1 from 4000rpm to 6400rpm.
Power and Torque figures vs Engine speed...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9615.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00845.jpg)
Some video's, enjoy...
Lancia Beta HPE 2.0 IE Standard Engine Rolling Road Part 1 (http://www.youtube.com/watch?v=nDAQHj11rZQ&feature=channel#)
Lancia Beta HPE 2.0 IE Standard Engine Rolling Road Part 2 (http://www.youtube.com/watch?v=0J6_6oo9oJs&feature=channel#)
Lancia Beta HPE 2.0 IE Standard Engine Rolling Road Part 3 (http://www.youtube.com/watch?v=u-3PcuYx5UE&feature=channel#)
Lancia Beta HPE 2.0 IE Standard Engine Rolling Road Part 4 (http://www.youtube.com/watch?v=T6n6XEHbIqk&feature=channel#)
Least I know now I can short shift and be bang on max power and with good torque, than the usual red line and change :D M-tech have good experience of megasquirt so once i've got all the bike bodies and manifold set up as well as the loom and all the rest required i'll probably take it to them to improve on the base map.
Should be picking up the manifold base tomorrow so i'll get a pic of that on here, I believe its going to be water-jet cut so no distortion to the material and sharp lines, just hope he's got his measurements right!

Interesting that the torque is bang on the money but the top end isn't quite where it should be. That suggests that the engine is fundamentaly healthy but something is holding it back. Did they have a play with the timing or anything else ?

No, was only a strap down and run while measuring the air/fuel mixture, all I can say about the timing was I did it by ear when I fitted the head and then got my local garage to check it, and told me i'd got it bang on. (I did watch him check it)
Engine certainly feels like its pulling like new as the figures confirmed. Managed wheel spin in second on the way there! But somethings not right, whether its timing or fueling, last time out on track it didn't feel like its usual self and the top end seems to have gone walkies, changing into 5th was almost like hitting a brick wall :-\

Interesting stuff....there's a distinct drop to what looks to be a potentially good curve with both power and torque at 2500 rpm....bang on. But the mixture doesn't start getting rich until 3k. I wonder if like Stuart says,the timing,either cam or ign,isn't what it should be?

I think it would be interesting to see the difference with the standard induction system back in place, results not at all bad though considering that measurement will not be directly comparable anyway

Absoluteley. There's no doubt that you've good a good engine there. The torque figure isn't so far off modern cars (eg Ford 2.0 Zetec 16V - 137lb/ft) that have got massively higher CR and 30 years more development !

I don't think any of us beta owners or general car fans arn't aware of how brilliant and ahead of there time the fiat/lancia twin cam is :) Every general person thats ever commented about the car has always said, those had one hell of an engine shame about the rust though, and everyone seems to say that :D At least they remember the performance just before the R word.
I'll be on delta turbo duty all next week as well as shed building when i've got spare time, so something to keep you upto date and a blast from the past...
Collected the intake manifold base today, nice job for a tenner :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00846.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00847-1.jpg)
Intake gasket on top, holes bang on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00848.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00849.jpg)
and most importantly it fits the head...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00851.jpg)
While I had 5 mins I tapped all the holes on the spare head to take the intake manifold, then swiftly stopped myself getting too carried away, i've got enough other things needing attention :D
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00850.jpg)
Some blast from the past...
What she was looking like after the 1st MOT with me...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF2836.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF2843.jpg)
Oh its me :-X
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF2839.jpg)
I bought a set of series 1 wheels as track wheels a year or two ago, did them up and sprayed them Gold, but didn't suit the car very well so sold them on, there out there somewhere...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC00457.jpg)

those early wheels are interesting,a few years back I was given 4 and fitted them to a berlina, what was really interesting was that, upon close inspection, two were very slightly different to the other two, as the design of the wheel centre was not quite identical. Big deal! you might say but one pair of them weighed about as much as a feather and were probably magnesium based alloy. It would be well worth finding a set of those to reduce your unsprung weight, if I remember right the very light ones didn't have 'originale lancia' cast on them    

Interesting to know, I did weigh one against the more common type and they weighed the same, should of weighed each one now :D

awsome build, will be interesting to see how the bike throttle bodys go, i'm thinking of going for twin 45mm dcoe pattern throttle bodies on mine with a Haltech computer, however you might just change my mind and i'm sure my wallet will thank you for it.

Yeh with purpose built throttle bodies costing £800+ this is hopefully going to produce the same or similar result for a considerably cheaper cost, well thats the idea.
With work on the delta turbo, other cars and a shed to build, the HPE has just sat on the drive waiting to have work done over the last couple of weeks. Items that needed attention was get to the bottom of this poor running at cruising speeds, and the "R" word!!!!
I started off taking all the induction hoses off, as I thought it might be related to the vacuum pipe from manifold to fuel regulator being blocked or partially, funnily enough when I checked the pipe was clear but on the manifold and regulator the ends were partially clogged with dirt somehow...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0222.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0223.jpg)
Put everything back together, started it up and no difference I could hear at idle, still running a little rough. It wasn't until I looked again and no.3 looked like this...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0226.jpg)
Turned it off, got the spark plug socket on it and it was loose! I havn't really touched them since doing the head a good 2 years ago now so may have been slightly looser than the rest when put in and with various track days and the rolling road might have worked itself loose.
Not only this, this is a normal plug...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0227.jpg)
Check the top of the same loose spark plug out...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0228.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0230.jpg)
I can only describe it as a tiny bit of stone that somehow made its way onto the top of the plug. Obviously while I was at it, I checked all the HT connections and found that 3 of the 4 tops of the spark plugs were lose, so they were done up hand tight and then with pliers, hopefully this has solved the problem but as I decided to get the welder out i've not had a chance to test drive it.
With MOT time coming up very soon, its about time I sorted out the hole thats been in my floor too long, its also the hole which was produced by a MOT station I don't normally use last year, and didn't even put an advisory down about it  :D
After poking it around this was the beauty...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0231.jpg)
Wire wheel and grinder came out...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0242.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0246.jpg)

Luckily all the rust under the pedals was only surface, so that was cleaned up and sprayed with underseal...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0244.jpg)
New bit of metal to go in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0245.jpg)
and in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0253.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0254.jpg)
Considering I havn't done any serious welding for a good two years now and only have use of a gasless welder, i'm reasonably happy with the weld considering the old thin metal the floor has, what do people think of it?

Sprayed up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0255.jpg)
This left me with some more holes to attend to..
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0257.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0258.jpg)
Another plate...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0259.jpg)
Welded in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0260.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0262.jpg)
I'm always getting the odd bit of surface rust on the floor as its only primered with a top coat, so i've undersealed the floor this time and then will spray it over in silver hence why it's not all masked off, you get the idea...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0264.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0265.jpg)

nice welding! if you are clever enough to compensate for the heat distortion (I'm not) I think gas weld is the bees knees much nicer than mig and gives a strong neat and long lasting result

With very little practice, using a gasless MIG on high volts was a bit of a challenge, basically always on the border line of a useless weld or too much heat blowing holes everywhere on the thin metal I think I did OK in the end. I prefer the point and do a straight line weld that looks neat and tidy, but I found it impossible to do with such thin metal, and thought having it on low volts wouldn't produce a good enough weld.
Some better pics. of the floor...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0269.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0268.jpg)
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0270.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0271.jpg)
I absolutely hate watching paint dry >:( so while I did, I found my front replaceable type bodies, got the wire wheel on them and sprayed them up with zinc primer and some gloss black, turned out well in the end...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0272.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0273.jpg)
Plan is, to cut the spax units out of my current sealed type, I re-welded, and fit them into these; Mark W assures me they will fit with a bit of force. As well as this i'm fitting and believe testing front polyurethane top mounts at the same time as the whole lot will be out, and as well as that i'm fitting some eccentric bushes in the top holes of the bodies to achieve negative camber and hopefully a lot more grip when on the limit :) I think this will be a slight improvement on the safety aspect as well as fine tune adjustment than clamping the bolt tight using big washers.

Welcome to my world! :D

That welding looks good sound,well done.

Have you slapped some seam sealer underneath to stop any water ingress?

I gave a generous spray of the same black underseal underneath until it literally was dripping from the floor, is there any specific type or make you can recommend? You are the expert ;)

I'm currently using one supplied by Halfords made by Upol. It's a big tin though,you won't want that much. I guess it should be ok if you've bathed it in underseal......Although i prefer waxoil for rust prevention  ;D

Well i've not solved the poor running problem at the moment which is annoying as I was planning on using the car this weekend! :( see... http://www.betaboyz.myzen.co.uk/forum/index.php?topic=597.msg2340#msg2340 (http://www.betaboyz.myzen.co.uk/forum/index.php?topic=597.msg2340#msg2340)
These are the plugs that have been in there a couple of years...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0275.jpg)
I fitted a spare distributor, but had to swap a few things over from the old one and finish off fitting a new pick up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0284.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0285.jpg)
While everything was loose and out from that inner wing I decided to go painting.
It was like this...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0280.jpg)
Sprayed...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0281.jpg)
Now looking like this...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0287.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0288.jpg)
Even things that aren't seen got a spray :D...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0286.jpg)

Looks good, have you checked for any vacum leaks? i once had an intermitant rough running problem turned out to be the smallest of pinholes on a vacum line from the manifold it only seemed to open when it got hot.

I'll give it ago and strip all the pipe work off and have a look, I initially thought it maybe vacuum related too. I've got a spare air flow meter I can play around with the CO2 adjuster to see how it effects it if I don't find anything, other than that I cant think of anything else to try. :-\
With the new distributor fitted, I need the local garage to check and adjust the timing so might have to leave it with him and see if he's got any ideas. I spent the best of 9 hours standing on the drive yesterday spraying and problem solving, so i'll give it another few hours before I go out again ;)

Realy nice project!
Do you know this one:

(http://img10.hostingpics.net/pics/722381three8.jpg) (http://www.hostingpics.net/viewer.php?id=722381three8.jpg)

No i havn't seen that one before, looks awesome but the big wheels and spoiler ruin it for me.

Well the update is I still havn't found the problem :-\ as pictured i've taken all the hoses and manifold off and found nothing. Only things I can think left to do/check is the timing adjusting so it's bang on, and the exhaust manifold has become loose (doesn't sound it), so that'll be what i'll be doing tomorrow. After putting everything back together, it is as if its running on three cylinders until 3k rpm then runs and pulls fine after that, i've managed to get rid of the back firing by adjusting the idle down and the throttle linkage up which seems to let more air flow.
I'm reluctant to spend money on a garage fixing it, if they can, as the throttle bodies set up is something i'm looking to work on and complete asap really, ready for some fun for this year, which is going to be new everything, but with the MOT due very soon, I need to get this done for another year before the fun can begin. ;)
Some more bodies pics...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0297.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0298.jpg)
I got my tubes cut and angled ready to be welded onto the base, I hope to have this done by the end of the week...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0301.jpg)
Started dismantling bits not needed...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0303.jpg)
Choke flaps removed, i'll be plugging the holes left. Starting to look like some jenveys, well I can wish :P...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0304.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0305.jpg)
It's guna be tight but I hope there's enough movement in the hoses to make the difference up of the offset of the bodies to the manifold.

Today I decided to replace the manky pipe that's been on the car since i've had it to see if this improved the running, which it didn't. Manifold off...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0309.jpg)
This left me with loads of space in the engine bay, only issue with the bodies is the fouling on the dipstick so this might have to be engineered around...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0310.jpg)
Manky pipe, and a better second hand one I generously taped up any signs of cracks...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0311.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0313.jpg)
While the manifold was off, I moved the starter motor cables to point as far down as possible, all taped up and replaced the connector with new, how they didn't short onto the manifold I don't know. Unlike me I didn't take a pic of that nor the whole lot being put back together :D
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0312.jpg)
One of the latest purchases from Mark (lanciabetaparts), some more bushes for another pair of adjustable transverse arms for the rear suspension...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0299.jpg)
Old removed with brute force...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0302.jpg)
Next update will be these fitted, what i've bought, what i've got planned, and hopefully the car running like it should. :-X

Those tb's look fantastic! *jealouses*  :D


Oh dear....those arch extensions gives me unclean and evil thought's about my Spyder.... ;D

Do it!  :D

Few smallish jobs to update on.
The other day I charged the battery up, because of it going off to the garage I thought it better at least have some decent amount of charge, fitted it, started the car and the car instantly started behaving itself! Drove it to the garage and it didn't miss a beat. The timing definately needed doing as it was 30 degrees out :D, but still drove fine. While it was there I collected a new alternator belt for him to fit while it was there, to come back and find he'd cut the bracket and welded a section in! He said the belt condition was fine so he'd modified the bracket, with my reaction of, oh ok then :D
So all seems well again for all of 2 miles of driving! The dreaded MOT is on tuesday so will have to see how it goes, sunstrips been taken out and original wheel back on for the horn (havn't got round to modding the racing wheel), so its all set.
Got around to fitting those adjustable transverse bushes, so thats ready to go on sometime...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0329.jpg)
The intake manifold is done, got a local company to weld the tubes on as there be visible for a cost of £15. As you can see from the picture, all the tubes are angled at roughly 80 degrees to the base (10 degrees off being flat) so that hopefully when mounted to the engine the throttle bodies will be roughly horizontal, thats the idea...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9744.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0348.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9746.jpg)
Bit more work on the bodies themselves, as I removed the choke flaps, obviously there were holes left in the bodies where the mechanism went through, to plug these up, I was recommended to use JB Weld, never heard or used the stuff but delighted with the end result, simple to use and hardens in a matter of minutes...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0326.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0328.jpg)

A quick search on fleebay and I ended up winning some trumpets on the cheap, the right length I was after (100mm, should sound awesome) and when they arrived fit absolutely perfect inside the bodies, so if i'm feeling tight I can give them a good old wack into the bodies, or do the same and weld them in which is what I'll more likely do.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9747.jpg)
I attempted to modify the fuel rail but with it being plastic and trying to fit a brass fitting to it, i think i've scrapped that idea and am going to look at whether I can modify a beta rail, or i'll be on the look out for something else. Roughly £100 has got me this so far...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9750.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9751.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9749.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9748.jpg)
As I expected, the difference from bodies to manifold is a problem. I've managed to fit the two central hoses which easily supports the weight of the bodies, so for the outside one's i'll have to use some flexible ally hose, as the hoses won't stretch as much as required. Only concern will be whether they collapse when I get around to it all running on the bodies, some reinforcement to them may be required.
Next update, MOT time :-\

Looking good. Just looking at the photo's and thinking for the outside tubes you could get some tube mandrel bent with a wide angle and cutting that in half and using both ends on each end of the manifold, it would allow you to have the throttle bodies solidly mounted straight onto the manifold rather than using flexi pipe on the ends and relying on the middle to hold it on. This is what i mean

Please excuse the crude drawing i am neither an artist nor a computer wizz, i also don't know how you guys seem to be able to post pics in your post between text and not just as an attachment at the end.  ???

Yeh there's quite a few ways I could do it, its just what's easiest, cheapest and works :D I know what I could do, very similar to your suggestion, but i'm restricted by the length of the whole intake tract, as it is now it's at optimum length for the rpm and will just clear the original rad fan. The issue of mounting them should be fine, as there well supported by the two central hoses, and if my plan works i'll be using an IE fuel rail which I can attach the bodies to and mounts to the engine as originally for extra support.
There's probably many ways of attaching pics. into the text, the way I do it, is to upload the pics. into photobucket.com, once uploaded each pic. is given an IMG Code, if you copy this onto the forum, the picture should show wherever you put the code in. But this means it's not permanent on the forum, in other words if I deleted it from photobucket the image would not show as it doesn't exist. (Badly explained)
Had a nightmare day so far :( yesterday the car was running fine and suprised me again with it's performance (i've been driving my 80bhp delta for 3 weeks solid), all the lights checked etc all the obvious items for the MOT, I bought two new firestone 185/65/14 tyre's for it, one needed doing another was old and on the limit, roll on to this morning and it's all gone wrong. TYPICAL!!!!!! :o
Thinking oh i'll just get in the car and drive it to the garage now, I get outside to find one of the new tyres flat as a pancake, pumped it up again left it for 10 mins and it started loseing pressure; It's done all of 3 miles so far, great! So this will probably fail the MOT as it'll be flat by the time they MOT it, I go to start the car and will it start, NO! :D Battery starts to drain so the jump leads came out and started at the second attempt, running very roughly so adjustments had to be made to the linkage and idle to get it running better, and yes the mis-firing/poor running has returned again >:( missing around 2-3k rpm as usual, so yes it'll fail on the emissions as well now, so there's two things before the MOT even happens.
Why do we do it ??? :D

After a disasterous morning things turned out as good as they possibly could. The car passed the MOT, and wasn't even given any advisories ;D Result!
After explaining about the tyre, that it has done 3 miles and seems to be loseing air they kindly topped it up with air and it hasn't lost any air since, i'll know by the morning if all is well. Only things that were mentioned was the wear on the nearside tyre which was previously on the rear offside and very slight movement in one of the rear struts, which may just be down to the top shock nut needing a slight tighten.
It's running even worse now, running on 3 cylinder about 75% of the time but he said for the MOT test by moving the ht lead up on the 3rd cylinder seemed to get it running on 4 and removing a vacuum hose seemed to improve things; anyway it passed the emissions test fine, so another years motoring (when it works) 8)

Time for an update...
I've got it running much better now, but not absolutely perfect. Put a new set of NGK plugs in (after adjusting the gap on them) and it went straight back onto four cylinders and running much better now i've adjusted the linkage again. The exhaust is rattling against the handbrake linkage/underside at idle, i've got rear adjustable transverse arms to fit, front adjustable camber bodies to fit, front poly top mounts and gear linkage bushes to fit as well as changing one of the switches for the electric windows (thanks to Geoff for them), so the cars going to be sat on the drive for a month or two while I do all that lot, at which time i'll be able to afford to tax and insure it by then hopefully. I've also got to get my LX through the MOT this month, as well as various jobs the turbo will need before its ready for the MOT also sometime this month; looks like i'll be out on the drive day and night whatever the weather :-\.
Back to the throttle bodies set up, i've ordered a built-in trigger wheel to an ally crank pulley which will take 6-8 weeks to arrive :o, so i'm going to try my best to have everything ready to bolt on and layed out by the time that arrives. The plan is to have it all setup, running and reliably! by june/july. Failing that, deffinately for beta meet/retro rides. I was asked several times last year whether I was going to take to the track at Sparkford, so this year I think I might have to ;), in the meantime keeping its standard 108bhp useable for events until then.
Anyway, I have done some work towards this, although not that much, look familiar?...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0356.jpg)
and painted...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0360.jpg)
some fancy 10mm braided fuel pipe...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0359.jpg)
I then had one of those moments..."hang on these bodies split apart from each other"...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0361.jpg)
Two bolts undone and the linkage removed in the middle, and bingo ;D; all four hoses fit the manifold...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0362.jpg)
This left me with a gap to make up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0363.jpg)
Bit of welding and some longer bolts, and the bodies are connected to each other again as well as the linkage for both...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0380.jpg)
Sprayed up the manifold with high temperature paint which is silver although looks more grey to me...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0379.jpg)
and finally, back to the fuel rail, instead of the standard beta regulator i've removed this and fitted an adjustable regulator "suppose" to be for an MR2, simply welding a bracket to the rail to hold it, looks reasonably smart and hopefully will be functional...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0378.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0375.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0376.jpg)
Using a spare beta rail seems to be the ideal solution, as not a big problem but allows me to use the original fuel rail for both input and output and already mounts to the engine in one place. Only issues are that i'll only be using the four injectors instead of eight, the cold start will need blocking up as its not required and the main issue of how to keep the injectors firmly mounted to the bodies :-\ that's all for now :)

Unfortunately i've been extremely busy working on delta's so the HPE has been sat on the drive. My LX had it's MOT which it passed without any advisories 8) I did have to replace the front discs and ball joints beforehand though! My latest car i've got my teeth into has been my long term project HF Turbo, http://www.lanciasport.com/forum/index.php?topic=2585.0 (http://www.lanciasport.com/forum/index.php?topic=2585.0) http://www.lanciasport.com/forum/index.php?topic=2585.15, (http://www.lanciasport.com/forum/index.php?topic=2585.15,) after getting it back from having a lot of welding completed, I changed the clutch which had it's usual complications, to then have the clutch release bearing explode in my LX, so decided to replace the whole clutch while I was at it in that and as a result havn't had any time other than changing delta clutches!
I did start the HPE up the other day which it fired up first time (cant ask for anymore), and with the cut-off switch fitted, the clock doesn't slowly drain the battery which is a bonus. The turbo has had its MOT which it failed on a few issues, so there going to be sorted by the garage as I have other commitments, so I should have some free time during evenings for the HPE, and with watching the racing at combe today it's got me into the mood to want to work on and drive the car again. So if possible, she'll be on the roads from may.
List for me to work on:
Adjust exhaust away from underside/handbrake
Fit adjustable transverse arms
Cut adjustable spax units out of current bodies
Fit adjustable spax units into replaceable type bodies
Fit front polyurethane top mounts
Set and mark negative camber on front bodies for road and track
Replace gear linkage bushes
Replace electric window switch
Strip some more weight out of it, (do i remove the front door cards and trim ???)
USE IT !!!  ;)
Remove injectors from donor MGF manifold
Fit and secure injectors and fuel rail to bodies

I'll think of something else in a minute, so i'll stop there. Anyone got any suggestions of things I could do to/with it, feel free to shout. I'd love to start on a cage but then there's the weight/strength argument and insurance complications.

