IVA Test!

After getting my old faithful Land Rover Discovery serviced, and my Ifor Williams Transporta trailer brakes checked I was ready for the long journey.  My friend Mervyn agreed to come with me for moral support, and also to help in case we broke down!

My plan was to take the GD down to Andy at the Grantham headquarters for a sense check, then off to Derby for the IVA.  With the overnight ferries being a bit tricky to get booked during holiday season, we managed to get some space which sort of worked.

Arriving in Aberdeen at 7am, we had a 422 mile trip to Grantham.  We stopped twice for fuel and made it to GD Cars at approx 4pm.  Andy had a quick look over my car and we made a list of things for us to to confirm on the Monday.

Checking the brake bias, and adjusting the handbrake

IVA Compliant Fog Light Fitted

IVA Compliant Head Rest In-Fills Fitted

Speedo re-calibrated to 33000 as per Andy's Spreadsheet calculation

Adjusting the steering to try to get her to self centre while driving in a circle

Lowering the fuelling at idle to ensure she was within emission limits - she was!

Arrived at Derby on the 30th July

Nervously waiting to enter the test bay

Being checked over

IVA Success!  A massive thanks to Andy!

In the trailer ready for the long journey home

Celebratory Steak!

Overflows

I installed a hose on the coolant expansion tank to route it to a safe location under the car in case any excess pressure wasa observed.  I fastened the hose to the chassis using P-Clips.

I also installed a hose onto the windscreen washer tank - just for aesthetics so it looks more symmetrical.  It won't see any pressure.

WHilst in the engine bay I fitted stickers to the brake & clutch fluid reservoirs reminding me to use DOT 4 fluid..

And, in the same small bag of stickers there was one for the brake adjuster.  I trimmed that slightly and stuck that on too.

Brake & Clutch Fluid Reservoir Connectors

I have never been too happy with the spade connectors used for the brake and clutch fluid reservoirs - I thought it looked unfinished.  I tried to search for the correct connector for the reservoir online, but could never seem to find one.  I did eventually find one that was nearly correct....

AMP 926470 is physically correct, however this is for 3 connections rather then the 2 that I have - and all other reservoirs I have seen have.  I ordered 4 of these along with the correct terminals which fit in the housing in an attempt to make it work.

I initially tried modifying the new connector to house 2 terminals rather than the 3.  By doing this the terminal lost it's ability to clip in correctly.  This was a no go.

The only other option was to trim down the terminals inside the reservoir connector.  The original connectors are 6.3mm wide, but because I had to trim the connector so a phantom 3rd would fit in the middle, these needed to be trimmed to around 5mm from the inner side only.  Using the Proxxon, I carefully trimmed each terminal until the new AMP connector could fit in.  I repeated this for all 3 switches.

I then crimped the correct terminal onto the wires and fitted them in.  Quite a lot of work just to make the connector look as if it should be there!

Brake & Clutch Bleeding

I bought a Sealey Brake & Clutch bleeding kit (VS 820) which came with a universal adaptor for fitting to multiple reservoir types.  However I needed to make a fitting to be able to connect it properly to each of my reservoirs as the universal adaptor couldn't quite fit correctly.  This will allow me to bleed each system myself and without any spillage (hopefully).

I turned out an adaptor out of some PTFE to allow it to fit under the screwed cap of the reservoir, and also for the Sealey quick connect fitting to be bolted through it.

Brakes!

GD supply AP Racing front discs and callipers as an upgrade.  They are 330mm x 28mm grooved discs and 4-pot aluminium callipers.  I assembled the disc to the bell using the bolt kit and fitted the callipers to the supplied aluminium blocks.  The stainless flexible hoses were also connected and fitted to the wishbones using stainless P-Clips.

Brake & Clutch Fluid Reservoirs

I decided to use 3x single reservoirs for the brake & clutch fluid.  I also decided that I wanted to run the flexible brakes hoses inside the bulkhead so that they weren't in the engine bay crossing the steering column.

The supplied brackets for the reservoirs were just plated steel so the first thing to do was create a new 1-piece stainless steel bracket that held all 3 reservoirs.  I measured them and then drew up a plan using Solidworks.  The reservoirs I used have a float with test switch built in, which is an IVA requirement (along with the stickers).  They came with just a hose connection, but since I wanted to use flexible hoses, I removed the connection, drilled and fitted aluminium -AN4 fittings with o rings which could then fit to bulkhead connectors to go to the master cylinders.

Where the front, rear and clutch fittings come up to in the engine bay, I marked where holes should go for 90 degree end flexible hoses.  I could then determine if it was all going to fit.

Once the bracket was made, I assembled the 3 reservoirs along with 90 degree fittings.  This then allowed me to work out where on the bulkhead these could be mounted.  I used masking tape and drew on a grid on the bulkhead and fitted the bracket with double sided tape.  This allowed me to stick the bracket to the bulkhead and close the bonnet.  From the front wheel well, I could look in with a torch and look at the marked grid to see where it could be moved.

Because of the fuel pressure regulator, and bonnet height it doesn't fit perfectly as desired.  I had to offset one of the holes in the bulkhead coming from the high pressure side of the master cylinder.

I then connected up the fluid level switch wires and should now just require the stickers.

Gearbox Tunnel & Brake Connector

Since I thought that the fuel system was complete, I decided to fit the Gearbox Tunnel Sheet.  This was just set on, and fixed using M6 x 20mm Set Screws.  In previous photos, you may have noticed that I used some black sealer to put a bead down between the sheet and the chassis.  I then put on the self adhesive foam that was provided by GD.

I then mounted the brake pipe / clutch bracket.  I still need to finalise what fittings I am going to use for the clutch bleed.

I have since removed the tunnel sheet again to alter the positioning of the fule supply hose and Y-Piece as per the previous post.

Rear Brakes

I fitted the rear brake pads and connected up the handbrake cable.  I also replaced the bleed nipples with stainless ones.

I need to shorten the handbrake cable, but unless I can get a measurement from GD, then I will have to wait until I fit the body and handbrake lever.  This is due to the fact that I don't know the "zero" position of the lever mechanism.  I will contact Andy and see how they work it out...  I also swapped around my p-clip mount on the diff, since it clashed with the O/S cable.