Gearbox Plugs & Covers

I remade one of the covers using more perforated sheet to provide some ventilation.  I still have a cover to make on the N/S of the gearbox, and one around the starter motor.  I have received the starter, so I'll bolt it in place and make a cover to suit.

I bought a mechanical speedo plug from Roadcraft UK, removed the shipping bung and fitted the new plug using a M6 x 16mm set screw.

Another Flywheel Cover

When I told Andy at GD that I was making covers for the flywheel / gearbox, he said to me "Make sure you leave plenty of ventilation".

If you refer back to my previous post regarding the flywheel cover, I made an aluminium cover.

Rather than drill holes in the aluminium cover, I used it as a template to make one from perforated sheet instead.

Just a couple more to do!

Coil Packs Installed

I have fitted the coil packs to the rocker covers and connected up the spark plugs.  For some reason, the mounting holes didn't quite line up and so I had to open out one of the holes on each frame.  All done now and just waiting for the engine wiring loom to be fitted to complete.

Exhaust Manifolds

I bought my exhaust manifold gaskets from Monkfish Performance to fit my GD supplied exhaust manifolds.  The gaskets can be found here.

I used stainless steel set screws with spring washers and washers to fit them.

I will have to modify my trestle supports to be able to fit the remaining underslung exhausts.  Watch this space.

 

Gearbox Connectors

I spent a bit of time trying to find the correct connectors for the Tremec T56 Magnum gearbox.  I have managed to find them and I have detailed them below.

For the Vehicle Speed Sensor (VSS): Dorman 645-213.  This comes complete as a pigtail connector and will require soldering in place.  I bought mine through RockAuto from here, but there are other suppliers available.

For the Reverse Light Switch:  Delphi 12015792.  I bought mine through SimtekUK from here

For the Reverse Lockout Solenoid:  Delphi 12052646.  I bought mine through SimtekUK.  They don't list it on their website yet, but if you contact them they will supply.

Flywheel Cover

I made an aluminium cover for the N/S of the engine / gearbox to cover the flywheel.  Just used a folded piece of aluminium and cut / filed it to shape.  It is fastened to the block using a M6 set screw and spring washer / washer.

Gearbox Bellhousing Openings

The bellhousing between the engine and gearbox has a few openings in it.  This must be a somewhat universal bellhousing, since there are openings for a mechanical clutch fork on both sides.  I can also see the flywheel on the N/S.  I am waiting for a starter to come, so I am not sure if there is a gap on the O/S.  Covers need to be put in place to prevent stones and debris coming in contact with the flywheel and clutch.

I am going to use aluminium to make up covers.  I have made up one so far, and have fixed it to the gearbox by drilling and tapping out for M4 button head screws.  I used a hoover to keep down on swarf.  I have started with the easy one, and the others will require a little more sculpting..

Radiator Cooling Fan

I have fitted the cooling fan to the aluminium radiator using the supplied stainless steel brackets.  This involved carefully drilling small holes into the aluminium frame and I used M4 stainless button head screws and nylock nuts.  The fan is a single 16" which I was told by GD that this had more flow than the twin fan option.

I am not 100% sure of the direction of flow yet, I will only find out when I connect in the wiring loom.

I will mount the radiator to the chassis once the heater pipework has been fitted to give me some room.  I am waiting on parts coming from GD, and I am going to attempt to make up my own heater pipes using stainless tubing and silicone hoses.  I will keep you posted.

Front Suspension

After I set the bump steer, I re-fitted the front shock absorbers and loosely bolted them up in position.  I still have to fully tighten the track rod ends.  I packed them with washers just to save the nylock nuts just in case I had to take them off again while checking the front toe.

Bump Steer

I have had a few weeks holiday in Cornwall and so have had little progress on the GD.  Also with the good weather I have been working out in the garden doing all the things that need doing.

To set the steering rack, I bought a Longacre Bump Steer gauge.  I managed to get it set up even with my chassis up on trestles and it seemed to work pretty well.  I managed to tweak the height of the rack to minimise the amount of bump steer.  This will have to be re-done once the car is complete so it has been left in the ball park.  I have attached a graph which interestingly shows how much the bump steer moves.  Each line is a difference of 2mm height.  I have left it where the line is closest to the horizontal.