Well I thought that it was the exhaust needing adjustment away from the body, but I soon found out that it was actually the central heatshield deciding it didn't like being attached to the body anymore. It was only being held on by the nut furthest towards the back while the other two are no where to be seen, causing it to rattle on the ansa/middle section. Worryingly thats one of the things i've never had to remove so I don't know whats happened there.
I've removed the heat shield for now, so will more than likely make a new one as the originals holes have been enlarged. To get the nut off I needed to drop the exhaust system; so why I was at it I've now fitted a secondary pair of adjustable transverse arms with betaboyz poly bushes, so I can adjust toe and camber now on the back. For now, I adjusted the arms to the same length as the original fixed arms, so geometry should still be the same.
I probably would have had enough time this week to fit all my new front stuff, but didn't fancy setting it up roughly, and changing to negative camber is probably guna put the tracking way out = shredding my tyres if I take it to Brooklands. The cars, all MOT'd and insured, so see if I can sort some tax out tomorrow, and as long as it's running fine i'll take it on saturday; be nice to compare to the laggy turbo.

Well I had a good drive down and back from brooklands the other week, really nice venue, the weather turned out to be better than expected and some great cars on show. First time i've had a chance to drive the car a decent distance this year and it didn't dis-appoint, nice to have some instant throttle response than waiting for a turbo to kick in and dump 140bhp in one lump. I remembered to set all the suspension to fully soft before we left, so had a nice smooth ride and saved my back in the process, but did mean I had torque steer whenever I wanted  :D Also on the way back home I joined the motorway, what was the car in front of me? Tony in is coupe.
(http://i135.photobucket.com/albums/q152/lanciamad_album/4568586395_8ee723ae6a_b.jpg)
Shock horror, I actually did some work on the car today, I wasn't in the mood with the damp weather today, but got some motivation and got to work with my new front setup.
One of my latest purchases from Mark, although i've had it for months :-X Front polyurethane top mounts...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0495.jpg)
Bit of paint...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0497.jpg)
Firstly I un-did the strut top nut while it was on the car, leaving it threaded a few turns, for removing easily later on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0493.jpg)
Both removed from the car, and then dis-mantled...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0499.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0500.jpg)
Then the real work started, my front spax are fitted in sealed type bodies which I cut then welded up, so I needed to cut the bodies once again to get the spax inserts out...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0502.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0503.jpg)
Then I had to fit the spax units into my replaceable strut body type, which already has the holes enlarged for the eccentric bushes to adjust camber. They did fit with some force (some metal tube, piece of wood and a hammer) and won't be coming back out of there in a hurry.
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0504.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0505.jpg)
Both done and dusted...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0508.jpg)
So by tomorrow the top mounts paint will be fully dry and hard and I can build the front suspension again, fit to the car and get playing :) Have no idea how much the eccentric bushes are going to adjust the camber nor how the suspension will be like with the top mounts, so should be quite interesting.
Another job on the list, replacing the gear linkage bushes...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0498.jpg)

Still not really progressed with the car lately but it is back on it's wheels again. Most urgent job is deciding on the camber I want and then have the tracking adjusted accordingly. Few more bits turned up for the throttle bodies setup last week, cost me an arm and a leg but it was worth it.
Ally crank pulley with built in 36-1 trigger wheel...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0587.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0585.jpg)
Crank position sensor with attached loom...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0588.jpg)
Crank position sensor bracket...
(http://i135.photobucket.com/albums/q152/lanciamad_album/Photo0590.jpg)

A very nice blog Marcus. What is the progress on your HPE? Will it be going with you to the AGM on sunday?

Have just read your update on the thread in Steering where you write the front wheels are now at -2 degs camber. It will be very interesting to hear your comments on how the car now steers and handles. So will see you in it on sunday at the AGM?

Regards,

Andrew

Hi Andrew, thanks for the comment about the blog always nice to hear something positive. It's a great record for myself and hopefully interests others. Latest progress with the car hasn't been much really, i've done some testing for a few new projects for Mark W, which delayed things but looks like there almost fully tested and should be ready to sell soonish.
As you've seen, the work that's been done recently is the suspension set-up of the whole car really. I've had the front and rear camber and toe adjusted to factory figures apart from the different camber i'm running on the front. I've only driven it back from the garage 10 miles set-up as it is, and it certainly feels strange. Keeping it straight feels like it's on a knife edge and it almost feels like the ground determines at what angle the steering wheel is to keep it in the straight position. (I have a smaller wheel with a central yellow band to make things worse) Turn in seems a little vague but it's unfair to criticise at this early time, I also have a plasticy old nearside tyre i'm desperate to wear out that gives no grip, was originally on the rear offside and has a few marks left on it where I spun the car at combe! I think I need to start chucking it about and getting some body roll going before I can comment fully.
All being well i'll be going to the AGM in it, i've only been to brooklands with it this year (and I cleared off looking at other cars for the whole day), so I plan to use it for most of the rest of the year. It's got a VERY busy month coming up, Lancia AGM, Llandow track day, Kilver Court - Beta Meeta, Retro Rides.
What car will you be in Andrew? Have we met? or probably seen each other at other events? Give us a shout if you or anyone wants to look at anything, it is effectively an advertisement for http://lanciabetaparts.co.uk/ (http://lanciabetaparts.co.uk/) with so many things fitted that Marks come up with.

Marcus,
Yep, we've met. Briefly at the Autumn AutoItalia Gaydon meet either last year or the year before.
Sadly I won't be arriving at the AGM in a Beta or even a Lancia, but another Italian marque.
Hopefully see you again on sunday.
Regards,
Andrew

Before I start, just like to say it was nice to catch up with Andrew, Eric, Jonathon (Congratulations), others and those that were a bit busy during the day I left alone. ;) at the AGM last sunday. Car went absolutely fine there and back and gave me some miles to get used to a some-what more balanced handling car, which i'm very pleased with.
Llandow
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF2919.jpg)
An eventful day unfortunately. Car ran perfect there, perfect back but only for 2 hours while at Llandow. From 12 til 4 I ended up chasing an electrical gremlin. Car was running fine, perfect even, for the sighting laps, session 1, 2 and 2 laps of the 3rd session then this happened...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF2926.jpg)
This is getting a too regular sight on tracks around the west :D It seemed to be exactly the same problem I had at Combe. As I came out of the corner, engine just cut out and I drifted onto the outside of the circuit. Tried re-starting and it was really struggling to turn over, giving signs of a flat battery, even though the battery was fine. Thanks go to the llandow marshalls that quickly towed me back into the paddock.
After the initial check, that both belts were still attached to relevant pulleys (they were!) I checked the fuel pump was pumping and pressure was getting to the injectors; it was. So attention went straight onto “spark” or the lack of it. Turned it over and no spark, there was no output from the coil even though there was a supply to the coil which was very hot may I add at this point. After hours of changing relevant parts, coil, amplifier and distributor still no luck.
As soon as the ignition was turned on the coil (which ever fitted) would start to get hot suggesting there was a short of some nature in the wiring which explained the poor turning over speed of the starter and I later noticed the voltage gauge was reading well below than where it normally does before you start cranking.
I started tracing and checking connections and wiring, pulled a connector apart which is the complete opposite side of the coil in the engine bay, put it back together and suddenly the voltage gauge on the dash read where it should. Connected all the original parts and wiring back together, and it sparked, everything back together, fired up 1st time! I can only presume either the wires lost connection or were corroded in some way causing either a short or a large amount of resistance. Luckily the connector in question is not one i’ve replaced yet so wasn’t down to anything i’ve done, but I will certainly be giving that connector a chop, investigation and replacing with a fresh locking one. Maybe it’s only coincidence but both times it’s happened while on track, after a while, so whether the coil is being able to cope with consistent high revs is still a ‘dno’.
Of course by the time I had it fixed and running, i’d replaced the wheels/tyres for the road one’s and packed everything away into the car so it was pointless going out onto the wet track. Did I mention it tipped down with rain from 1pm till we left?! Left the circuit forgetting I hadn’t softened the spax dampers and realised after the first bump in the road! Pulled over in the nearest layby, softened them all within a minute and drove perfectly all the way home with my back still in one piece.
Enough of talking about what went wrong, and onto what went right. What a circuit!!!! Only roughly a mile in length and it has all you want, two straights long enough to get your foot down, I managed 93mph in fourth i’m told. A chicane which people were extremely surprised how quickly I was going through (about 60/65mph) a long sweeping right and some very slow 2nd gear twisty left and rights leading to the back straight, looks simple on a track layout picture, and slightly different behind the wheel. It’s a fantastic circuit for testing brakes and suspension as power is almost irrelevant if you cant stop or get round the twisty bits.
After the sighting laps, I went out for the 1st session getting used to the car and track, and it only got better, came in, checked tyre pressures and the nearside front and rear had rocketed up 7 psi each in 10 laps! Let the pressure back down to equal all round and then 4psi lower for the nearside’s to compensate which seemed to do the job.
Session 2, especially towards the end I was at the limit of the cars and my ability I would say. I passed an AC Cobra replica and was slowly catching a 1.9 205 GTI given another lap or two I would have been looking for an overtake.
Session 3 I went out by myself, very much the same as session 2 but slightly lighter this time without a passenger which could only help, unfortunately I then had the problem which ended my track time, but while I was out there I was having great fun and had more people admiring and asking questions about the car and what was under the bonnet, than didn’t these just rust away which was nice.
Me and a Zetec Turbo’d Morris traveller!....
(http://i135.photobucket.com/albums/q152/lanciamad_album/1-3.jpg)
I think I can quite comfortably say it’s the best handling HPE in the UK at the moment, it was such great fun, predictable and very grippy in the sweeping bends; it was a joy! What impressed me the most was how it coped with the single car wide slight off centre of the chicane. Slight right, left and very right, with the steering wheel! While at pushing 65mph it just gripped and held on for dear life, this is where I was gaining the most on others and keeping up with faster stuff in the bends. The 205 I was chasing for example was using some of the run off to widen the angle of the sweeping right hander while I didn’t need to. I did miss having an LSD round the very tight twisty corners (2nd gear), understeery and full throttle in 3rd leaving the corner was basically a drift of understeer across the track, but we cant have everything.
After 3 sessions I have officially shredded one of the front track tyres, the others on the limit and the backs will last a couple more events yet. I’ve turned all my discs a nice shade of blue and funnily found the brakes a bit fadey on the journey back once they were stone cold, once I started using them (when I got off the M4) they came back to life.
Like everything, you can always improve something or everything! But she still lives on as a working progress and did me proud for the time I was on track. Now I just need a LSD, bigger brakes and more uprated springs!
Some video’s to recover from the mass of writing...
Llandow Charity Track Day 21/7/10 Lancia Beta HPE Track Car (http://www.youtube.com/watch?v=xvwkC03pfxc#)
Llandow Charity Track Day 21/7/10 Lancia Beta HPE Track Car 2 (http://www.youtube.com/watch?v=Kdv5e1X2L-s#)
Llandow Charity Track Day 21/7/10 Morris Traveller (http://www.youtube.com/watch?v=CHk7KIt2zXw#)
See you guys in a couple of weeks at BETA MEETA 10 (Kilver Court) and Retro Rides! Still ummin and rrrin whether to take to the twisty sparkford track.

Progress is slow, and steadily getting slower at the moment but this is the latest anyway...
With the manifold for the throttle bodies set up, I was really struggling for an easy answer of attaching the injectors and fuel rail securely, so am in the process of trying something a bit different. My answer, using the IE intake manifold with some modifications. It's a perfect fit, already has everything in place for attaching the injectors and fuel rail, of course i've got a spare! and just requires a take off for the brake servo as far as I can work out, as i'll be running a fixed fuel pressure and problem fixed.
I got the hacksaw out....
(http://i135.photobucket.com/albums/q152/lanciamad_album/22082010117.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22082010118.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22082010119.jpg)
A few hours later....
(http://i135.photobucket.com/albums/q152/lanciamad_album/22082010120.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22082010121.jpg)
Now i'm just in the process of cutting and smoothing everything to take some silicone hoses to join the manifold and bodies together...
(http://i135.photobucket.com/albums/q152/lanciamad_album/22082010122.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22082010124.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/22082010125.jpg)
I have been using the car again more recently, last sunday visiting the village of imber thats only open a couple of weekends a year suprising some more modern machinery as I went, and managing to spin both wheels as I went off down the road to the suprise of my passenger, that would be the light drizzle and rubbish tyre combo :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/1009192000005_jpg-for-web-normal.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/19092010203.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/19092010204.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/19092010207.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/19092010209.jpg)

I've made the decision which I will probably regret, to take the car off the road til march (MOT time), the only event I would do is a charity track day at castle combe (which i've done for the last 2 years) in November, and the tax runs out at the end of this month so it's going to sit on the drive and hope it tips it down when it comes to the day it would be going round the track.
With it off the road, i'm going to try and work on some projects i've started and frankly given up with. Also start saving up for various parts for the car and also a seperate engine build, to be fitted next winter; the idea being I get my budget throttle bodies conversion all up and running next year, give a good testing before the winter, have my uprated engine ready to go in, and then do a full front end rebuild with the uprated engine on bodies.
I was going to do a seperate post about my proposed engine build, but as it's going to be fitted to this car anyway I might as well mention it here, please feel free to speak your mind. As with many things, cost has been the biggest consideration, so bare that in mind; i'm going to do as much work as possible, but will have to get a local company to do the machining for me.

Bottom end:

Recently bored out block to take 84.6mm pistons
New 84.6mm High Compression pistons
Crack tested Lightened flywheel with balanced crank
20% uprated SPEC racing clutch
Aluminium Crank Pulley with built in trigger wheel
Baffled sump with Accusump system and VX oil cooler

Head:

Oversize stainless 43mm intake valves, and 37mm exhaust valves.
3 angle valve seats
Port and polished
Iskenderian racing valve springs
Fiat Strada 130TC camshafts
Adjustable cam pulleys
Racing spark Plugs

Induction/Fuel:

Custom manifold fitted with GSXR750 throttle bodies, remanufactured IE Injectors, IE fuel rail fitted with an adjustable fuel pressure regulator.

Ignition:

Wasted spark ignition from a Ford, megasuirt ECU and wiring loom

Exhaust:

4:2:1 mild steel ANSA manifold, leading into a straight through pipe to a rear single silencer.

Some parts I have already purchased which helps, but some of the new and as a result, expensive parts are still to buy, somehow it doesn't look so bad when it's individual costs. I wouldn't like to work out the total bill.  :-X

I have also moved my battery to the trunk on my 1981 Beta Coupe.   I am having electrical problems most probably due to not enough ground.    I looked at your photos showing the battery box and the one showing the front left corner of the engine compartment but cannot see exactly where you attached the gournd (earthing leads).   Could you take another photo(s) to give me a better view of what you did please?

Also did you run a ground wire off the - battery post to the chassis in the rear and another to the gear box?


Thank you - Todd

Hi Todd,
What i've done is run a wire from the negative battery terminal (post) to the chassis, this is mounted to the chassis via the mounting hole for the rear bumper, I don't have a bumper which makes it a bit easier to fit. You then need to run another negative wire from the gearbox to the chassis, I did this by attaching it as it does normally on the gearbox and then attaching it to the chassis via one of the bolt holes (cleaned up) used for holding the battery tray in place. Of course you can attach this anywhere as long as the gearbox and chassis have some connection to improve the earthing, I would also make sure that you use the same thickness of wire for the earth in the back if possible, from gearbox to chassis can be about half as thick as a minimum. 
If you want some pics to clarify, i'll post some on here at the weekendm let me know. By the way, welcome to the forum, be great to see some pics of your car.
Marcus.

Thank you for the quick response.

The ground from the engine to chassis using one of the battery tray bolt holes should be easy. 

However I still would like to see a photo showing exactly where you located the battery negative ground lead to the chassis in the trunk area.    I have removed both bumpers also.    I am worried about drilling into the gas tank or drilling multiple holes and not hitting the chassis.  With these unibody cars it is hard for me to tell the different between body panels/filler panels and chassis.

I took some photos of the engine compartment tonight and will try to post them.  I am quite pleased with the way I was able to clean things up and simplify the layout, wiring and hoses.    You will see that I repositioned the air flow meter and used a K&N Filter.   I was able to make a simple custom bracket to support the air flow meter by connecting it to the raditor support.   I also did some cosmetic bits like black powder coating the struct braces, using bright red spark plug wires, having the main water pipe chromed and black wrinkle paint with Lancia highlighted on the valve covers.

Two more questions.   I noticed your rear strut brace.  Did you make these or buy them off the shelf?     A local tuner shop has some very nice looking adjustable strut braces with the main shaft being a thick piece of polished aluminun on sale for 50% off at US$25.00 each.

I have been debating removing the whole AC/heater unit from the interior to reduce weight further.  Just can't pull the plug.  Seems a difficult thing to replace if I ever wanted to turn it back into a road car.



Thank you.

Marcus

Talk to me about Con Rods at the NEC I might do you a deal on the Carillo ones with bearings ready to go. I really do not need 3 sets of Forged Con Rods and I would like to see you driving a monster of an engine on the track. For racing the old FL conrods are a big risk unless you really know they are an ultra low mileage well stored item. 

Also forget the used VX Oil Cooler you need a 235 x 19 row matrix and used coolers have a nasty habit of adding rubbish to engines. It is easy to setup with push on hose at home especially if you use old garden hose to sort the lengths and orientation first.   

On your home made manifold it might be better to get a welder to fit some short tubes from aluminium stock for your bodies to fit via motorcycle flexy tube. Silicon will rot with petrol and pulse under vacuum. The Colonel can tell you where to buy the right flexy tube.

Keep up the great work.

Eric

as Eric said :

http://www.allensperformance.co.uk/products-manifolds.html (http://www.allensperformance.co.uk/products-manifolds.html)

manifold joints in nitrile rubber (made for motocycles) multitude of sizes

Geoff

There you go...
(http://i135.photobucket.com/albums/q152/lanciamad_album/24102010255.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/24102010256.jpg)
Cheers for that Geoff, i'll look them up when I get to that stage. I am aware of a few people having trouble with silicone hoses as you describe Eric, mainly them losing shape when under load, so may well use the motorcycle tube, if not have them solidly mounted to the manifold in some way. Valid point about the oil cooler, new is always best, i'll probably get new goodridge fittings/hoses, have it all set-up and in place with the vx items and measure up what I then need in new. I'll probably mount the oil cooler in front of the radiator, if I cant mount it by the side suitably.
I probably won't make the NEC this year, but i'm sure i'll be at some event in the spring of next year to discuss con rods with you, I certainly won't need any til next year anyway! Monster of an engine would certainly be fitting for the purpose, what actual output from the proposed plans I get, I have no idea. Reliability and more bhp than standard would be a start :)

Before registering for my question, I followed your project for quite a while, looking forward to seeing those throttle bodies in action :)


I'm also interested in the answer to this question, I was thinking about designing my own strut brace for front and rear for my sometimes trackdayed Beta Coupe (http://www.betaboyz.myzen.co.uk/forum/index.php?action=gallery;sa=view&id=167), but while searching the BetaBoyz forum I found out you already have a strut brace at the rear.

