ALRC Project

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Hi, all I have been in the workshop today working on the fuel system, I made a bracket to mount the pumps, on which I used aluminum brazing rods and it turned out quite strong.
Then piped up 4 filters, two pumps a one way valve in the vent line and the swirl pot and tank. I would of liked a bigger tank but I will see how far this one will take me.
Also I have mounted the coolant res which some of you will notice is a defender item

I will be fettling the inlet manifolds next and fitting the ITB's in place so I can then make the engine cover and a few other composite panels.

 
Owl looking good as always! The fuel tank you have fitted will it last a 7 mile comp do you think?? I was worried about my tank which seems to be roughly twice the size as yours best guestimate from pics. Maybe my concerns are not justified at all. will have to measure and work out just how big it actually is.
 
It's a 3 gallon tank and 2.5 ltr swirl, I would of liked a larger job but it came at the right money.If it does only 3 mpg it will be enough, I can't see it using more than a couple of gallons on the longest lap I'm likely to encounter.
Just the aggro of filling up every lap but then why drag fuel round you don't need, LOL even my navigator has to empty their pockets and wear plimpsols.
 
Lol my concern isn't justified lol will cost you loads a money driving to the fuelling area tho as we're not trusted to fill up our tanks without spilling it ourselves!
 
Hi Guys, I have been messing about with various things today. I port matched one of the inlet manifolds to the throttle bodies which went well, then I started the other only to find that when it was fabricated one of the runners is slightly off (prob distortion) so I will cut it off and redo it.

I am thinking of making the wheel arch liners and spats out of HDPE so I purchased a small sheet of 3mm. I can heat it and shape the arch ok but I need to buy a hot air welding gun. I made an attachment for my hot air gun to try but it don't work, I don't think it is too hot just to much volume of hot air so I gave up on that for today.

I have a pair of GRP wings which I don't like for many reasons one of which is that the wheel arch is to far back, so I am redesigning them and using them to make molds then I will be able to make new wings whenever I need one. I am thinking of using the same fabrication techniques as the guys that make slalom kayaks so they will stand a bit of hammer.

 
GRP is fibreglass right? Not an ideal panel martial for a offroader IMO as it cracks rather than bends
Did I read right, your going to make a set of HDPE wings as well as inner arches and spats or you sticking with some form of fibreglass for the wings?
 
If I can weld HDPE which I should be able to I will make wing liners and spats in HDPE, the wings will be made using Eglass and Diolen. Diolen has many of the properties of Aramid but is cheaper. Kayak manufactures use this layup and very strong components can be made with good impact and abrasion resistance. having said that what ever you make Comp Safari wings out of they don't last long if you are taking the cut through's :rolleyes:
 
Last year I saw a thermo form place drop a loaded skip onto a £4k GPS system inside their housing the skip did deform the unit but it was designed to crush and deform and still protect the internals very impressive!
 
discomark10 said:
GRP is fibreglass right? Not an ideal panel martial for a offroader IMO as it cracks rather than bends
Did I read right, your going to make a set of HDPE wings as well as inner arches and spats or you sticking with some form of fibreglass for the wings?
Click to expand...

GRP = Glass Reinforced Plastic and while much of it does crack it's really down to which resin and percentage mix you use, fibreglass tends to get a bad name from it's use in anything and everything even when not appropriate in it's early days, but it has come a veeeeeery long way since then.
 
It should be ok weight wise as most of the reinforcement will be Diolen and I plan to use a vacuum bag process which bleeds of excess resin.
I have been in two minds between composite and Ali neither option is ideal but Ali wings are expensive to buy or difficult & time consuming to make where as once the mold is made a new wing takes very little time and the materials aren't that costly.
 
Hi Guys. I have just spotted these bellows type axle breathers which are 65 bucks from the USA which seems a bit steep. So I have been looking for something similar over here, any of you guys seen anything that will do the job.

 
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