If you designed them yourself could you perhaps share the strut dimensions/spacing, would help me out a lot :)

Hi, Yeh the rear strut brace is a home-made jobby. My initial idea was to have it computer designed (which i did) and send it through to the mill we had at college, which would have made perfect base plates by the hundred if I wanted, but the software required between computer and machine they hadn't purchased or got working so I ended up making one by hand which meant the finish wasn't great and i'm also a much better welder now! :D The connecting shaft is hollow with a threaded sleeve welded either end which allows the fitment of rose joints either end for the perfect fit and easy fitting. I won't be making another or improving the current one as i'll be welding a solid bit of bar between the two struts as part of the roll cage, if that ever gets done.
Base plate = i/d = 95mm o/d= 175mm with a pcd of 135mm (roughly); the connecting shaft is roughly 780mm but this is adjusted to fit depending on the bracket, hence the rose joints to be able to adjust the length.
Bit more on the working progress manifold, I finished removing all the material I had to for the hoses...
(http://i135.photobucket.com/albums/q152/lanciamad_album/07112010266.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/07112010261.jpg)
Quick mock up of what it'll look like...
(http://i135.photobucket.com/albums/q152/lanciamad_album/07112010264.jpg)
Some re-conditioned injectors with brand new rubbers fitted...
(http://i135.photobucket.com/albums/q152/lanciamad_album/04122010270.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/04122010272.jpg)
Latet mock up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/04122010273.jpg)
Things I can think of, that still need doing to the manifold and bodies are:
•   Trumpets welded to bodies
•   Bike injector holes blocked off
•   Solidly space the bodies straight
•   Fit hoses and clips
•   Source/find the retaining plates for holding injectors in place
•   Buy and fit fuel hose for injectors to rail
•   Clean manifold
•   Drill and have take off welded on for brake servo hose
•   Port and polish manifold to intake gasket size
Shout if i’ve missed something; now i’ve got a list to work to I better get on with it!

I may have missed something but how are you connecting to the air flow meter
or is that now obsolete ??

Geofff

Marcus

I assume you are using the bike body Throttle Postion Sensor in place of the airflow meter or a map sensor to measure load? Have you got the Pin outs for the TPS? Do you know what the flow rate is of those injectors and have you done the calculations to check they match your power expectations? You can buy injector pocket plugs from Jenvey if that helps. You need Nitrile hoses those silicon ones will not stand up to the petrol first going all soggy before collapsing under vacuum.

Keep going I look forward to hearing the beast in action.

Eric

We did discuss this before, need to be flouro-silicone , couple of links:

http://www.allensperformance.co.uk/products-manifolds.html (http://www.allensperformance.co.uk/products-manifolds.html)

http://www.viperperformance.co.uk/plainpage.php?pgId=28 (http://www.viperperformance.co.uk/plainpage.php?pgId=28)

although if the injectors are after the hose I suppose it wont really matter, aside from
the fact that silicone is soft and tends to deform/collapse under vaccuum.

Geoff

Marcus,

Oil resistant reinforced silicon (with wire) tubing is available to stop it collapsing due to vacuum or being affected by oil, but it is pricey and has a substantially thicker wall than the silicon tubing you look to have acquired. Although not sure about petrol. Have you thought about using aluminium pipes in effect fabricating a manifold between TBs and the manifiold?

Apologies for the late reply. Project throttle bodies and project HPE have been on the back burner for a good few months since working on my HF Turbo which is almost complete now. After the lack of Beta's (no HPE) at Brooklands and the recent talk between friends about building a purpose built car for the track it has given me a bit of a kick up the ass regarding my HPE which has been sat on the drive too long now.
The throttle bodies setup is still something I want to complete, as it has potential to improve performance for a very limited budget if my plans are successful. I will just have to have a good sort out in the shed and find everything I have and see if i've got everything I need to get it all setup; then get to work on the bodies and manifold and then go visit my friendly rolling road to get it all fitted and setup. Chances are I will invest in some hose as the colonel suggests as I only need to connect and not strengthen the setup as the manifold attaches as originally and the fuel rail will also fit as before, so the hoses/clips should be good enough to support the throttle bodies.
First off, I found I DIDN'T have any holes in my floor as the water had collected pretty well from either a leak through the side window seal, sunroof or bulkhead, yet to be found. I'll have to get the hose pipe running from different angles and find where it's coming in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0400.jpg)
Next, the bonnet brackets have corroded and become so stiff when opening the bonnet the hinge was actually bending the metal around it and causing a crack in the metal...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0402.jpg)
I've welded up the crack best I can, not ideal welding such thin/rusty metal but got there in the end. Now in primer ready to be sprayed met silver some time, hopefully some grease and WD40 will penetrate the joints and ease them off, if they don't i'll have to have the bonnet off and clean and grease the pins...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0415.jpg)
Onto some more modifications planned, not many Beta's have a roll cage in them never mind a HPE but thats the plan! I've had the B pillar hoop made about 3 years ago now and it just occupied the garage, but I pulled it out today and got to work, first sanding it down getting rid of some outer surface rust, cutting the legs down so it should now fit and spraying it in primer...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0418.jpg)
Once dried, i've given it a coat of smooth black. I know there will be some cleaning up needed to weld some bars to it, and obviously at the base where it will be welded to the chassis but the majority of the awkward areas to paint when welded in the car should be covered. I'll probably go for some brush on smooth black hammerite once the cage is completed...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0419.jpg)
Current plan is to put it through it's MOT this month and get it back on the road for June. Once on the road then get the cage fully welded in and arrange for the outside to be rubbed down and re-sprayed as the paint has reacted with moisture over the months and come up with loads of pimples gradually getting worse across the whole car; he's happy to do it free of charge, but there is some tiny rust issues i'm happy to pay for and also the changing of the front wings for lighter options i'll expect to be paying for.
I've got some plates, foot plates and gussets coming for the cage so will probably get them in place and then arrange for the A pillar to B pillar tubes to be made, with the rest just being straight pieces connecting the B pillar to rear turrets.

I'm not sure if this comment is relevant but I know in this part of the world (NZ and AUS) when you get a roll cage approved by the motorsport governing body you need to have the cage either inspected or photos taken prior to painting after it has been installed. This is particularly around the welds on the plates to the body and the bends of the cage. I'm not sure if you have taken photos of the main hoop already or whether it has to be in the car etc but I would assume the UK is as strict as others seeing as it all adheres to the FIA regulations.

Hopefully this is a wasted comment and you are on top of it!

No your quite right in saying so, to be FIA approved it needs to be fitted and welded in by an FIA approved welder. I am however not to fussed about this as the car will never be raced in a competitive nature, it is being built to somehow still be road legal as well as mainly being a well sorted track car. I plan to keep the car and will never be able to afford to go racing and if I could it certainly wouldn't be in the HPE! The prices i've had quoted for a cage to be made are can only be described as horrendous, hence the route i'm going. If it comes down to it, i'm pretty sure you can organise test pieces to be sent out to you, weld them in place and send back for assessment, to class you as an approved welder, and would class it FIA approved if need be.

Finally got around to welding up my front struts with modifications so it's now a fixed -2 degrees negative camber on the front, with future plans of adjustable top mounts for increased camber changes, but this will only be when I get the car going any faster than standard trim with suitable braking upgrades to match...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0456.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0458.jpg)
Spent the best part of a day making up plates for the roll cage to sit on, plenty of welding, grinding and filing produced this lot...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0426.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0434.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0464.jpg)
I've decided that I don't want to cut away at the dash, so am going to fit the A pillar mounting just in front of the dash which should also just clear the inside door handles...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0437.jpg)
Got my A pillar to B pillar tubes bent, should fit perfectly once cut down, the cardboard never lies...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0462.jpg)
and with the car booked in tomorrow for the MOT, I had a few little jobs to sort out, one being replacement front wipers; so I opted for some modern style aero wiper blades...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0440.jpg)
I'm pretty confident the floor pan to sill join is going to need attention and possibly a bit on the rear turret, but other than that pretty happy with the rest, see how she gets on I suppose :-X Gives me a couple of weeks to get it sorted anyway.

Well that made my day, turns out I didn't need those couple of weeks, went straight through with just a comment about getting the last ancient road tyre i'm trying to wear down, replaced; happy motoring ;D
As soon as June comes around, should be back on the road for more fun, see if I can improve on the 995 miles I covered in it over the last year :-[ and see about this roll cage and bodywork re-spray mk2.

Good stuff!. keep your fingers x'd please.. my MOT is 2pm tomorrow :-\

How do you get on?
Made a bit of an effort on my bike bodies setup, nothing major but at least something. The original injector pockets have now been blanked off with some jb weld...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0466.jpg)
Injector brackets found and fitted, new fuel hose...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0468.jpg)
Roughly how the intake and fuel rail should look...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0469.jpg)
I got impatient, so made a start on the roll cage over the last week, still not decided on the exact design in the rear but have made a start. Spent most of the day on it and still seems like i've got nowhere, waiting on a few things in the post but have got the B pillar hoop in and one of the A pillar pieces. Weather permitting i'll get the other A pillar piece in and connecting A pillar tube tomorrow and then start on the tubes for the rear. I think my target is to get it all in minus the door bars by next weekend, how it stands so far...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0475.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0476.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0481.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0482.jpg)

You have been busy Marcus! - good to see the progression.

I have a question about your roll cage design, why did you not extend the front section to the point where it would follow the roofline and then butt up against the A pillar?  I would have thought that it would have provided a bit more strength in the event of any impact, or have you kept it a few inches away from the A pillar so it acts as a kind of crumple zone and the A pillar absorbs the initial impact and then the cage does its bit after the impact forces have been reduced?

It's not a criticism,  just trying to work out if design has improved over time. On my old grass tracking VX Coupe I recall the Safety Devices cage I recall that the vertical sections were aligned and tight against the A & B pillars but that was 12 - 13 years ago!

The support platforms you have fabricated are almost identical like those provided with the Safety Devices cage I had.

You've been damn busy yourself from what i've seen ;) Your have yours on the road before I finish this cage! I would have liked to extend it forward onto the A pillars, as I expect some of the available cages would do? But as i'm trying to do it to a budget (as usual) I was restricted to the sharpness the tubes could be bent to by my local motorsport shop (you can probably notice in the pic the angles are not of the same shape as the A pillar) and also the length of tubes. I'd have to pay an extra £20 per tube for another metre of which i'd only use 10cm's roughly, so I can live with it. TBH it's all work in progress, i've got the design in my head but constantly changes when i'm fitting it.
From looking at it sat in the seat, I can only see the A pillar absorbing the impact (heaven forbid) and hitting the bar, so either way should do it's job effectively, hopefully never to be tested!

As you can see in the last pic, the A pillar tube mounts towards the rear of the platform. I was actually expecting it to be fitted in the middle, but once i'd cut it down and changed the angle it ended up being towards the back; so design change again, once the cage is effectively done, i'm going to triangulate at the platform with some of the many off-cuts of tube which should support the tube a lot more and double the area of impact in the case of rolling; I mean strengthen the chassis up some more ;D

I'm glad I fitted pretty decent spreader plates, especially for the B pillar mounts, when welding them in and building up some pretty decent heat I managed to put a small hole through (which got welded up), and considering thats one of the cleanest bits of metal, it concerned be a bit when I came across a chap abroad that had welded straight to it; it wouldn't surprise me if the cage went straight through it on impact.

This morning I cut the tubes from B pillar to rear turrets, so am ready to fit most the cage now, just need to do a little grinding and weld everything in; damn weather :-\

Only thing I haven't decided on is the rear diagonal tube, it's going to be mounted from one of the top corners of the B pillar but haven't decided where to mount the other end, can you remember where it did on yours Matt? Anyone got some pics to give some inspiration?

Yes, mine was exactly like the one in the picture below.  IIRC this rear diagonal cross brace piece on my Safety Devices cage was not welded, it was bolted in place, the top and bottom corner had a welded flange, similar to the way detachable door bars are fitted and the cross brace slotted into place and then had o3 x M10 bolts at each end.

   

Cheers for shedding some light on it Matt. I was considering welding it in, and was still contemplating where to weld it to, make another plate and weld to arch, weld directly to one of the other tubes. But think i'll go along with the bolt in option, the door bar type fitments are a lot easier to weld in.
I've been on it, on and off all week, so slowly getting there. B pillar to rear turrets are in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0485.jpg)
A pillar cross piece brackets welded in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0490.jpg)
Door bar brackets welded in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0492.jpg)
Door bar...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0489.jpg)
Painting begins...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0493.jpg)
The to do list for the cage:

• Cut diagonal tube to length and weld connections either end
• Weld connection brackets on b pillar tube and nearside rear turret tube
• Weld plates on rear turrets
• Cut and weld tube between rear turrets
• Paint cage
• Triangulate at A pillar mountings

Bit slow on the progress, but diagonal is now in place, typically I ran out of welding wire with half of one of the brackets to weld but there you go...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0504.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0506.jpg)
Although it flew through the MOT, i'm going to sort out some corrosion on the rear turret while i've got the welder out, and then weld a couple of spreader plates for a solid tube in between both rear strut towers; corrosion to be dealt with...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0507.jpg)

Finally getting there with the cage, other than some optional triangulation on the A pillar foot plates and a few touches of paint to complete the painting, jobs almost done, and now looks like this...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0543.jpg)
This is the replacement for the strut brace in the rear, some solid tube in between the two towers...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0541.jpg)
My view out of the rear window mirror...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0544.jpg)
I'm taking the opportunity while i'm at it to smarten up the inside, so it'll be getting a good hoover, then an undersealing where required and the whole floor sprayed in some 620 alluminio met, haven't decided whether to take the carpet out of the boot area but I think more than likely it'll be coming out with the door cards soon to be on the cards to shed some more weight as well. As well as this i've managed to purchase a matching seat to my drivers side bucket seat, so that'll smarten it up no end, already swapped over subframes so just a matter of fitting once i've finished painting.
And last of all i've got a sunstrip made advertising our wonderful club (forum/website), but instead of the blue that got sent with it, i'm going to be using my usual black fading to clear sunstrip with writing over the top which will suit the car more...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0509-1.jpg)

Some various treatment and painting pics...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0596.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0597.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0598.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0601.jpg)
Matching passenger seat now in, with a similar 4 point Luke harness as the drivers side, replacing the 3 point previously...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0602.jpg)
Cars not far off from being useable now, just needs a good clear out of the inside, have a go at fitting the sunstrip, check all levels and pressures and see if it'll turn a wheel after being sat for 2 months :-\ All going well I hope to get it moving down to the petrol station by end of play tomorrow and get a few miles done evenings next week, hopefully to be happy with it for the Lancia Motor Club AGM next weekend and the all important Beta Meeta '11 the week after.

Wow, over 10,000 views  ;D ;D ;D
Well i'm delighted with the car so far, fired up first time, has been faultless since being on the road and have enjoyed every mile of the 300 odd i've done over the last couple of weekends.
First was the Lancia Motor Club AGM at Cheltenham pictured here...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9205.jpg)
As I don't listen to the Colonel i've crossed my harnesses...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0616.jpg)
I then got to work on some odd jobs that always get forgotten about, such as the lose wiring to the fusebox...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0606.jpg)
Which is now a bit tidier...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0607.jpg)
Some black cable tidy for the wiring down the offside inner wing...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0605.jpg)
I was lucky enough to buy a new omp steering wheel still in the packaging on ebay. I like the old one I had but was starting to wear and get tatty so I thought I would try this one. It is dished perhaps too much, but from saying i'd go back to the old one it's starting to grow on me, and I suppose it's what you get use to. Opinions on looks? ...
Old...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0609.jpg)
New...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0614.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0610.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0613.jpg)
I got bored of looking at a rusty water rail and bland colours, so a few things got a bit of painting while I finished painting the cage and latest addition, some 8.5mm Red Magnecor Ignition Leads...
Before...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0608.jpg)
After...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0617.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0619.jpg)
And finally, a brilliant day out at this years Beta Meeta :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF9273.jpg)

Latest little action for the car was Prescott Hill Climb for the Retro Rides Gathering. Really worth a day out if your into the classic/retro/modified/rat/wolf in sheeps clothing kind of thing! First two runs went fine, but once back to the paddock turned it off to save fuel and let it cool down. To find it struggling to turn over and as a result not fire up. After failing to bump start it, and checking all the wiring I found that the connector for the ignition barrel didn't look right, pulled it apart, back together and fired up first time. Decided to do another run and then park up for the rest of the event, I could have got another run or two in but no point risking it too much with a long-ish drive home. Not sure if it was the pure heat that it was producing while running in the paddock or not but it was very hesitant from idle upto 2k rpm for the 3rd run, it made me think the timings out, but was perfect for all the journey home.
Considering I ran it in full road setup, i.e. road tyres (2 hard plasticy fronts) with all shocks set to fully soft I think it did me proud. Not as much understeer as I was expecting, although quite a bit of tyre squeal it held its own through the corners but it might have been lacking in the power department against some 400 bhp machinery, some with sequential boxes, I can dream ::)
(http://i791.photobucket.com/albums/yy199/LittleBlue88/Retro%20Rides%20Gathering%202011/IMG_0592.jpg)

(http://i61.photobucket.com/albums/h42/andypandy_2006/retrorides%20gathering%202011/DSCF1083.jpg)

Well it's been a while but i'll update you on what's happened since the last post, which hasn't been a lot up until a couple of weeks ago. I last used the car back in september for Rallyday 2011 at Castle Combe where I took part in the Lancia session on track. The car did well considering I didn't set it up for the track, running standard tyres and suspension on a very slippery damp track. Luckily we narrowly missed a downpour just as we left the track and i've just found some footage featuring my car, pleased I kept in front of that integrale for so long! ;)
Club LanciaSport at Rally Day 2011 - Castle Combe (http://www.youtube.com/watch?v=q68xObUQh0s#ws)
This is when issues started to take place, first off erratic idle and pick up from low revs, then overheating and to top it off driving back home it suddenly cut out a couple of miles from home. After fumbling with the ignition barrel connector luckily it fired up again, and I got home where it's stayed on the drive looking sorry for itself.
With time being spent on the HF turbo and the new arrival of a joint-owned 206 gti :-[ which i've used a couple of times at track days i've just not had the time or enthusiasm for the HPE, but with the 40th anniversary this year it's time I put some time and effort into making it to as many Beta related events I can this year.
In a quest to sort my first problem, overheating. I took the decision to go through the whole coolant system replacing as needed. Starting off with draining what little coolant there was in it, I removed the hoses and got the radiator out to check over and smarten up. I gave this a quick spray over to tidy it up having not found any issues with it and fitted a new fan switch while I was at it...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0023.jpg)
While inspecting the old fan switch i'd found one of the wires had rubbed through the insulation and may have been shorting/earthing out not telling the fan to cut in which may have caused the overheating, as well as finding some of the other wiring from fan to switch bare to the elements. I then decided to go the whole hog and replace the water pump while I was at it, not having done so since having the car and not knowing when it was last replaced. Apart from a slightly troublesome removal of the pulley I soon had that changed, still amusing it didn't come with a rubber o ring for the water pump to bottom water rail...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0039.jpg)
After doing that I then took the decision to replace all of the hoses I hadn't already got from Mark W, with new silicone hoses, these included the two that go to the heater matrix, two that go to the induction manifold and header tank to bottom water rail. I haven't taken pics of these yet but will do once i've solved all leaks. Having checked and replaced, radiator, water pump, all hoses, I thought I was winning until I went to top up the coolant no leaks whatsoever until the dreaded small drip inside (lucky I don't have carpets!)
With no leaks coming from where the pipes connect or the heater valve, and the drip coming from the base of the middle console I can only presume the heater matrix is at fault. Having removed it and found it to be a little rusty, where the heater valve connects to it, was completely blocked with what looked to be some kind of sealant type substance which makes me think how much water actually flowed through it, if any...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0042.jpg)
I've got a heater matrix coming from Mark W (Thanks for the speedy help) which I hope to fit tomorrow all going well, which will just leave the heater valve the only object to be checked as I did notice a bit of water seepage when a little pressure was put on it at the centre join while removing from the matrix and removing the hose that connects to it. I've put a parts wanted request for this just in case I find that this now leaks once I connect it all up again, but would like to keep a spare anyway, so please get in touch if you have one...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0041.jpg)
I then by accident came across perhaps why I was down on power when I did the rolling road but spot on with the torque figure!?

Having removed the dizzy cap to get better access to hoses and the gear linkage, I checked the rotor arm and found excessive movement which i'd imagine would give quite vague ignition timing. Looking at the arm itself it doesn't appear to have excessive wear...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0028.jpg)
but with no movement in the shaft the rotor arm is at fault. I've got a new item coming to try but if there's no difference I may have to try various arms to find the correct item.
Another job i've had down for a long time was replacing the ancient gear linkage bushes with some of Marks. I bought them probably a year if not more ago, but knowing they were time consuming and awkward kept putting it off until last week. While half the engine bay is missing and the car is up in the air due to flat tyres, I decided the time had come; and just in time too. While removing the linkage connected to the gearbox end, the other end connected to the pivot just fell off. After some fun with the vice and the pressure of a hydraulic jack with the help of some wood and metal tubes the new bushes are in place and linkage fitted to the car; I don't think that'll be coming off in a hurry!....
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0024.jpg)
Then with the future in mind, i've decided to change the wheels for a couple of reasons. Firstly I can widen the track of the car, fit wider tyres, it will allow future upgrade of front brake calipers and also I think there going to look pretty good too...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0031.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0032.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0033.jpg)

Having briefly trial fitted the wheel, there shouldn't be too many issues on the front but remembering that some spacing would be needed on the rears I also managed to buy some wheel spacers off the rear of a 16v integrale to try...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0038.jpg)
Which seems to give just enough clearance between tyre and rear strut body. I've checked with it raised and on the ground and it's tight but seems to be clear, I will need to finally check once the suspension is settled to make sure...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0035.jpg)
I'm looking to get all the wheels refurbed pretty soon if I can, and once I manage to source the relevant wheels bolts to fit them I shouldn't be far off. (http://s135.photobucket.com/albums/q152/lanciamad_album/?action=view&current=1-4.mp4)

Unfortunately I couldn't make it to Goodwood; just too many jobs to complete on the car and I keep finding issues and other things I might as well do why i'm there. The cooling system saga goes on, having changed everything but the rad, in true fashion it sprung a leak, you can just about see the leak from the middle of the pic going to the right...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0064.jpg)
I'm hoping to get this in sometime this week to be re-cored by a local company and will then fit a new slim fit fan to match the secondary one already fitted to free up a bit more space in the engine bay.
Having got it running again pre leak, I also found that my exhaust manifold is blowing and being wrapped in heat wrap I don't know how badly it's corroded until I get it off. After a quick rummage through the shed I found the original which will have to go back on for the time being. I've got some new exhaust gaskets coming for it and it still looks to be in pretty good condition so hoping that will be straight forward enough...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0063.jpg)
On a positive i've got the integrale wheels back from being refurbished. Having the rim as it does, that needed to be diamond cut with three of the wheels needing straightening out so they could be cut. This is the finished product...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0061.jpg) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0062.jpg)
I've got the tyres ready to go on and the relevant wheel bolts needed for the rear wheels, so once i've sorted all the coolant and running issues i'll be down to the local tyre fitters to finally be back on the road with it.

Marcus

It is looking good and you were missed at Goodwood! For the wheel bolts Demon Tweeks can supply on a next day basis (proper 10.9 grade not Chinese chocolate items) you just need to tell them the thread and length.

Cheers

Eric

Yes looking good.

Very good work!!! I am impressed!!! 

Loving the new steering wheel and rims too.

Dan

Those rims look fantastic!  Where did you get them refurbed?  I have the same rims, but nowhere near the same condition.  I have some some nice toyos to replace the worn rubber, and maybe I should get the rims done at the same time to get the car looking pristine again.

Cheers

Darren

Car is looks better every time we get an update.

Thanks for the comments guys :)
I got the radiator re-cored by a local company, and thought I might as well free up slightly more room while i'm at it, so have fitted a slim fit fan in replace of the original...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0074.jpg)
I'm pleased with the rims, they are actually so good it highlights the bodywork issues even more now! Because of the way the wheels are, the wheel is refurbed, powder coated anthracite or whatever colour you want, and then has the rim diamond cut. Unfortunately that means it gets expensive. I got these done by lepsons in Swindon, but they also have a place at Gilllingham. I contacted a few local places to me but they all said go to lepsons, as having the diamond cut facility seems to be quite specialist.
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5534.jpg)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5536.jpg)
I managed to get some cheap and cheerful tyres at a good price so have gone with those, as i've decided to give the HPE a rest from track action this year, (well track days anyway) so road going track tyres aren't a must. Yet. I've gone with 10mm spacers on the rear for the tyre to clear the strut and 15mm on the fronts for lock to lock, and no doubt will aid with big brake upgrades for the future.
I seemed to be having resistance/earthing issues with the battery in the back so have now refitted in the front for the time being until I can sort it. Even then, having re-attached the original earth, gearbox to battery, that wasn't good enough, so have run a wire from battery to chassis and all is well again. While having teething problems, I did manage to test drive everything covering 70 miles over the day without major issue getting everything warmed up, no coolant loss, brakes freed, so not bad for not moving since September.
It was suppose to be MOT'd monday but having battery issues, I couldn't get it in until today and should see where I am with it tomorrow. Hopefully not a long list of things to do as Norfolk is still the aim! :)

Where did you obtain the cooling fans please ?

Thanks for the info - Swindon's not a million miles away - will give some thought.  Look forward to the next update!

Cheers

Darren

The fans were just an ebay purchase, there's plenty of them at various sizes to suit whatever application. A slimmer design with i'm sure a much more powerful motor than the originals have.
It's been a while now, but from memory I didn't have much to do for the MOT, a very strange one was movement in the rear offside suspension, which I was told seemed to be top mount failure, which I knew it wouldn't as i'd only fitted the poly top mounts to the rear recently. It turned out that the nut securing the spax shocks in the strut body had somehow loosened itself off and all the movement was just down this.
Due to new MOT guidelines at the time, although I think there gradually going back to the original rules after VOSA poked their nose in, I had to replace ball joints and track rod ends, purely down to worn gaiter/rubbers.
There was some welding needed to the rear turrets directly behind strut bodies, a bit by floor pan to sill on the offside and the car would cut out if the fusebox was touched! Turns out the connector had become loose from the wiring from the battery to right side of fusebox and depending on where the fusebox was moved would depend on what worked. A couple of minutes bodging the wiring to get home and all was well.
That was the thursday, I then got to work sorting out the wiring properly when I got home, loading some bits and bobs in the car and the next day we travelled towards norfolk :)
After approx 2 hours driving from wiltshire, we stopped at a service station for a break, to then continue the journey. But of all times, the ignition barrel decided that when the key was turned the starter would not engage, and the barrel had quite clearly failed, I presume the points inside are worn/broken. So after checking all wiring I could quickly check was ok, I found some spare wiring, made up the relevant connectors to join to the wire going to the starter, tapped it onto the battery + and it turned over and fired up first time. Panic over, the car drove faultless to norfolk, around the tour day and the journey back, I think it wasn't far off 500 miles in 2 and a bit days, and my back survived with the odd cushion here and there of course. So if anyone thought why I had the bonnet up all the time it was purely just to start the car.
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSCF5037.jpg)
All in all you couldn't fault the weekend, one, if not the best weekend we had of the year weather-wise, with a great selection of beta's on a well organised event ;D 
http://www.flickr.com/photos/lanciamad/sets/72157629922862850/ (http://www.flickr.com/photos/lanciamad/sets/72157629922862850/)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5614.jpg)
I haven't really done anything with the car since, hence the lack of updating the blog, but what I did spend half an hour doing the other day was removing the offending ignition barrel...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0298.jpg)
I was pleasantly surprised to find that by punching the bolts, I could reasonably easily tap the bolts around until the barrel clamp fell into two...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0300-1.jpg)
I also found some remanufactured wheel centre caps i've had for a while to fit into the integrale wheels, don't worry it's only cobwebs that make the wheel look like it might have marks...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0299.jpg)
Of the four fitted, two of the Lancia emblems popped out on them which was a bit annoying, but nothing a bit of glue won't sort.
That's pretty much all I can think of at the moment, and I expect fitting the replacement barrel will be next on the agenda 8)

Been quite a while since doing any work on the HPE, but as it tries to warm up I thought I better finish off the last job I had on the go. Suspecting that the ignition barrel had failed, with I presume failure of the contacts for the starter position, I managed to find a spare barrel with key, from first glance seems in good condition and most importantly works...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0837_zpsc5c78bca.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0837_zpsc5c78bca.jpg.html)
I know back in the day in seemed a popular modification to fit a relay between switch and start motor, to have the relay doing most of the work of the switching, so while I had the ignition barrel fitted I did the exact same thing, picked up a new relay and wired it up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0838_zps0c58bc23.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0838_zps0c58bc23.jpg.html)
Disconnected the coil, turned the key and it turned over lovely, built some oil pressure up, connected the coil and fired up first time :) Needed to slightly adjust the idle once it warmed up as it was ticking over a little slowly but apart from that all seems well.

Dear Marcus,
Good to see you are progressing with the HPE. It seems that you have set a "mini trend" with your wheel choice, they look fabulous and suit the HPE really well. I found a set on Ebay recently in good condition that need refinishing,  and if possible I would like to get ours done in metallic anthrecite to match our silver HPE VX. Also "Dodgems" (Amanda and Steve) also have got a set that they are getting refinished down in Exeter!

However could you tell me how much the diamond cutting process actually removes in terms of material from the front face, as our Integrale wheels have curved front edges to all the webs and yours now have a definate "machined edge"? Or have i got a set of Delta 1600GT / HF Turbo wheels, (that were similar but finished in a single colour silver if I recall)?

Keep up the good work,
best,
Chas and Anne. :)

The HF Turbo wheels were only 14" and the Integrale's were 15", should help work out what you have.

Chas,

Integrale wheels were 15" 6" wide on the 8V and 7" on 16V, Delta HFie wheels were 14"

Beat you to it by 25 seconds lol

Cheers Guys, it looks like I have got a set of HF Turbo's rather than Integrale. Still would like to know about the diamond cutting though!
Best,
Chas. :)

Although diamond cut wheels looks great, I found them to be a pain, as you regularly have to clean them & protect them with something like Poorboys sealant/polish.

I had diamond cut alloys on my M3 and Lepsons advised that they could only be cut twice, then you throw the rim away as you start to compromise the strength in the alloy.  Eventually I took them off and sold them before the finish got kerbed, dinged, scratched or blemished thus meaning another trip to Lepsons and circa £115 per alloy!

Maybe for a show car then yes, I'd say it's possibly worth it, but not for a car thats driven regularly.

Hi Chas,
Sounds like you have HF Turbo wheels if there silver, although I have seen integrale wheels for sale that have been previously painted. If you have a look at the size that will explain all. I've got a feeling the 14" wheel may fit straight on without the need for spacers, I needed to fit spacers and get longer wheel bolts for the 16v integrale wheels.
These are HF Turbo alloys...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0282.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0282.jpg.html)
This is the first HPE I saw with the wheels, thought they looked good so became a copycat :D...
(http://i135.photobucket.com/albums/q152/lanciamad_album/hp05.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/hp05.jpg.html)
The turbo wheels do differ a bit to the integrale one's and the diamond cut process is needed for the machined and polished look to the rim. I'm not quite sure of the process, but I do know that my donor wheels had reasonably bad kerb damage, so presume the rim is cut back as far as needed to remove damage. Expensive but happy with the result. A simple tip I was told when I collected them, if your getting someone else to fit tyres to your refurbished wheels, make sure you cover the rim generously with masking tape, so that it gives some protection to the rim when fitting the tyre.
Marcus.

They do suit the car very nicely, gives it a bit of an "037" look

Dear Marcus,
Thanks for the info and pics. The HF Turbo wheels you show are very like the ones I have got, however the webs around the rim circumference come up to the outer flat edge but curve down to the center rather than have a defined line. (If that makes any sense). That curve would make masking for the inner darker colour very difficult as there is no defined "edge". I wonder if I have a varient that is just usually painted one colour?
I will try to post a pic to explain later.

BTW: It must be tough living with the "037 look!"

Will get back with a pic.
Are you going to Bristol this weekend If so, see you there.
Best,
Chas and Anne. :)

It's very hard  :D
Yeh if you can, post a pic up of the wheels you've got and we should be able to work out where they came from. Not sure if the 4wd differed from the turbo wheels or not.
I'll probably be at Bristol in the morning for a couple of hours, see you there.

HF Turbo ie wheels and the HF 4WD wheels are the same, it was only the carb fed Early HF turbos that differed and had the same wheels as a Prisma.

Dear Marcus,
Here as promised are a couple of photos of my Lancia Cromodoras. You are right they are 14" (and I suspect 5 1/2J width). However you will see the difference in the "web" compared to 15" Integrales', and this will cause a problem if I wish to go the two tone colour option. Any thoughts?

PS: Missed you at Bristol, however I saw your photos. Nice.
Best,
Chas. :)

Hi Chas,
Yeh these are HF Turbo wheels, I see what you mean about the "web", never paid much attention to it in comparison but I see what you mean now. I would have thought you could quite easily have the two tone option without touching the "webs", but if you wanted the webs cut like the rim i'm not sure if they could do it, but expect its quite possible as I would have thought they would still use the same process as Integrale wheels.
I kept an eye out for people but it was only a passing visit and I think everyone else was looking round the show by the time I got up towards the fiat's/lancia's.
Marcus.

The micro-blistered paintwork aside, the few rust spots around the car were starting to bug me, so i've made a start on making things a bit tidier bearing in mind the whole car will need to be rubbed down and have a full respray at sometime in the future.
This crack in the rear quarter panel was of great annoyance...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0868_zps3998e3f4.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0868_zps3998e3f4.jpg.html)
Quite an area of filler was needed to straighten out the damage to the panel before I got the car...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0869_zpsd1f92620.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0869_zpsd1f92620.jpg.html)
Told you...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0871_zpsd3593a34.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0871_zpsd3593a34.jpg.html)
Some bubbles on the offside front wing soon turned into holes...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0874_zps6900d229.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0874_zps6900d229.jpg.html)
Top of rear quarter panel...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0877_zps226b4457.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0877_zps226b4457.jpg.html)
Some more filler / fibreglass work rubbed down...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0882_zps66bbd46e.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0882_zps66bbd46e.jpg.html)
Bit smoother...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0884_zps29a5b737.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0884_zps29a5b737.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0894_zpsee597729.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0894_zpsee597729.jpg.html)
Split on the bonnet...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0888_zpsddaf6f4a.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0888_zpsddaf6f4a.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0898_zps3bfb763e.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0898_zps3bfb763e.jpg.html)
Front wing ready for final coats of primer, i'm not overly fussed about the front wings and valance as I've got fibreglass wings to go on when the respray happens along with the series 1 valance to fit...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0899_zps8b3f4a24.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0899_zps8b3f4a24.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0906_zps669e63a4.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0906_zps669e63a4.jpg.html)
Replaced the aero wipers with some others as the rubbers had gone...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0913_zpsf329a0c8.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0913_zpsf329a0c8.jpg.html)
Was reasonably easy to get them to fit, the pins will be getting cleaned up and sprayed black sometime...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_0914_zps3f7bded2.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_0914_zps3f7bded2.jpg.html)

Should the dent above the OS rear wheel be pulled/pushed out? It wouldn't need so much filler then.

The panel unfortunately was severely creased in from a side impact in it's past, that rippled it from just above the sill to just below the window. When it had a restoration and re-spray back probably 5-6 years ago now, the bodyshop said that was the best they could make it, having to fill what was left. I expect any further panel beating would probably distort the panel now, so will have to make do.
Having limited funds and time to do anything with the car, i've taken a slightly different approach to sorting out the bodywork with the cost of a respray etc; and have decided to be a bit bold and different ::)
The plan is to now rub down the offending micro-blistering, treating the minimal rust areas, giving everything generous coats of primer and then vinyl wrapping the car front to back in 4d carbon fibre myself with a few helping hands; looking at a max cost of around £150 hopefully.
Once the first batch of vinyl turned up I dug the fibreglass wings out, which had generally held out well, had to fill a few imperfections from manufacture but were ready to go after an hours work...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1557_zps575c1c10.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1557_zps575c1c10.jpg.html)
Starting with the nearside front wing, I gave it ago at wrapping it all in one piece, which was an interesting challenge! Looking at the shape of the panels, this is probably the worst to start with having to negotiate wrapping it around the wheel arch and the front of the panel bearing in mind it all started off as just a rectangle of vinyl.
I'm generally happy with the first attempt, i'm not going to pretend its an immaculate job, but you would need to look for the slight imperfections which aren't noticeable from a distance nor a photograph. This is the first panel wrapped...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1652_zpsa45e7063.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1652_zpsa45e7063.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1653_zpsd85fecc0.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1653_zpsd85fecc0.jpg.html)
Bearing in mind the original wings are still on, this will give you an idea of the colour change and how it should eventually look...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1656_zpsff77c48f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1656_zpsff77c48f.jpg.html)       (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1655_zps644df086.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1655_zps644df086.jpg.html)
For the offside wing i've done it slightly differently to make it ultimately easier to do and to prevent little imperfections, so that the finish is smooth but at the cost of overlapping pieces. Overall it doesn't look too bad but might go back to it at a later date once i've got a bit more practice in...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1666_zps9a23926a.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1666_zps9a23926a.jpg.html)     (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1662_zps61b917dd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1662_zps61b917dd.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1663_zps4908de41.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1663_zps4908de41.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_1664_zps0e23b8e6.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_1664_zps0e23b8e6.jpg.html)

I think the plan for the doors and side panels will be to over lap pieces underneath the lines of the car matching the weave of the pattern as best as possible if it's not possible to get a good finish as one whole piece on the panel as I did with the first wing. Big areas such as the roof and bonnet will be covered as one piece.

Once the car is covered I might highlight certain parts of the car such as the window frames, around the bonnet pins, possibly even the mirrors, handles and grille in a slightly lighter silver 3d carbon fibre look. The idea is for it to stand out without looking tacky and if it should be parked in the local fast food outlet most weekends, but were see how it goes! ;)

Next step, choosing the best of the earlier type front valances I have and getting it prepared for the next load of vinyl :)

Time seems to fly these days :-\ a change of shared track car, daily runner, not enough time, money and the usual excuses, there's not much to report on the car since being parked up.
Bodywork issues and decisions aside, i'm hoping to spend some time continuing on the long term ambition of getting my budget throttle body setup all together and on the car in the not too distant future, famous last words.
I have a lot of the parts bought, it's just going to be the fitment and setup side which is going to take some time I feel.
One of the parts i'm yet to purchase is an O2 / lambda sensor, which of course is going to need to be fitted to the exhaust system at some point, so this is my next little project towards the overall aim.
I had an Ansa manifold fitted a little while back, but at the time, with the norfolk betameeta upon me and the car needing to get through the mot, I had to put the original manifold and downpipe back on as the Ansa was blowing. With it all wrapped in heat wrap I couldn't tell how bad it was and it's been in the shed and not looked at until today.
It didn't sound or feel great with what felt like a lot of crunches and flakes of paint trapped in the wrap, so it was time to get unwrapping the heat wrap that didn't look too great anymore and see how bad it is...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6392_zpsac75716f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6392_zpsac75716f.jpg.html)
Having given it a good rub off all over, it turns out to be in a lot better condition than feared and still has many more miles in it yet...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6396_zps5b293f6f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6396_zps5b293f6f.jpg.html)  (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6393_zps0dfeee8a.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6393_zps0dfeee8a.jpg.html)
The offending blowing is from a crack along the weld, thankfully in an easy place to repair...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6394_zps5c0705dd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6394_zps5c0705dd.jpg.html)
and a closer look...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6395_zps634a6c24.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6395_zps634a6c24.jpg.html)
Plan for the manifold is to weld the crack up, give it a thorough sand over and drill a hole to weld a boss in place for the lamda sensor. This is probably going to be fitted just before where the middle section joins the manifold, where it goes from 2 into 1.
I'm going to use the exhaust manifold gasket to do a bit of work to the ports and see if I can remove a bit of material with the dremmel, and then give it a thorough covering of heat resistant exhaust paint to smarten it all up.
Once that's all done it'll be re-wrapped in new heat wrap and metal ties and be in fit shape to go back onto the car... eventually!

Had a couple of hours spare this weekend to get to work on the exhaust manifold. Firstly drilling a hole for the lambda/o2 sensor and trial fitting the bung to be welded in place...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4081_zpsf54d4f06.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4081_zpsf54d4f06.jpg.html)(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4083_zps0013321d.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4083_zps0013321d.jpg.html)
Managed to dig out the welder and get zapping, haven't done welding for a while so reasonably happy with the results and should be fit for purpose. Crack and boss welded up...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6398_zps81cc3a70.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6398_zps81cc3a70.jpg.html)(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6399_zps9bc35a82.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6399_zps9bc35a82.jpg.html)
Manifold now in a useable condition...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6397_zps7826b600.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6397_zps7826b600.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6400_zps705fac02.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6400_zps705fac02.jpg.html)
Next step, give it a good rub down, covering of heat resistant paint and a re-covering of heat wrap.

Why are you going to paint it then wrap it?

The heat wrap doesn't prevent corrosion. The paint will to a certain extent

that makes sense although i don't imagine that there will be much moisture building up on the outside of the pipe even with the wrap. its got its own dryer.....the corrosion generally comes from  within on exhausts but I've never had problems with the downpipes before? they run so hot they just dry out when you park up?

Exactly that Stuart, the paint is purely to protect the exhaust a little from the elements and dreaded rust, I also personally think it looks nicer although it's pretty much hidden in the engine bay anyway.
The main reason for wrapping it as well, is not particularly for the benefits if any for performance but to try and contain the heat the manifold is producing, as I don't particularly want to change the steering rack gaiters every year.

Have you considered fitting louvres into the bonnet to drag some of the heat out from under there? I fitted four to the saab 99 turbo I had at strategic positions in the bonnet to remove heat build up and drag cool air in too. Cheap fix if you are tuning the motor. I think the worry of fire on the wrapping when it gets oil soaked is too big a downside?

I also wrapped the exhaust manifold in my car and can confirm it does work very well. It certainly lowered the temperature under the bonnet and should allow the gaiters work longer ;)
However I am afraid if this not impact the lifetime of the genuine manifold itself due to increased temperature of the cast iron made element.

hope this pic links?
(http://i306.photobucket.com/albums/nn280/smartski_photos/DSCF2866.jpg) (http://s306.photobucket.com/user/smartski_photos/media/DSCF2866.jpg.html)
(http://i306.photobucket.com/albums/nn280/smartski_photos/DSCF2869.jpg) (http://s306.photobucket.com/user/smartski_photos/media/DSCF2869.jpg.html)
(http://i306.photobucket.com/albums/nn280/smartski_photos/DSCF2880.jpg) (http://s306.photobucket.com/user/smartski_photos/media/DSCF2880.jpg.html)

The problem as I see it on the Beta is that the hot exhaust is at the very back of the engine bay, and with the engine canted over towards the back, makes getting a decent vent of hot air out the bonnet much more difficult, though when you are not moving, would be useful I would guess?

Peter

i also used four inch ducting to feed cool air into the engine bay under a ram effect from a duct in the front spoiler. the vents kept the motor cool when in traffic as you could see the heat haze leaving the car and the two at the front of the bonnet fed cool air in when at speed . combined with the front air scoop and piping it worked really well. standard rad set up was fine. its all a question of effort and cost i guess? easy enough to fit an extractor fan set up in the engine bay to suck or blow the air out too but hot air rises makes louvres the obvious mk 1 unbreakable solution.
never been a fan of heat wrap.

It tends to be radiant heat that's the problem with tubular manifolds in the Beta.

The primary and secondary pipes run very clode to the rack, fuel lines, brake lines and speedo cable.

Wrap isn't ideal but it's the best way of safegaurding them.

Even with wrap I had underseal melting and drippin off the underside of mine when I first put the manifold on.

thats practically a design fault then?

a nice black 900 on the left  8)

I think so. E.g. poor shielding and location

sold all three and bought a porsche 911
(http://i306.photobucket.com/albums/nn280/smartski_photos/SANY0038.jpg) (http://s306.photobucket.com/user/smartski_photos/media/SANY0038.jpg.html)
(http://i306.photobucket.com/albums/nn280/smartski_photos/SANY0027.jpg) (http://s306.photobucket.com/user/smartski_photos/media/SANY0027.jpg.html)
this one
(http://i306.photobucket.com/albums/nn280/smartski_photos/IMG_0798.jpg) (http://s306.photobucket.com/user/smartski_photos/media/IMG_0798.jpg.html)
traded in six months ago a convertible 911.......had 200 cars plus in my time-32 years driving- and I'm showing no sign of slowing down. the HPE and the saab c900 have many similarities in many ways. both practical hatches with a sporty bite. its why I'm currently looking for a vx HPE in good nick to add to the fleet.

Really tidy work on the grooves in the bonnet of the white saab, doesn't look out of place at all. Under bonnet temperatures have not really been an issue for me, the wrap is mostly for protecting the rubber gaiters for the rack that are rather close when the manifold is in place.
Having given it a good clean over it got a couple of generous coatings of heat resistant paint...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4090_zps76cc0df4.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4090_zps76cc0df4.jpg.html)
Freshly wrapped with heat wrap...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4148_zps7d57bba7.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4148_zps7d57bba7.jpg.html)
Then fitment was a joy as ever, having already put it on once and taken off again you would have thought it would be easy, but was still as awkward as ever to get on, just about managed to get it on with the anti roll bar disconnected both sides and the car lifted up as far up as I could, but eventually it went on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4180_zps6ac1b604.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4180_zps6ac1b604.jpg.html)
Been making a bit of progress with the throttle boddies project recently, and started by removing all of the original bosch injection system and intake manifold...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4138_zps3723a7ff.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4138_zps3723a7ff.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4144_zps4241a4fa.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4144_zps4241a4fa.jpg.html)
Couldn't help but mock up the replacement manifold and see what issues are yet to come...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4152_zpsd314467c.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4152_zpsd314467c.jpg.html)
Firstly trying to get it all in from engine to trumpet, i've managed to move the radiator forward a couple of inches, and have options to either fit the fans on the front of the radiator or cut the hoses down a few inches to give more clearance from the fans and allow enough room for an air box to be fitted...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4157_zps650a68cc.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4157_zps650a68cc.jpg.html)
What I thought was going to be a potential problem, turned out to be an easy fix. The dipstick tubing was fouling on the new setup but with a slight bending it now clears and the dipstick still pushes down smoothly...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4146_zps517d407f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4146_zps517d407f.jpg.html)
Having a quick look at throttle cabling, the original might be able to be used with some slight modification to the fixing of the cable...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4154_zps7146aae8.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4154_zps7146aae8.jpg.html)
With the suzuki boddies already fitted with a TPS, I was keen to make use of it rather than having to make one fit the linkage and have to make a bracket for it, so have managed to cut down a three pin connector to fit the pins...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4165_zps89a59163.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4165_zps89a59163.jpg.html)
With the new setup, it requires a crank sensor and trigger wheel so with this the crank pulley had to be removed, and is being replacing with an alloy one with trigger wheel fitted to the back of it...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4167_zps109228e5.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4167_zps109228e5.jpg.html)(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4169_zps8d01e265.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4169_zps8d01e265.jpg.html)
Old and new...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4171_zps8762f414.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4171_zps8762f414.jpg.html)
Crank pulley, sensor and bracket now in place, just the small matter of the alternator belt fouling on the bracket and sensor at the moment, see... http://www.betaboyz.myzen.co.uk/forum/index.php?topic=2756.msg18139#msg18139 (http://www.betaboyz.myzen.co.uk/forum/index.php?topic=2756.msg18139#msg18139) hopefully once this reasonably major issue is resolved, things should come along nicely :)

Looking good chap - just be very careful about the relative positions of the crank position sensor and the missing tooth on the triggerwheel.  I had made the assumption that it was supplied correctly placed, and then wondered why I had problems getting her to run.  I had to have the wheel repositioned.

Cheers

Darren

nice crocks :)
911 is also mine cup of tea, and actually has some design similarities to 900s
good taste and great collection  8)

Looks impressive, but don't you think that in a such arrangement your engine will suck hot (and thin) air just from the radiator?

My thought as well. Check out the rally Betas engine which ran twin twin chokes, they had angled inlets. They also increased the angle of the engine from the vertical, but would guess that is a non starter for you due to exhaust manifold.

Guess you could also run some form of plenum chamber as well, but it makes it complicated.

Peter

An airbox is the simple solution. Custom rad (ie low and wide) is another albeit more expensive one.

On mine I had also thought about some ductwork  - but I'm concerned it might limit the airflow through the radiator.

if you put the ducts low in the chin spoiler they will not effect airflow over the cooling rad?

It's something I will have to re-check before I finalize everything and make sure everything is tight again, I think the EDIS works with the missing tooth being 90 degrees (9 teeth) in advance of the sensor ??? Sensor pointing at the 9th tooth with the engine set at TDC.
Spent a bit of time on it today, and most importantly look to have just solved the issues with the alternator belt fouling on brackets etc... http://www.betaboyz.myzen.co.uk/forum/index.php?topic=2756.msg18164;topicseen#msg18164 (http://www.betaboyz.myzen.co.uk/forum/index.php?topic=2756.msg18164;topicseen#msg18164)
Inlet manifold, Fuel rail and injector wiring now on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4207_zpsbf60df3f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4207_zpsbf60df3f.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4208_zps48871654.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4208_zps48871654.jpg.html)
Pipe work that ran to and from the inlet manifold is no longer needed, so the smaller pipe from the back water rail now goes straight to the T piece for the heater matrix/head...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4209_zps0b942db5.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4209_zps0b942db5.jpg.html)
New wiring loom to go in, have thread it through the bulkhead into the engine bay so far, will look forward to wiring it all up as one of the last things to do...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4210_zpsfaadeefd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4210_zpsfaadeefd.jpg.html)
Last thing I managed to get done was a bracket for the EDIS module and Coil which is connected to upper water rail using the mounting point originally for the auxillary air device...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4212_zps89eb1a77.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4212_zps89eb1a77.jpg.html)
Waiting on a package from the US, some odd bits and pieces and then next job will be making a bracket for the new fusebox and relays.
The plan is to make or buy an air box, which will let me fit the intake air temp sensor in and also allow a feed of cold air which will be ducted to an air filter with the nearside main beam removed or ducting from the front valance up towards the filter.

That's exactly what I did. It works well but the rolling road suggested it was slightly restrictive. This might be my design or it might just be inherent in having a box.
Hence why I'm thinking of ducting cold air from above the rad to sock type filters over the trumpets. It's not urgent as I've plenty of power but you can always have a bit more....

Stuart

Do NOT go for socks on trumpets it will reduce your power and if you draw in hot air potentially cause detonation on your existing calibration. There is also increased fire risk and sometimes they get sucked in causing lots of damage. Increase inlet pipe size to the air box e.g. 76mm and ensure there is a stand off from the trumpet mouth to the facing wall of the air box of at least the choke diameter of the throttle bodies. Try to bring the walls surrounding the trumpets to at least half the TB internal diameter. You might want to taper down the airbox from the inlet and this is often done to help even flow with side entry air feeds.

You know why I know this stuff. I just want to prevent you wasting time and money.

EW   

Eric,


The work is cheap enough to do but the main incentive is not destroying the engine so I appreciate the suggestions.

I'll be running wide band lambda before I do anything on the intake so I'll be able to see what effect the changes have on mixture via the Emerld logging system. I'll probaly run closed loop eventually.

The intake is 76mm with a decent cone filter on the end in a cold air area. The trumpets are 48mm and the airbox 90mm deep (I think-  I'll check). The airbox walls are over 25mm from the trumpets. All this suggets the design should work.

On the rolloing road taking the lid off the airbox liberated 6bhp and made the mixture go lean (it could have taken about 7% more fuel) so it's obviously a restriction - the question is where ?

It looks like with my setup as it is, my only option is going to be using an air box with an inlet behind the n/s main beam, as the trumpets are only a few inches away from the rad as well as being smack bang in the middle.
Managed to get pretty much everything mocked up now, as far as I know all the wiring is now connected, once I have it running I can make a start on tidying all the wiring, soldering a lot of wiring to remove a lot of the crimp connectors and a general clean up once i've decided on some bracketry and how to go about mounting an air box...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4267_zps4d69f803.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4267_zps4d69f803.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4268_zpsa2893969.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4268_zpsa2893969.jpg.html)
New fusebox for the Megasquirt / Edis setup now features 5 relays, to take control of the ECU, fuel, ignition, starter motor and cooling fans. With it all being switched through the relays, the original ignition switch should have a lot less current running through it...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4237_zps0c5e951d.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4237_zps0c5e951d.jpg.html)
Lambda/O2 sensor now fitted, i'm using the Innovate LC-2 Wideband Controller which has an air/fuel ratio gauge which I hope will fit quite neatly in the gap for the radio along with two other gauges...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4269_zps86c6b16b.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4269_zps86c6b16b.jpg.html)
I've managed to plug in the laptop and have a little play with the functions for megatune and tunerstudio. So far I have managed to get a few readings working for various sensors, such as lambda, tps, coolant, air temp etc which is an encouraging start. However what i've found out is that because I will be running the Ford EDIS ignition system, the current ECU will either need to be upgraded to support this or I will end up selling mine to fund an improved replacement. With christmas soon upon us and lots of businesses closing down up until new year, it looks like it maybe some time until I can get the ECU modified and have a go at getting it running. :-\
Darren is/has run a very similar setup to what i'm trying to achieve and has kindly sent me his map, so i'm hoping that apart from the ECU issue it won't take too much fiddling to have it running, famous last words.

ECU was sent off to be upgraded and now back with me :) Hoping to have everything mocked up, plugged in and make a start on setting up a map to run it soon / find out why it won't ::)
While the ECU was away, I thought I better investigate the condition of the inner wing as signs were starting to show in the engine bay, which i'm sure would have been picked up on the MOT. Look to have caught most of it in time, from strut top back is mainly surface rust, from strut top down towards the lights turned out to be more sealant and paint holding the arch together than metal...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4301_zps7df83850.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4301_zps7df83850.jpg.html)
Still a few more things to do on it, but mainly there...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4312_zps3efe257f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4312_zps3efe257f.jpg.html)
The gauges arrived for water temp and oil pressure, so decided to fit these along with the air/fuel ratio gauge. Luckily the original radio blank is just wide enough...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4286_zps29b9febe.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4286_zps29b9febe.jpg.html)
I've got to connect up the signal wires yet but all seems well...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4291_zpsab5db080.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4291_zpsab5db080.jpg.html)(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4292_zps1cdfa9e0.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4292_zps1cdfa9e0.jpg.html)

It's all coming together nicely!  Look forward to hearing that it's running, and then the fun really starts!!

Cheers

Darren

Slowly but surely it's getting there :) So many small, time consuming jobs to do all the time but hoping that the fun isn't too far away now.
Repairs to the inner front wing now complete, just a bit of painting to do in the engine bay and it should look reasonably tidy...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4329_zps2ab4ebbd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4329_zps2ab4ebbd.jpg.html)
Last week I had a go at connecting everything up and see where I was with the Throttle Bodies install, according to megasquirt all was well apart from the coils not firing. It seems that the hall effect sensor I had as the crank sensor isn't compatible with running the EDIS ignition, so it was back to the drawing board. I've bought a VR sensor which is pretty generic to replace it; the one I bought just happens to cover a lot of the Fiat range.
I'm still contemplating on how i'm going to resolve the crank position sensor placement / re-routing of alternator belt, but managed to mock up some brackets well enough to allow me to fit and test the new sensor.
Holding out hope I connected up the new sensor, turned it over and still no spark. :-\ Thankfully it was just a case of switching the wiring around and the coil came to life and sparked on cranking.
I'm pleased to say, she's alive! ;D
https://www.youtube.com/watch?v=I1B1ofbegmk&feature=youtu.be (https://www.youtube.com/watch?v=I1B1ofbegmk&feature=youtu.be)
I'm sure there is plenty of work to be done and problems to overcome before it's fit for the road, but it's nice to know that all the wiring seems good and it does run, if quite roughly at the moment. The very brief time I had it running, there seems to be a lot deformation to the hoses under vacuum for in particular 2 & 4 for some reason ??? I managed to have a quick look at the laptop, and the only concern seems to be that according to megasquirt it was running at an ignition advance of 28 degree's. Will have to do my research into setting up the EDIS setup as this seems way off...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4334_zps8248a012.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4334_zps8248a012.jpg.html)

Well done matey, a very large hurdle cleared!!! 👍👍

Check the relative positions of TDC, the crank sensor and the missing tooth on the triggerwheel to be absolutely certainly that they're all EXACTLY correct to one another.  Check the spark map too to confirm that the advance should be a lot less at Tickover before you do anything else.

Seeing the pulses in the ITB connecting tubes is normal as you're not using solid.  Mine pulse too and it's not a problem.

Keep the updates coming!

Cheers

Darren

Well not quite the progress I wanted, but nothing normally goes to plan nor anywhere near the predicted time schedule. A few things that i've done over the months to keep things updated. Hopefully i'll get more time soon to push through some of the smaller but most time consuming jobs, and get it closer to being road worthy once again ::) :o
Additional oil pressure sender with union and pipework...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4417_zps17507441.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4417_zps17507441.jpg.html)
Trying to see a simple way of clearing the crank position sensor, with it mounted in the original designated place for the trigger wheel, I mocked up some bracketry and idler...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4474_zps94e36ff8.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4474_zps94e36ff8.jpg.html)
I wasn't too happy with the added strain on the belt and the offset that was caused by having to have the alternator slightly out of line, and after a re-think, managed to fit the sensor between the alternator belt and power steering belt, and redrilling and attaching the trigger wheel to match up with the sensor at tdc...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4874_zpss1ny1r6v.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4874_zpss1ny1r6v.jpg.html)
Brakes, wishbone, ball joint and anti-roll bar reconnected...
(http://i135.photobucket.com/albums/q152/lanciamad_album/20150721_182024%202_zpscmajhoev.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/20150721_182024%202_zpscmajhoev.jpg.html)
The lambda/o2 sensor wiring held in place by clips...
(http://i135.photobucket.com/albums/q152/lanciamad_album/20150721_181959%202_zpswizlxpmm.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/20150721_181959%202_zpswizlxpmm.jpg.html)
Wheels go back on after too many months :-\, I think they suit the car quite well and couldn't resist a pic before it went back onto the ground...
(http://i135.photobucket.com/albums/q152/lanciamad_album/20150721_192825%202_zpsrs3obx78.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/20150721_192825%202_zpsrs3obx78.jpg.html)
Having got it back onto it's wheels again, I managed to set it with a rough fast idle to move the car about enough that I could get the rear end lifted for a change. I bought the straight through middle section for the HPE from Mark many months ago, and decided it had to go on even though the list of things to do is still never ending. New next to old, it feels like it weighs half the weight of the original...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4877_zpsljwqfojz.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4877_zpsljwqfojz.jpg.html)
Took some persuading but now fitted, ansa 4-2-1 manifold straight through to the standard rear silencer...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4879_zpshnx9oaty.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4879_zpshnx9oaty.jpg.html)
A couple of video's of it running at idle and fast idle, still a lot of learning and mapping needed before it hits the road but doesn't sound too overly loud and sounds quite raspy, I still think the throttle bodies will be making the most noise when at full chat...
https://www.youtube.com/watch?v=Qv_ZjyxGbZQ (https://www.youtube.com/watch?v=Qv_ZjyxGbZQ) https://www.youtube.com/watch?v=GAvnDwJvhQI (https://www.youtube.com/watch?v=GAvnDwJvhQI) https://www.youtube.com/watch?v=UClJajyQRSM (https://www.youtube.com/watch?v=UClJajyQRSM)
Hoping to have more to update on over the next few weeks rather than months. Next step, plan a revised list of jobs that need to be done, it could be quite a list :D

Marcus

Great progress but I think you will fail Goodwood noise testing and probably Castle Combe so start planning a straight through silencer where the 2nd box went and a clamp on tail silencer (Merlin do them). I am looking forward to seeing this car back to the track.

Cheers

Eric

That's an ingenious solution on the crank pickup but won't the movement of the engine relative to the subframe cause problems? Or is your engine solidly mounted?

Eric, i'd imagine your quite right, if decibel apps are anything to go by it's around 90db at idle! :o :D I however don't plan to track the car for at least a year, so no need to worry about noise levels until then. I think a full year will be needed for niggles, future upgrades and changes that I can iron out by having it back on the road.
Stuart, it's very much going to be trial and error, I have thought the same. So far so good, but the engine hasn't been put under great load yet, so i'm unsure of the maximum potential for movement. It's been a right pain, as from what I can see it's the only place that the sensor will fit and not effect the belts as originally intended. There doesn't appear to be anywhere other than where i've mounted it to fix the bracketry, so if the movement does become an issue, I don't know whether to upgrade the mountings to the PU items to minimize the movement or think about welding the bracket to the side of the sump pan possibly.
Been doing a few odd jobs recently, lots of wiring needed soldering, routing and fitted out of the way...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4935_zpsytkupsp1.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4935_zpsytkupsp1.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4936_zps8optnikj.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4936_zps8optnikj.jpg.html)
The original lights were starting to show there age and the chrome retaining rings had seen better days, so some new replacements fitted...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4920_zps1npeg1zf.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4920_zps1npeg1zf.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4919_zpsveelkknb.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4919_zpsveelkknb.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4921_zpsgqagjphv.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4921_zpsgqagjphv.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4923_zpscuziofhg.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4923_zpscuziofhg.jpg.html)
Using some sock type filters for the time being, but will be soon ditching these for an air box with cold air feeds to either side if possible, being fed from the valance...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4940_zpsdzgm4l5e.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4940_zpsdzgm4l5e.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5031_zpsvynjn13n.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5031_zpsvynjn13n.jpg.html)
Not sure what it was orignally designed for, but I bought a strut brace a while back on the cheap which I intended to adapt to fit to the front; hour or so with the grinder, a drill and a spray can didn't turn out too badly...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_4993_zps1jfloso3.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_4993_zps1jfloso3.jpg.html)
Treated myself to some new caps and a general degrease of the engine bay...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5016_zpsym2fikbq.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5016_zpsym2fikbq.jpg.html)
Couple of other little jobs, replaced the wiper motor, fitted aero style wipers, got the horn to work with the dished OMP steering wheel, tidied the wiring inside and gave the inside a good wipe over...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5019_zpsyfmkazpt.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5019_zpsyfmkazpt.jpg.html)
Got a few things to check over and tidy up, but apart from that hope to have some guys give it the once over and look at getting it mapped to somewhere sensible in the next week or so. Once that hurdles cleared, a big hurdle. I can look at getting it through an MOT; it's going to need a bit of attention to the nearside rear sill and the front cross member, but hopeful for not too long a list after that. When I get there........ :-\

Like the strut brace design, only issue is I cannot see how you adjust it, so cannot tension it. Was it the correct size as bought or was there some cutting and shutting required?

Peter

Don't some tracks have DB limits? Or is that just Goodwood?

All tracks normally have a limit of around 98-102db at 3/4 max revs around a metre from the tailpipe, i'm yet to measure what it currently is with the single box system, but as i'm going to only use it on the road this coming year, it's not something I need to consider and I can always refit the original middle section or adapt the straight through pipe as Eric's mentioned. I'm quite surprised at how quiet it is considering, it's only above 3000rpm where it gets quite raspy.
It was a cheap punt from ebay really, it just happened that the main tube was of the correct length that I just needed to cut and re-drill the mounting plates to fit the strut tops; I purposely made it so it was only just possible to fit the two bolts, once tightened everything becomes under tension, it was a nightmare to get off again!
Amazing how the time goes, over two months later but I have been busy behind the lack of updates, so be prepared for a photo overload coming up ;D.

Since the last update, I finished off sorting out the wiring loom, routed various wiring and pipework and got it to a stage of being able to drive itself. Next step the rolling road; booked in as a rolling road session plus modifications required as problems were found, it was off to the tuners with the help of a trailer. Before they started any mapping, they found that the relatively poor running was due to a failing injector and with the plugs now 3 years old with little mileage, a precautionary change would be a good idea before torturing the engine. Luckily I had a spare fuel rail in the shed so the next day further investigations could be made after the injector was replaced and the plugs changed.
The good thing was the guys were relatively impressed everything was in place for such a custom build, but anyone will say that when your paying them money ;), the few modifications they made were as follows...
The inlet manifold originally was letting air in as the hoses didn't have much material to be clamped to, so some extentions were welded on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5156_zpsevftbfvx.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5156_zpsevftbfvx.jpg.html)
The linkage was adapted so the bodies could be adjusted independently of each other...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5159_zpsjpgyjjfg.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5159_zpsjpgyjjfg.jpg.html)
Trumpets held in place by reducer hose and clips...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5157_zpst2nv2zxt.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5157_zpst2nv2zxt.jpg.html)
And the big one, that crank position sensor! On first investigation it appeared that the original sensor placement was doing the job but with further runs and checks it was pulling away from the sensor when under load. So with a rethink, a bracket was made that meant the sensor was in basically the same place but utilized two bolts that hold the sump on, in which the sensor and trigger wheel will always keep the same gap...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5209_zpsbhvmcog7.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5209_zpsbhvmcog7.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5214_zpsecuoobbo.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5214_zpsecuoobbo.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5216_zpspotrqmop.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5216_zpspotrqmop.jpg.html)
Final result, mixed emotions really, it would have been nice to think a gain of 20+ bhp was on the cards, but as I got to the latter stages of the build it was more the relief that the project had actually worked and i'd got it working rather than what bhp it was going to produce. Here's the final run...
(http://i135.photobucket.com/albums/q152/lanciamad_album/494379e2-6985-42ab-856e-e69569df1834_zps6edocngo.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/494379e2-6985-42ab-856e-e69569df1834_zps6edocngo.jpg.html)
For comparison, the same place rolling road it in 2010 running the standard equipment producing 108bhp @ 5400rpm and 127ftlb @ 2500rpm, it's currently running at 114bhp @ 6100rpm and 110ftlb @ 4600rpm. The drop in torque i'm not quite sure about, they suggested that the engine timing maybe slightly out and it didn't seem as though it was flowing quite as well as they'd expect. The potential for bhp will only hopefully double with any future engine modifications, and think the setup is begging to be on a big valve high compression engine really. Although i'm not sure of why the drop in torque yet, it's still a 6bhp gain on the standard engine and the map shows that where previously the max torque was at 2500rpm and dropped off slowly it now actually starts from 2500rpm and actually gains all the way to 4600rpm where it slowly drops off; i've only driven it a few miles but it's noticeable and it really does seem to pull like a train.
 

Having got it up and running, and now mapped running the bike throttle bodies, my attention turned to jobs that would have to be done for the MOT. Without looking too hard, the nearside sill had deteriorated quite badly in the 3 years since I last had to have a look at it, and I decided to give it ago at repairing myself. I don't claim to be a professional welder nor bodywork expert, but considering i'd done very little of both and can't afford to spend mega money on the car after the latest project i'm reasonably pleased with how the repairs went, even if I have to revisit somethings in the future, like replacing the whole sill, sections or panels that Mark is now making available in the future. Something I do plan to do once i've got bored of bolting things on and run out of modifications I can afford ::)
That scary moment when grinder hits the paint...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5095_zpsn4pkshjd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5095_zpsn4pkshjd.jpg.html)
Found that the usual area for rusting at the top of the outer sill by the door shut was covered up with fibreglass and filler last time around...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5092_zps6zyvxrep.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5092_zps6zyvxrep.jpg.html)
Inner sill, thankfully caught in time, before and after...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5097_zpsqsqnsrwx.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5097_zpsqsqnsrwx.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5102_zpsi9jjxlvw.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5102_zpsi9jjxlvw.jpg.html)
Outer sill bent to shape as close as I could make it...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5110_zpsdevgdowm.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5110_zpsdevgdowm.jpg.html)
Finding some metal...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5112_zpssu0v1s2a.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5112_zpssu0v1s2a.jpg.html)
and filled in with metal this time...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5130_zpszrqylmmw.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5130_zpszrqylmmw.jpg.html)
Chasing the rust going up the rear arch, it took nearly 1cm thick of filler to discover metal which in the end was mostly rust anyway...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5132_zpsmvmwj02j.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5132_zpsmvmwj02j.jpg.html)
More grinding...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5136_zpsupior5et.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5136_zpsupior5et.jpg.html)
This has so far been the best example on my car of the famous rusting from the inside out...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5134_zpsx934igjq.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5134_zpsx934igjq.jpg.html)
Yet another repair section...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5140_zpsalphweej.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5140_zpsalphweej.jpg.html)
Filling in the imperfections...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5148_zpssqj6dj8i.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5148_zpssqj6dj8i.jpg.html)
and nearly there...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5183_zpsc008l8ni.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5183_zpsc008l8ni.jpg.html)
Due to accident damage a massive amount of filler was used on the offside rear panel which eventually cracked and then came off as one, i've tried filling it mostly with fibreglass this time to see if it will bond more successfully...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5149_zpsif5ngyjz.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5149_zpsif5ngyjz.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5184_zpsm9lccsac.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5184_zpsm9lccsac.jpg.html)
Having a break from the bodywork, i've fitted an oil catch tank with site glass to replace the previous setup of having the original pipe venting via a filter over the engine, covering everything in a very fine mist of oil vapor, with it now going to the catch tank near the rad, so far so good...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5175_zpsdlqforsx.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5175_zpsdlqforsx.jpg.html)

With the sill now complete and the only thing I knew needing attention being the front cross member, I took the car for it's MOT. Luckily I get on with him well and he said he'd give it a once over before putting it through the system and let me know of anything major before he went through it thoroughly. It had previously had to have a plate welded on the cross member before and without the use of a ramp wasn't something I fancied doing myself. Having paid little attention to it as I knew I wouldn't being doing the work, I turned up at the garage hopeful there's not much needed, to be told it's worse than first thought, he'd seen a crack in it and the state of it, wasn't worth attempting patching. With them not being able to fit it in for weeks and it would need pretty much everything removing including subframe, engine etc I brought it home and decided to start stripping the car and see how far I'd go with it.
This is the crack that he claimed, but to be honest the way it seems to be connected, by about 6 spot welds on three tabs as I found out, suggests that this is how it is and the sealant gives the impression it's seem welded...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5206_zpspggcqati.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5206_zpspggcqati.jpg.html)
Front of the car taken off...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5202_zps8wi4vpia.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5202_zps8wi4vpia.jpg.html)
That messy patching repair previously done for an mot a while back...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5203_zpsihtocoef.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5203_zpsihtocoef.jpg.html)
I worked out that what was once feared that I would have to drop everything out and strip the engine bay completely, i'd be able to get away with supporting the car, subframe, and engine independently and be able to cut out the offending section, which I did...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5230_zpsuyn0g1pl.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5230_zpsuyn0g1pl.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5233_zps8zzvpcnp.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5233_zps8zzvpcnp.jpg.html)
Once off it was clear that it was on it's last legs...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5234_zpsdxkwutvf.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5234_zpsdxkwutvf.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5235_zpsvdxisj8x.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5235_zpsvdxisj8x.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5236_zpsyeizacez.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5236_zpsyeizacez.jpg.html)
The only good news if there was any, was that i'd purchased almost by mistake getting on for nearly 10 years ago, a front cross member in decent condition and more amazingly managed to find it! Thankfully still in good condition, I got to work on removing any surface rust...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5225_zpsbwvamakh.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5225_zpsbwvamakh.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5226_zpsxycxc7ef.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5226_zpsxycxc7ef.jpg.html)
and then painting and preserving the replacement...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5238_zpsn4exizz3.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5238_zpsn4exizz3.jpg.html)
It appeared to me that the original seemed to be welded in 6 places via the three tabs, but with this replacement I hope it's on there for life now, seam welded all tabs and wherever possible, I also welded an additional plate either end for added strength...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5241_zpsphithzx2.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5241_zpsphithzx2.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5242_zpsmdvf7hcc.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5242_zpsmdvf7hcc.jpg.html)
Replacement fitted, it was a relief that everything went to plan and everything fitted perfectly...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5247_zpslelumdu9.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5247_zpslelumdu9.jpg.html)
Having thought I could put the welder away, the hole in the floor where the rubber bung fits gave way, so thought I better do something about it...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5254_zpsjqopolik.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5254_zpsjqopolik.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5310_zpstoq6f04w.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5310_zpstoq6f04w.jpg.html)
and then thinking that was that, a check over the suspension, I came across corrosion setting in on the rear strut...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5258_zpswturvnmx.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5258_zpswturvnmx.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5257_zpsfe6gn6zn.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5257_zpsfe6gn6zn.jpg.html)
Some grinding and repair work later, I could finally put the welder away...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5259_zps6srwm8ua.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5259_zps6srwm8ua.jpg.html)
Back to the MOT, everything got the thumbs up but for a rear wheel bearing needing replacing and yet another little patch under the jacking points each side, last friday comes along and 12 months on the road are mine :) I won't be taxing it until the beginning of December or possibly January, but it's nice to have got it through the MOT now lights limited and I can't wait to get behind the wheel again...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5278_zpshgv9zt10.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5278_zpshgv9zt10.jpg.html)
Things for the future, although the fibreglass wings are very good there's some slight imperfections to deal with so i'm slowly working through getting them ready...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5283_zpsaqsywua4.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5283_zpsaqsywua4.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5279_zpsfyqvmiez.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5279_zpsfyqvmiez.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5280_zpsulk82qo2.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5280_zpsulk82qo2.jpg.html)
Another reason for being broke, with the future in mind and bodywork to sort, all rust issues are resolved and a lot of weigh loss will be achieved by fitting fibreglass doors, these are for the coupe so I will have to modify the window frame to fit the HPE but really pleased with them, fitting all the door locks and hinges will be a challenge in itself i'm sure, but no plans immediately for them to go on...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5284_zps24z0r1yk.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5284_zps24z0r1yk.jpg.html)

(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5286_zpsew1kdaa7.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5286_zpsew1kdaa7.jpg.html)
and finally for now, with various welding repairs and general wear and tear over the years, a good clean out and repaint of the floor awaiting the arrival of some hopefully more comfortable bucket seats for those longer journeys and road driving I will hopefully experience in the coming year, I don't even think my back could take the potholes juddering through a seat with literally a piece of material separating your spine from springs...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5308_zps11jou23v.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5308_zps11jou23v.jpg.html)

More inspiring work- keep it going!

Makes my winter plans seem pretty minor!

Good luck.

Mark

Marcus

Well done.!!

Eric

Good effort Marcus!

Have followed this for a couple years now, but now Im must ask about your lower pulley with the timing wheel...

I think you mentioned that you purchased it from BetaBoyz?  I haven't seen it on the website, was it a special order item?  I need 2-3 of them myself for EFI projects that I have building up in my garage.

Does anyone else know a source for these?

thanks in advance

Nice, are they the doors from Belgium? are they good? want to get them myself.

I bought them from someone selling them on ebay, I believe from Belgium but it wasn't from Guy that runs the abarth museum over there. Pretty happy with them, a few imperfections and scratches to deal with but nothing a few hours filling and sanding won't sort, the least of my worries compared to the adjustments i'll have to make for them to fit the HPE  :)
If you mean the crankshaft pulley, then mine was bought from millers mule that incorporated the correct number of grooves for me to still run the power steering and had a 36-1 trigger wheel fitted.

Well a lot has happened since the MOT, but not with the car unfortunately, not taxing it until last month, the only mileage it's done since driving back from the garage has been around the block a few times and a 6 mile journey to it's new home where i've moved to, hence the lack of funds and time for the car. Certainly the best 6 miles i've driven for a while  ;D
As well as this, Buddy the labradoodle has also joined the household...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC06531_zpsheyzraa2.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/DSC06531_zpsheyzraa2.jpg.html)
As you can see, i've trained him well, already getting the bug to get his paws dirty...
(http://i135.photobucket.com/albums/q152/lanciamad_album/DSC06545_zpsxuqqxgys.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/DSC06545_zpsxuqqxgys.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/DSC06546_zpstkaz6dhd.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/DSC06546_zpstkaz6dhd.jpg.html)
The dished OMP steering wheel I had on it, started to disintegrate a bit so the latest change is now to a momo more flat style wheel with a chunkier feel...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6112_zpscbdwrwsw.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6112_zpscbdwrwsw.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6114_zps8cvhaxyb.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6114_zps8cvhaxyb.jpg.html)
The bucket seats i've had in it for a good few years are a bit tired and harsh on the back for road journey's especially as most shows are around the 2 hour mark, not that i've had chance to get to many :-\, so i've got these more padded style bucket road seats to try, but do plan on eventually investing in a full wrap around style bucket seat, but it's all ££££, this will do for now...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5314_zpsbtwxoha1.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5314_zpsbtwxoha1.jpg.html)
With moving into the house and Buddy around, i've still had the beta in the back of my head of what a mammoth amount of work needs and could be done on it, and conveniently with the new shed built (ideal spray booth), the collection of panels to go on the car at my parents place have slowly been coming over to be worked on and sprayed up. The pictures don't show the extent of the lacquer peel and dullness the paint has gone but this is what she looks like now...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6675_zpscaetgw1f.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6675_zpscaetgw1f.jpg.html)
With that in mind, and wanting to get back stuck into it, fibreglass is the way forward, the amount of weight saving overall i think will be quite considerable and to not worry about rust ever appearing again on almost half the car, i've made a start. I can't ever consider getting a proper spray job done in the next year or two, so for now have had a go myself, it's going to at least be an improvement if not an immaculate job, fibreglass wings....
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6619_zpsrh7samwb.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6619_zpsrh7samwb.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6620_zps16duw4ky.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6620_zps16duw4ky.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6641_zps0bamhgkk.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6641_zps0bamhgkk.jpg.html)
Front valance is of an earlier model and still made of steel...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6618_zpshoprrjee.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6618_zpshoprrjee.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6640_zpspk5fsvpm.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6640_zpspk5fsvpm.jpg.html)
Having decided to bite the bullet, I ordered a fibreglass bonnet from Guy in Belgium, it's been something i've always wanted to get for the car since I bought it 10 years ago :o and just seemed the right timing to do all this work together, so here it is as it arrived...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6575_zpsgey7tywa.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6575_zpsgey7tywa.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6576_zps3vps165i.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6576_zps3vps165i.jpg.html)
A few imperfections to sort and bit of extra bits and pieces to trim it turned out reasonably well...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6588_zpssrs86puj.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6588_zpssrs86puj.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6590_zpsqgcj0zak.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6590_zpsqgcj0zak.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6642_zpson1imqps.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6642_zpson1imqps.jpg.html)
Back into the collection of spares, I dug out a good condition bonnet trim and gave it a once over...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6632_zpsurrpyqcb.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6632_zpsurrpyqcb.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6634_zps6witc0oa.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6634_zps6witc0oa.jpg.html)
Having got the bonnet sprayed up, thoughts turned to how I wanted to attach it, with the current bonnet being attached by two bonnet pins and the original hinges, i've decided it would be better if the whole bonnet could be removed quickly and easily and thought i'd move away from the usual bonnet pins and go with 4 aerocatch's that the btcc cars use...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6612_zpsfb41nh8s.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6612_zpsfb41nh8s.jpg.html)
The moment you think, "should I be doing this"...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6676_zps68xww6h0.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6676_zps68xww6h0.jpg.html)
Too late  :o :P...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6679_zpscyyfdjho.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6679_zpscyyfdjho.jpg.html)
No regrets, really think the silver and black work well...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6691_zpsd5y0bna5.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6691_zpsd5y0bna5.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6692_zpsij1fh3dr.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6692_zpsij1fh3dr.jpg.html)
I've still got to weld up an area where one of the mounting points will be and look into what the bonnet or an aerocatch is fouling on to lower the bonnet nearest the windscreen so it sits flush but this is what it'll look like, probably the best pic to show the difference from new paint and old...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6695_zps58xtc8pk.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6695_zps58xtc8pk.jpg.html)
Plan is to also ditch the standard front sidelight/indicator units i've used since removing the bumper and I will run the sidelights inside the dipped beams and then have a single slightly smaller indicator unit mounted on the valance. With that in mind, I am also contemplating whether to see if I can adapt the front VX spoiler in some way, I presume it normally mounts and is shaped for the front bumper so lots of cutting will probably be required and not sure of what else may need blanking for it to look quite right, but I guess it'll be trial and error...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6670_zpsspr7rymq.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6670_zpsspr7rymq.jpg.html)
and finally, back in the day, hopefully this will happen again sometime soon... :)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_5500_zpsrah5hur6.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_5500_zpsrah5hur6.jpg.html)

Quite a bit of progress there. Your paint work looks fine on the photos.

Funny how the fibreglass bonnet is basically a replica of the original (which I guess was used to make the mold). Couldn't they have saved even more weight by using more basic bracing on the underside?

Marcus

Great work. I think you would be better with a chin spoiler via ebay than trying to mod the VX item unless you cut away the whole area that was behind the bumper.

Keep it coming.

Eric

Thanks Neil :), to be honest; I think for cost vs. appearance it's ok, i'm not one for show and shine and let's face it, it wouldn't get very far in a concourse competition! But the idea is purely to make it presentable again for a few years, it may need the odd touch up here and there, but i'd rather spend bits and pieces on other idea's than keeping it immaculate. It had a reasonable "restoration" getting on for probably 8 years ago, and with the paint issue a year after being done, and then the usual hot spots of rust showing through again, if I have to do a few area's every couple of years it will keep it tidy'ish (and me busy) :D As your see further down this post, i've done a bit more, and has probably come to around £150-£200 all in, so in comparison to a full respray job probably 10 times that i'm happy enough with it 8)
With the bonnet, I think it's negligible whether you could really make it much lighter with having enough strength to keep the outer skin from flexing anymore than it already does, but I was certainly surprised that they went to the effort of replicating an original to that degree


I think your right Eric, I see Mark is now selling a front spoiler that looks pretty good, but not sure whether I will be bothering yet, starting to like the front end as it is and the amount of sleeping policemen and kerbing about now, i'd probably spend more time fixing it back on than anything else :D

So onto the latest updates...

Bodywork. The replacement fibreglass wings I bought sometime ago are for the earlier cars, so it was off with the front end and on with the replacement early series valance and wings, lot's of little bit's and pieces to cut out to get the wings to fit but at a glance wouldn't tell much of a difference. Just finishing lining everything up, and thought i'd fit a stick on plate lower down out of the way of the radiator...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6860_zpssbkt5oc8.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6860_zpssbkt5oc8.jpg.html)

The original sidelight/indicator units taken out of the IE front bumper did the job but weren't particularly attractive nor slim fitting, so i've moved the sidelights into the dipped beam unit's and fitted round LED unit's to the front which had it's own implications...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6928_zpstmyzkztu.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6928_zpstmyzkztu.jpg.html)

Because the LED unit's as I soon found out, have a lot less resistance than a standard bulb the relay would flicker quickly as if a bulb had been blown, consequence of this, i've had to fit a resistor in line which has done the job...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6929_zpseyoy24lc.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6929_zpseyoy24lc.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6956_zpstlzgspn9.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6956_zpstlzgspn9.jpg.html)

Down the other end, I also replaced the rear number light unit's i've been using for LED, which showed up some resistance issues i've bypassed, more on that later...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7210_zps9inha786.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7210_zps9inha786.jpg.html)

Back up front. Just because you never know, and I never know if i'll be using it on track again I thought i'd fit a tow strap that tuck's nicely out of the way behind the valance and mounted to the subframe. The obvious choice is normally to have a red, maybe black tow sticker, but I thought i'd go with a subtle grey against the silver for now...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6981_zpsmelotwhf.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6981_zpsmelotwhf.jpg.html)

Some examples of the worst area's than needed attention before they got too out of hand...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6991_zps52hzzz3y.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6991_zps52hzzz3y.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6989_zpspyouxe4h.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6989_zpspyouxe4h.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7028_zpszvargpqs.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7028_zpszvargpqs.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7031_zpsjtaordx5.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7031_zpsjtaordx5.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7051_zpsaktnerc7.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7051_zpsaktnerc7.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7032_zpskkldmhs6.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7032_zpskkldmhs6.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7029_zps6padffei.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7029_zps6padffei.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7048_zpsp9uxihsp.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7048_zpsp9uxihsp.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7027_zpsz7xevpfa.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7027_zpsz7xevpfa.jpg.html)(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7052_zpss7klakot.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7052_zpss7klakot.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6992_zpskaqhouls.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6992_zpskaqhouls.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6990_zpsk6s6tryh.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6990_zpsk6s6tryh.jpg.html)

Onto thinking when would the brown holes end, I actually got a chance to start making it look pretty again (well try to)...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7011_zpsbamapiwm.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7011_zpsbamapiwm.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7050_zpsqrrisr3q.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7050_zpsqrrisr3q.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7017_zps86pwlzoc.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7017_zps86pwlzoc.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7060_zpshoq2xqg2.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7060_zpshoq2xqg2.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7061_zpsemg8fk2j.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7061_zpsemg8fk2j.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7019_zpsvr9w54oj.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7019_zpsvr9w54oj.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7116_zps4axtwaar.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7116_zps4axtwaar.jpg.html)
Was finding it hard to find a tailgate badge as the original had started to peel and fade, it's not concave like the original but the front badge of a delta/thema does just about fit and the pin locations are the same for fitting into the tailgate...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7112_zpsv9n8weod.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7112_zpsv9n8weod.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7117_zpsjcdt27zp.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7117_zpsjcdt27zp.jpg.html)
The bodywork side is pretty much done now, just the biggy of trying to get fibreglass doors to fit and work :-\ :) then hopefully it will at least all be the same shade of silver! I've started working on them, as they are really for the coupe the window frame is of a different profile so I will be cutting and shutting the top corner to extend the frame by whatevers needed...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_6980_zpsg1r6yj54.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_6980_zpsg1r6yj54.jpg.html)
There's lots of little pieces to cut out and drill to make it even possible to mock it on the car, but my biggest issue is the mounting of the door to hinge, as you see there's no actual bracketry inside the door ::) ...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7014_zpsiqro2ryh.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7014_zpsiqro2ryh.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7013_zps8eoexwhv.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7013_zps8eoexwhv.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7012_zpsmo7x71j3.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7012_zpsmo7x71j3.jpg.html)
Lot's of masking later the window surrounds and gutters got some fresh black paint...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7166_zpsorgedyj4.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7166_zpsorgedyj4.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7165_zpsjnuorygq.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7165_zpsjnuorygq.jpg.html)
With the mot fast approaching, baring in mind i'd done about 30 miles with it since the last one, I couldn't believe that the chip that's been in the window ever since i've had the car (10 years) all of a sudden decided to crack a cm. It's never caused an issue as the wipers park pretty much on top of it and is just out of the mot failure area but with it's venture to crack, I tried some home repair resin you can buy from most stores, and for the price actually did quite a good job...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7105_zpsnlihhguv.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7105_zpsnlihhguv.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7107_zpsrk9xbbi7.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7107_zpsrk9xbbi7.jpg.html)

MOT in mind, the rubber bung in the passenger side floor had slight corrosion to the side of it, so to be on the safe side decided to cut it all out and weld in a piece for argument sake of corrosion next to a hole :D...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7201_zps9i8gkg3e.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7201_zps9i8gkg3e.jpg.html) (http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7203_zpsuj6f0i2c.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7203_zpsuj6f0i2c.jpg.html)

Sorting out the lighting and checking everything over, I came across an issue with resistance when the dipped beam were on affecting the power to the rear sidelights, to get around this i've fitted a relay and fresh wiring for the lights and WHAT :o a difference it made! Side lights, dipped and main beam...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7220_zpseotf8rlf.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7220_zpseotf8rlf.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7221_zpsn5azcxm6.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7221_zpsn5azcxm6.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7222_zpsxbvmkidg.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7222_zpsxbvmkidg.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7219_zpsf7gn0dvc.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7219_zpsf7gn0dvc.jpg.html)

Having bought a replacement coolant sensor and doing a coolant change ready for winter, I finally got the gauge working and was nice to see what part of the green actually represented as a number...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7306_zpsqjy9ja6m.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7306_zpsqjy9ja6m.jpg.html)
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7307_zpsnjnezin8.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7307_zpsnjnezin8.jpg.html)
I took it for a spin and once up to temperature on the move at speed it doesn't want to go above around 72 degree's, pulled over to let it warm up before putting the twin fans on, and there dropping the temp by around a degree every 10-20 seconds, so the capability to keep things cool seems to be there.

And finally, MOT passed ;D, one advisory of a track rod with some play which works out nicely as the tracking needed doing anyway! So was delighted with that, everything else got the thumbs up for another year, so hopefully i'll do a bit more mileage than last year :-[ Early xmas present to myself, the next project along side the doors, little teaser for you...
(http://i135.photobucket.com/albums/q152/lanciamad_album/IMG_7334_zps0tuufdlw.jpg) (http://s135.photobucket.com/user/lanciamad_album/media/IMG_7334_zps0tuufdlw.jpg.html)

Great Inspiring work Marcus and I am intrigued by the carbon fibre puzzle.

Eric

I see photobucket have annoyingly changed their status on 3rd paty sharing, so on a dark winters night in the future I will have to recover the pics and update the links as I go, hopefully my flickr account will allow me to upload photo’s from now on….
Same old story, where does the time go?! But I will persist with back dating the blog to present, before my memory fails me.
My bit of carbon fibre takes shape as the brake air ducts which bolt onto the wheel in this case my 16v integrale wheels, as used by integrale’s and many other rally cars normally for tarmac stages…
(https://farm5.staticflickr.com/4328/35272945073_fc3a9c6da3_z.jpg) (https://flic.kr/p/VJX4Fp)IMG_8091 (https://flic.kr/p/VJX4Fp) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Weighing in at 380 grams each they weigh not much more than a wheel trim I would imagine…
(https://farm5.staticflickr.com/4313/35912785612_e96630cb17_z.jpg) (https://flic.kr/p/WHupYQ)IMG_8098 (https://flic.kr/p/WHupYQ) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

For show more than practically, I very much expect so! But I think it gives it a bit more aggressive look to the car and goes with the theme of what the car’s always been about, evolving over the years. I expect wheel arch extensions could be very much on the cards in the future to finish the look, but for now these are them fitted…
(https://farm5.staticflickr.com/4315/36041490126_30563d27f7_z.jpg) (https://flic.kr/p/WUS4mb)IMG_8097 (https://flic.kr/p/WUS4mb) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr (https://farm5.staticflickr.com/4315/36041490816_44c8f4b654_z.jpg) (https://flic.kr/p/WUS4y5)IMG_8096 (https://flic.kr/p/WUS4y5) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Having cleared the parts and tools out of the back of it (you’ve still got to make use of it being an estate), I gave it a once over and a fresh paint over the floors, wheel arches and touched up a few area’s on the cage…
(https://farm5.staticflickr.com/4321/35241320174_c1abd21ee9_z.jpg) (https://flic.kr/p/VG9YGw)IMG_8126 (https://flic.kr/p/VG9YGw) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Onto wiring, having already replaced the ignition barrel after it failed on the Norfolk beta meet (The last decent run the cars had), and although the second hand unit was functioning, the block connector was becoming troublesome, and the choice was to either replace or get rid of completely…
(https://farm5.staticflickr.com/4329/35241319504_faa55d3649_z.jpg) (https://flic.kr/p/VG9YuY)IMG_8134 (https://flic.kr/p/VG9YuY) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

I got rid of it completely… and then decided to get rid of the ignition barrel… and the next thing I know I’ve got wires everywhere and the cigarette lighter is no more as well…
(https://farm5.staticflickr.com/4295/35241318574_8a85ac3c37_z.jpg) (https://flic.kr/p/VG9YdW)IMG_8135 (https://flic.kr/p/VG9YdW) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Cigarette lighter replaced by a push-button start with the override switch for the radiator fans and air-craft style ignition switch with fresh wiring and relays…
(https://farm5.staticflickr.com/4303/35241317974_f0d2defd51_z.jpg) (https://flic.kr/p/VG9Y3A)IMG_8141 (https://flic.kr/p/VG9Y3A) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4329/35241317344_6888c0c1a0_z.jpg) (https://flic.kr/p/VG9XRJ)IMG_8142 (https://flic.kr/p/VG9XRJ) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

With the cigarette lighter removed, by chance the trio of cig lighter, usb dock and voltage gauge just happens to almost fit perfectly in the ash tray space, I’m yet to finalise the fitting but all wired up and working…
(https://farm5.staticflickr.com/4307/35272937883_ea8f9890bd_z.jpg) (https://flic.kr/p/VJX2xr)IMG_8234 (https://flic.kr/p/VJX2xr) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

With the temperature gauge now up and running, it was interesting to see what the original gauge actually represents as needle position – temperature…
(https://farm5.staticflickr.com/4323/35272942793_33650c1547_z.jpg) (https://flic.kr/p/VJX416)IMG_8146 (https://flic.kr/p/VJX416) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4294/35272942553_1f58c918ed_z.jpg) (https://flic.kr/p/VJX3VX)IMG_8147 (https://flic.kr/p/VJX3VX) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4303/35272942283_f1647e8050_z.jpg) (https://flic.kr/p/VJX3Ri)IMG_8148 (https://flic.kr/p/VJX3Ri) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4303/35272941923_98f8b3452c_z.jpg) (https://flic.kr/p/VJX3K6)IMG_8149 (https://flic.kr/p/VJX3K6) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Roll cage padding added to the cage, also becomes quite a comfortable headrest…
(https://farm5.staticflickr.com/4302/35272940623_994813cdc6_z.jpg) (https://flic.kr/p/VJX3mF)IMG_8160 (https://flic.kr/p/VJX3mF) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4311/35272940913_ee81d99d38_z.jpg) (https://flic.kr/p/VJX3rF)IMG_8158 (https://flic.kr/p/VJX3rF) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Having one of those I forgot I had that moments, I came across the better quality fuel pressure regulator than the cheap and cheerful one I first used. So it was off with the old original fuel rail I’d modified…
(https://farm5.staticflickr.com/4318/35272939203_cbdcc9f48c_z.jpg) (https://flic.kr/p/VJX2Wc)IMG_8187 (https://flic.kr/p/VJX2Wc) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

And made a start on the mk2. First cutting the original pipework away from the rail…
(https://farm5.staticflickr.com/4300/35272940203_f4902253ce_z.jpg) (https://flic.kr/p/VJX3er)IMG_8178 (https://flic.kr/p/VJX3er) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Then giving it a decent rub down, generous paint and mocked up fitting the regulator…
(https://farm5.staticflickr.com/4291/35272939923_4b9e07ea68_z.jpg) (https://flic.kr/p/VJX39B)IMG_8179 (https://flic.kr/p/VJX39B) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4304/35272939623_88d3b189fc_z.jpg) (https://flic.kr/p/VJX34r)IMG_8186 (https://flic.kr/p/VJX34r) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Fuel rail on, fitted a lot better with correctly sized length fuel hoses to injectors and fresh hose clips. Fuel pressure set from 2 bar to the 3 bar it needs, and it ran perfectly…
(https://farm5.staticflickr.com/4297/35272938653_6e08aa92fd_z.jpg) (https://flic.kr/p/VJX2LH)IMG_8189 (https://flic.kr/p/VJX2LH) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Time running out, although I’ve kept the car going through Mot’s over the years, it had only done 80 or so miles since BetaMeeta 2012 in Norfolk, so a couple of days before this years event (BetaMeeta 17) I thought I better start putting some mileage on and run it for a decent amount of time. Circling the local area through villages and then braving the main roads everything ran as it should and the sticky brake pedal started to disappear more with use, hour and a half of running and 50ish miles, all good…
(https://farm5.staticflickr.com/4294/35272941633_fb7d34c5fb_z.jpg) (https://flic.kr/p/VJX3E6)IMG_8154 (https://flic.kr/p/VJX3E6) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Couple of days later, ready for the off…
(https://farm5.staticflickr.com/4292/35272938183_cbfa17af64_z.jpg) (https://flic.kr/p/VJX2CB)IMG_8233 (https://flic.kr/p/VJX2CB) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

When your running a 4 branch through a straight through pipe out to the single original silencer cruising along the motorway with no sound proofing, there’s a lot of noise going on!...
(https://farm5.staticflickr.com/4195/34849055816_5762593dbb_z.jpg) (https://flic.kr/p/V6uwaW)DSC01675 (https://flic.kr/p/V6uwaW) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

The weather was on our side just 15 miles until we reached destination, and then while out and about was changeable…
(https://farm5.staticflickr.com/4245/34502128960_c63dc4955a_z.jpg) (https://flic.kr/p/UyQqUq)DSC01611 (https://flic.kr/p/UyQqUq) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Only issue of the whole journey for me, was one of the bonnet pins had decided to become loose, and just happened to be when out on the drive with the others while going along the motorway which wasn’t convenient. But we still managed to keep up without the fibreglass bonnet making an exit, quick tighten up and job done, must remember to Loctite them!…
(https://farm5.staticflickr.com/4203/34725476472_99e668614d_z.jpg) (https://flic.kr/p/UUz9kA)DSC01620 (https://flic.kr/p/UUz9kA) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

A very enjoyable day, I could only make the Saturday of this years event, and completed 366.8 miles for the day without any running issues at all…
(https://farm5.staticflickr.com/4322/35272937623_98b787819f_z.jpg) (https://flic.kr/p/VJX2sX)IMG_8236 (https://flic.kr/p/VJX2sX) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

My photo's of the event... https://www.flickr.com/photos/lanciamad/albums/72157683975630506 (https://www.flickr.com/photos/lanciamad/albums/72157683975630506)

Ok, so I decided that enough was enough and the various bits and pieces for an engine build i'd collected over the years would only be any good if they were actually ever used than gathering dust and corrosion in the shed :-\
Time frame for the build isn't much of a concern as the standard ie engine is still going well and continues to be bomb proof in the car, I could have made life easier by robbing what I need off the current engine for the new build but have decided to leave the car alone and build this completely separately, robbing some bits off a short block I bought from one of the montecarlo guys years ago which has just been sat outside since. Picture overload...
This is the chosen head of the three I came across...
(https://farm5.staticflickr.com/4427/35593908343_3e966c9204_z.jpg) (https://flic.kr/p/Wej5ST)IMG_8496 (https://flic.kr/p/Wej5ST) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4418/35593906063_12bd92fb99_z.jpg) (https://flic.kr/p/Wej5cz)IMG_8498 (https://flic.kr/p/Wej5cz) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Pair of camshafts from a 130tc, I maybe utilising the exhaust cam for the build...
(https://farm5.staticflickr.com/4343/35593906953_73888353c3_z.jpg) (https://flic.kr/p/Wej5sV)IMG_8497 (https://flic.kr/p/Wej5sV) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Exhaust manifold in place, you could see the amount of material that could be potentially removed...
(https://farm5.staticflickr.com/4344/35593905263_96b01afee0_z.jpg) (https://flic.kr/p/Wej4XM)IMG_8499 (https://flic.kr/p/Wej4XM) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4435/35593904093_061c346e60_z.jpg) (https://flic.kr/p/Wej4BB)IMG_8501 (https://flic.kr/p/Wej4BB) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
So I did :D ...
(https://farm5.staticflickr.com/4334/35593903063_6e8c2a3f60_z.jpg) (https://flic.kr/p/Wej4iR)IMG_8502 (https://flic.kr/p/Wej4iR) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

I don't profess to knowing exactly what i'm doing nor recommend anything that I've done or are doing, but am purely going to do this engine build as another one of many projects that I will enjoy and experiment along the way than having any goals of achieving X amount of bhp. The goal is to of course get more bhp, but for what amount isn't something i'm affixed about; as long as it runs becomes reliable and gives the enjoyment of completing my first full engine build i'll be happy :) I have financial constraints to what I can personally afford to this, so in some cases parts have been sourced at cost, but to balance it off, as much of the work and build that can be realistically completed from the driveway, will be. The Haynes manual, guy crofts book and help from members will be my best friend along the way, especially Eric that has been great with info. and has already been there before with what works and doesn't, so thank you.

Having got quotes to do various bits, I thought with nothing to lose I would go about porting and polishing myself, if I was to buy anything from Guy then savings had to be made somewhere! The dremel hasn't seen much action, so about time it paid it's way. Crudely the ports were opened up to be as consistent as possible and then sanding smooth over and over...
(https://farm5.staticflickr.com/4336/36233704532_78d79543b3_z.jpg) (https://flic.kr/p/XcRcZE)IMG_8506 (https://flic.kr/p/XcRcZE) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Below is the result of halfway through smoothing off everything, the more you dig the more the imperfections show...
(https://farm5.staticflickr.com/4431/36233703832_3cb5d5d160_z.jpg) (https://flic.kr/p/XcRcMA)IMG_8507 (https://flic.kr/p/XcRcMA) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Even the dog wanted a go...
(https://farm5.staticflickr.com/4429/36004924610_618de0606b_z.jpg) (https://flic.kr/p/WRCDGf)IMG_8539 (https://flic.kr/p/WRCDGf) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Onto removing valves, very dry rusty valves. Having bought a spring compressor a while back, what ever was tried it didn't seem to want to know, until I remembered an old relic I had, and using the classic they don't make them like they used to they all came out reasonably easily...
(https://farm5.staticflickr.com/4382/36004927810_384d1fe567_z.jpg) (https://flic.kr/p/WRCEDq)IMG_8526 (https://flic.kr/p/WRCEDq) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Exhaust side out...
(https://farm5.staticflickr.com/4439/36233703182_907bcc9f3e_z.jpg) (https://flic.kr/p/XcRcAo)IMG_8515 (https://flic.kr/p/XcRcAo) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
All out...
(https://farm5.staticflickr.com/4382/36233702012_3291d42c0c_z.jpg) (https://flic.kr/p/XcRcfd)IMG_8516 (https://flic.kr/p/XcRcfd) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Valves out, the true amount of corrosion and carbon deposits can be seen...
(https://farm5.staticflickr.com/4430/36233701272_b627979092_z.jpg) (https://flic.kr/p/XcRc2s)IMG_8517 (https://flic.kr/p/XcRc2s) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Valves removed and measured, exhaust...
(https://farm5.staticflickr.com/4374/36233700462_f4da7c6546_z.jpg) (https://flic.kr/p/XcRbMu)IMG_8518 (https://flic.kr/p/XcRbMu) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Intake...
(https://farm5.staticflickr.com/4390/36004936320_ab4803de7e_z.jpg) (https://flic.kr/p/WRCHb9)IMG_8519 (https://flic.kr/p/WRCHb9) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
To be replaced by, exhaust...
(https://farm5.staticflickr.com/4429/36004933470_fc301d528e_z.jpg) (https://flic.kr/p/WRCGk1)IMG_8521 (https://flic.kr/p/WRCGk1) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Intake...
(https://farm5.staticflickr.com/4340/36004935100_7e3e3f954e_z.jpg) (https://flic.kr/p/WRCGP7)IMG_8520 (https://flic.kr/p/WRCGP7) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
These valves I bought many a year ago, thankfully in good new condition and have stayed that way. I think the plan for 2018 will be to source a VX head which Alan might be helping me out with and then utilising the bigger, I think 44mm intake and sodium cooled exhaust valves, but for now i'm going to go with what I've got which should give a fair improvement.
Removing studs...
(https://farm5.staticflickr.com/4335/36004932280_a1f290a3b2_z.jpg) (https://flic.kr/p/WRCFYu)IMG_8522 (https://flic.kr/p/WRCFYu) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Who would ever believe I can be organised when I want to, not that I will be using much of the old but you never know...
(https://farm5.staticflickr.com/4360/36004928840_e96efa2b41_z.jpg) (https://flic.kr/p/WRCEXb)IMG_8525 (https://flic.kr/p/WRCEXb) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Initial cleaning of port before and after...
(https://farm5.staticflickr.com/4360/36004923080_13bec9a736_z.jpg) (https://flic.kr/p/WRCDeS)IMG_8542 (https://flic.kr/p/WRCDeS) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4380/36004922580_365133bec4_z.jpg) (https://flic.kr/p/WRCD6f)IMG_8543 (https://flic.kr/p/WRCD6f) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
and more...
(https://farm5.staticflickr.com/4397/36357136796_cf65255fe1_z.jpg) (https://flic.kr/p/XoKQ79)IMG_8545 (https://flic.kr/p/XoKQ79) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4350/36004920760_41c54831f2_z.jpg) (https://flic.kr/p/WRCCxS)IMG_8546 (https://flic.kr/p/WRCCxS) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Exhaust port comparison, the guides are yet to come out and final polishing to be completed but you get what i'm aiming for...
(https://farm5.staticflickr.com/4341/36004919300_25cb1cdb81_z.jpg) (https://flic.kr/p/WRCC7G)IMG_8550 (https://flic.kr/p/WRCC7G) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Hi Marcus

On the subject of porting, have you ever read any books of or seen any videos by David Vizard?

If not well worth reading and viewing. One nugget was in a video where he talks about some testing of K & N filters and the conclusion he came to why they worked so well, I can dig out the link if anyone is interested (it was part of a recorded lecture in Oz if I remember correctly)

Peter

Hi Peter,
I hadn't, some very interesting opinions. Having watched a bit on youtube, coating intake valves is an interesting thought, he also mentions using a 80 grit to finish, I've gone with 180 so far, you could probably go higher for the exhaust side but different engines behave a bit differently and a bit of turbulent air is not always a bad thing on induction so I've been told, so i'll probably leave it there.
More picture overload...
This is the block i'm hoping to use for the engine build, previous owner stripped it down, had it bored to fit 84.6mm pistons and then never got around to putting it back in. It's been in the shed for getting on for 9-10 years, so has gained outer surface rust but had been painted a light blue colour which has kept it reasonable. The top of the block I will have skimmed, for peace of mind I will probably remove the core plugs and fit new as they seem to be prone to rusting from inside out unless I can physically see there condition and will strip all components to degrease and clean. I have managed to turn the crank and the bore conditions still look to be good, so hopefully a light hone will only be required fingers crossed; the previous guy said that the bearings were changed at the time of the build so hoping that crank and bearings will be in good condition, although I expect with the rods i'll be using I may need to buy new integrale bearings anyway...
(https://farm5.staticflickr.com/4398/36004918690_119d7589cf_z.jpg) (https://flic.kr/p/WRCBWb)IMG_8569 (https://flic.kr/p/WRCBWb) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4406/36233685442_348c257d1a_z.jpg) (https://flic.kr/p/XcR7jw)IMG_8574 (https://flic.kr/p/XcR7jw) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4337/36233685832_40e442021f_z.jpg) (https://flic.kr/p/XcR7rf)IMG_8573 (https://flic.kr/p/XcR7rf) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4415/36233685052_f8d6329f1c_z.jpg) (https://flic.kr/p/XcR7cN)IMG_8575 (https://flic.kr/p/XcR7cN) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4343/36233683732_f238ef7bf2_z.jpg) (https://flic.kr/p/XcR6P3)IMG_8578 (https://flic.kr/p/XcR6P3) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4413/36357106526_7a2c34f711_z.jpg) (https://flic.kr/p/XoKF7f)IMG_8638 (https://flic.kr/p/XoKF7f) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Onto shiny things, it's taken a little while to decide on how far to go, where to source parts and what was affordable, so from a mix match of sources I've come up with the following; with some of it coming from our friends in the US with all the import taxes on top of shipping etc I went with one mass order...
Rear water plate...
(https://farm5.staticflickr.com/4351/36233683402_64a6580b31_z.jpg) (https://flic.kr/p/XcR6Hm)IMG_8581 (https://flic.kr/p/XcR6Hm) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
My colour scheme is going to be red and black eventually for the engine, so sticking to the red theme, auxiliary pulley...
(https://farm5.staticflickr.com/4430/36233682842_755ec8c008_z.jpg) (https://flic.kr/p/XcR6xG)IMG_8582 (https://flic.kr/p/XcR6xG) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4334/36004913300_81106690d8_z.jpg) (https://flic.kr/p/WRCAkf)IMG_8583 (https://flic.kr/p/WRCAkf) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
New bronze valve guides...
(https://farm5.staticflickr.com/4422/36004912660_eb3b4b33c2_z.jpg) (https://flic.kr/p/WRCA9d)IMG_8584 (https://flic.kr/p/WRCA9d) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Adjustable camshaft pulleys...
(https://farm5.staticflickr.com/4398/36004911920_a9b4b0508d_z.jpg) (https://flic.kr/p/WRCzVs)IMG_8585 (https://flic.kr/p/WRCzVs) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Auxiliary shaft with apparently no lobe for fuel pump, which may prevent it playing with the conrod if ever mis-timed...
(https://farm5.staticflickr.com/4418/36004911190_0c916e6c94_z.jpg) (https://flic.kr/p/WRCzGS)IMG_8586 (https://flic.kr/p/WRCzGS) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Crankshaft timing belt gear...
(https://farm5.staticflickr.com/4361/36004910460_5bd9dca29a_z.jpg) (https://flic.kr/p/WRCzuh)IMG_8587 (https://flic.kr/p/WRCzuh) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4343/36004910080_cd1f27a9b9_z.jpg) (https://flic.kr/p/WRCznJ)IMG_8588 (https://flic.kr/p/WRCznJ) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
High compression pistons, 84.6mm...
(https://farm5.staticflickr.com/4436/36004909570_45e8b2931a_z.jpg) (https://flic.kr/p/WRCzdW)IMG_8590 (https://flic.kr/p/WRCzdW) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4401/36233679192_0f5afe2bef_z.jpg) (https://flic.kr/p/XcR5sL)IMG_8591 (https://flic.kr/p/XcR5sL) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Fuel pump block off plate...
(https://farm5.staticflickr.com/4430/36233678582_e4046d1d5d_z.jpg) (https://flic.kr/p/XcR5hf)IMG_8592 (https://flic.kr/p/XcR5hf) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
When the engine is swapped, I will give the engine bay a good tidy up and paint, so some new grounding pods won't hurt...
(https://farm5.staticflickr.com/4346/36233677482_dbcac2a5a7_z.jpg) (https://flic.kr/p/XcR4Xh)IMG_8593 (https://flic.kr/p/XcR4Xh) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Crank breather hoses...
(https://farm5.staticflickr.com/4342/36233676572_4c8c6cf538_z.jpg) (https://flic.kr/p/XcR4FA)IMG_8594 (https://flic.kr/p/XcR4FA) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Plug for oil pump / distributor...
(https://farm5.staticflickr.com/4393/36233677992_76a65b2f43_z.jpg) (https://flic.kr/p/XcR575)IMG_8595 (https://flic.kr/p/XcR575) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Timing belt and bearing...
(https://farm5.staticflickr.com/4394/36233675362_3a80ed2592_z.jpg) (https://flic.kr/p/XcR4jJ)IMG_8596 (https://flic.kr/p/XcR4jJ) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Flywheel bolts...
(https://farm5.staticflickr.com/4428/36401487705_c2be10d70c_z.jpg) (https://flic.kr/p/XsF95Z)IMG_8598 (https://flic.kr/p/XsF95Z) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
I need to mount the EDIS ignition better than it is now, so will probably make use of some exhaust mounts somehow to help with vibration and keep it directly off the engine as it is now...
(https://farm5.staticflickr.com/4408/36401487445_661cd231f7_z.jpg) (https://flic.kr/p/XsF91v)IMG_8599 (https://flic.kr/p/XsF91v) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Cylinder head studs...
(https://farm5.staticflickr.com/4382/36401486955_a17822718f_z.jpg) (https://flic.kr/p/XsF8S4)IMG_8600 (https://flic.kr/p/XsF8S4) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Engine gasket set, notice the missing cam box gasket :( luckily I've got a gasket set for a head kicking about so I can pick and choose with what to use...
(https://farm5.staticflickr.com/4422/36401486605_0bfbb56610_z.jpg) (https://flic.kr/p/XsF8L2)IMG_8601 (https://flic.kr/p/XsF8L2) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Sump gasket...
(https://farm5.staticflickr.com/4365/36233672462_db300b3c0b_z.jpg) (https://flic.kr/p/XcR3sJ)IMG_8602 (https://flic.kr/p/XcR3sJ) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
and another...
(https://farm5.staticflickr.com/4380/36233672072_8253d113ee_z.jpg) (https://flic.kr/p/XcR3m1)IMG_8604 (https://flic.kr/p/XcR3m1) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
In the confusion they must have sent two sump gaskets without sending two cam box gaskets, notice there's differences between them...
(https://farm5.staticflickr.com/4399/36233671552_6cbe553097_z.jpg) (https://flic.kr/p/XcR3c3)IMG_8605 (https://flic.kr/p/XcR3c3) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr

Less shiny stuff, having read and been told that the vx flywheel with a thema/integrale clutch is the best option to cope with more power (I can hope) cheaply, right time and place, half an hour up the road one became available, same old story he had planned to do a locost single seater project and it was a few of the parts he had left that never made it to the car/project 10+ years ago...
(https://farm5.staticflickr.com/4339/36233669482_4c6d85d6e1_z.jpg) (https://flic.kr/p/XcR2zm)IMG_8610 (https://flic.kr/p/XcR2zm) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4378/36233669772_ec7e5b2703_z.jpg) (https://flic.kr/p/XcR2Em)IMG_8609 (https://flic.kr/p/XcR2Em) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Back to the head, the intake side didn't warrant too much material being taken away...
(https://farm5.staticflickr.com/4388/36233671272_ae45a1c1b3_z.jpg) (https://flic.kr/p/XcR37d)IMG_8614 (https://flic.kr/p/XcR37d) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
I've just been concentrating on tidying it all up and smoothing out the short turn radius...
(https://farm5.staticflickr.com/4345/36233668722_5eaa0b4417_z.jpg) (https://flic.kr/p/XcR2mf)IMG_8618 (https://flic.kr/p/XcR2mf) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Combustion chamber tidy up...
(https://farm5.staticflickr.com/4360/36233668392_bd0eb5b80b_z.jpg) (https://flic.kr/p/XcR2fy)IMG_8621 (https://flic.kr/p/XcR2fy) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4429/36233667992_3e44ea5cd1_z.jpg) (https://flic.kr/p/XcR28E)IMG_8622 (https://flic.kr/p/XcR28E) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Did a bit of blending to the combustion chamber, just to remove any potential hot spots but wanted to do the bear minimum as anything removed would lower the compression ratio...
(https://farm5.staticflickr.com/4375/36233667202_0559c979d6_z.jpg) (https://flic.kr/p/XcR1U3)IMG_8623 (https://flic.kr/p/XcR1U3) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
and cleaned up a bit...
(https://farm5.staticflickr.com/4399/36233670992_8b154531f3_z.jpg) (https://flic.kr/p/XcR32o)IMG_8624 (https://flic.kr/p/XcR32o) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Like I said, i'm no professional :D but it's been fun 'having a go' I can only hope for some improvement from what came out the factory and has had 35 years worth of wear and tear. A very poorly advertised clutch came up which had been fitted and then removed as it was the wrong item for them, luckily for me as a bit of a punt I picked it up and it was what I was after, 228mm thema clutch...
(https://farm5.staticflickr.com/4395/36357103946_e6c369d5d2_z.jpg) (https://flic.kr/p/XoKEkL)IMG_8636 (https://flic.kr/p/XoKEkL) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4410/35593876433_cebd9fafcc_z.jpg) (https://flic.kr/p/WeiVoH)IMG_8626 (https://flic.kr/p/WeiVoH) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Took some cleaning of the location lugs...
(https://farm5.staticflickr.com/4356/35593876583_55f4b23919_z.jpg) (https://flic.kr/p/WeiVri)IMG_8625 (https://flic.kr/p/WeiVri) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
and then fits like a glove...
(https://farm5.staticflickr.com/4372/35593875933_ecec7301e1_z.jpg) (https://flic.kr/p/WeiVf6)IMG_8628 (https://flic.kr/p/WeiVf6) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Onto the man which is a god when it comes to these engine's, I ordered Guy crofts 3a inlet camshaft that should work quite well with a 130tc exhaust cam ;D 1mm top hats also...
(https://farm5.staticflickr.com/4355/36357108566_30b86d9a1d_z.jpg) (https://flic.kr/p/XoKFHq)IMG_8630 (https://flic.kr/p/XoKFHq) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4399/36357109046_a2d336227a_z.jpg) (https://flic.kr/p/XoKFRG)IMG_8629 (https://flic.kr/p/XoKFRG) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4345/36357107816_614b9d5c96_z.jpg) (https://flic.kr/p/XoKFuu)IMG_8631 (https://flic.kr/p/XoKFuu) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4374/36357107116_2c857577f5_z.jpg) (https://flic.kr/p/XoKFhq)IMG_8632 (https://flic.kr/p/XoKFhq) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
I'm yet to tap all the holes on the head but have got round to doing all the spark plug holes and thought that I may have had to helicoil the spark plug hole for 4, but having tapped all of them it seems to have come up pretty good...
(https://farm5.staticflickr.com/4393/36591047635_fa5f76b80b_z.jpg) (https://flic.kr/p/XKqFDD)IMG_8674 (https://flic.kr/p/XKqFDD) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
When porting and polishing, time isn't money when you do it yourself, but I think i'm pretty happy with it now...
(https://farm5.staticflickr.com/4386/35781723873_dfe0241da2_z.jpg) (https://flic.kr/p/WvUFTF)IMG_8676 (https://flic.kr/p/WvUFTF) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4418/35781722263_52bb5240da_z.jpg) (https://flic.kr/p/WvUFpV)IMG_8677 (https://flic.kr/p/WvUFpV) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4337/35781720423_739170d7be_z.jpg) (https://flic.kr/p/WvUESc)IMG_8678 (https://flic.kr/p/WvUESc) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Deciding on what to do again, at the end of the day, years down the line I will probably muck around with changing heads, for bigger/better etc but would rather have the bottom end done and dusted for a very long time, so with the block work soon to be going on I've bought some new forged conrod's which should do nicely once I decide what bearings I need for the crank and will feature an oil spray mod to them before being fitted...
(https://farm5.staticflickr.com/4383/36453057991_b9037561b8_z.jpg) (https://flic.kr/p/Xxes8R)IMG_8655 (https://flic.kr/p/Xxes8R) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4394/36591048485_a615566c28_z.jpg) (https://flic.kr/p/XKqFUi)IMG_8658 (https://flic.kr/p/XKqFUi) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4339/36591048915_556f92885b_z.jpg) (https://flic.kr/p/XKqG2H)IMG_8657 (https://flic.kr/p/XKqG2H) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
(https://farm5.staticflickr.com/4403/36591048225_37c875a068_z.jpg) (https://flic.kr/p/XKqFPP)IMG_8659 (https://flic.kr/p/XKqFPP) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
A few other bits once it get's really serious and things get taken out and put in, new power steering and alternator belts...
(https://farm5.staticflickr.com/4416/35781717263_4cb9a855f7_z.jpg) (https://flic.kr/p/WvUDVH)IMG_8680 (https://flic.kr/p/WvUDVH) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Water pump...
(https://farm5.staticflickr.com/4389/35781716073_eae752a370_z.jpg) (https://flic.kr/p/WvUDzc)IMG_8681 (https://flic.kr/p/WvUDzc) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Water sensors for cylinder head...
(https://farm5.staticflickr.com/4379/35781715013_00b871a620_z.jpg) (https://flic.kr/p/WvUDfV)IMG_8682 (https://flic.kr/p/WvUDfV) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
All important sticker...
(https://farm5.staticflickr.com/4375/35781713893_b79c58b887_z.jpg) (https://flic.kr/p/WvUCVB)IMG_8683 (https://flic.kr/p/WvUCVB) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Baffled sump kit courtesy of the betaboyz to keep the oil where the oil should be, and will also be complemented by an Accusump setup that should protect the engine from whatever G I throw at it as well as initial start up wear...
(https://farm5.staticflickr.com/4376/35781712723_3530106639_z.jpg) (https://flic.kr/p/WvUCzr)IMG_8684 (https://flic.kr/p/WvUCzr) by Marcus Robinson (https://www.flickr.com/photos/lanciamad/), on Flickr
Onto sunday, off to retro rides  :)

I'm interested that you have Maxpeeding rods. Are there any milling marks on the inside of the flutes?