Meeting this Wednesday

From Stuart Saare:

Yes, the Kinetic system can be cleaned, bled and installed all the way up to the final steel line -> rear valve unit connection across the rear cowling, but it sounds like this will have to be done before the engine goes in. But after that, yes the only issue is spilling fluid onto the engine/diff whilst connecting the rear valve units but it is relatively easy to do, and can be done cleanly.

I agree that it is still a good idea to meet on Wednesday, I can't make it till probably 8.30 though. If I'm sure there are plenty of jobs that can be done even without the engine being installed this week, it sounds like we may still be missing rear upright internal parts.

Re: engine in schedule

From Jonathon Lowe, 30/03/09:

"I think best to assemble engine with the plenum fixed. It’s too difficult otherwise. I’m happy to wait till Kinetics is all good.

Still yet to pop the question to Silvia but I think John will be fine with it.

I recommend Wednesday happening still, just to touch base and discover any other issues there are.

Did someone want to pick up silver tape to fix some of the heat shield areas?

I’ll be at Codexa from 6pm."

Revising the schedule

From Morgan McDermont, 30/03/09:

"As far as I remember, 06's plenum cant be removed once the engine is in. It's trapped. However you might be able to dislodge it enough to get the steel pipes through the chassis. I assume it is just enough to poke them out under the valve units and do the nuts up?

If the pipes were cleaned, sealed and installed before the engine, could the rear valve units be fitted later on? Is the main issue the spillage/mess?

I think i would vote for postponing the engine-in until the Kinetics are sorted properly. Between Codexa and the GuzV2 workshop (Jono: how'd this go?) there is probably space/time. This would give us extra time to make sure the rest of the jobs list is done properly ready for reassembly."

Bad news about Kinetics

From Stuart Saare, 30/03/09:

"I have bad news regarding Kinetics. I spent the weekend cleaning the disgusting filthy state of the Kinetic equipment thanks to 08 f-tards, and once everything was cleaned and sorted I was able to get a better look at the parts I had collected. The biggest issue is the valve housings - because 08 and 07 used either 06's or 06 spares, we are short of housings. I found two in the lab during our scrimmaging but it turns out one of them is useless, the other could have dodgy dimensions which I will need to measure once I get some new calipers. Best case is we need one new housing but I suspect we need two, which could take a couple weeks. Those 08 [team members] really messed [things] up.

The internals from 06's rears are incomplete - have found some of the parts but some internals will need to be made, and probably the existing ones calibrated because the matching pairs are now mixed together.

Also the damper gland nut tool is MIA, so I couldn't open the dampers up to clean them - will need a new tool made. In the process of cleaning everything I found some chopped/worn seals that will need replacing.

It is possible that I could bleed from the front to the end of the steel lines, and put that in the car before the engine goes in, then leave some plugged lines until new housings and internals are made and assembled. However, I don't have time to bleed that part of the system until next weekend, and Kinetics being the fiddly thing it is, I'd budget the whole of next weekend to get it done. The steel lines have to go in before the engine does, I think - but maybe they could be fitted around the engine, and then complete the rear valve unit connection with the engine in place and just cop whatever fluid gets spewed about.

I don't know how we are going timeframe-wise for continuing to work out of Codexa. I'd say it'll take 3 weeks to get Kinetic sorted, assuming all sorts of things. So I guess the options are to delay engine-in, or go ahead with changing the Kinetic system plumbing to an 07/08-style system. I avoided changing the plumbing because it could cost over $200 for some new hoses and fittings, and the original stuff works perfectly if you aren't planning on regularly opening the system. If we go ahead with changing the plumbing, the car can be completely reassembled without Kinetics, then after the 3 weeks I expect it to take to get the system ready, it should just bolt straight on.

IMO, the plan is thus: proceed with engine in ASAP. Once engine is in, I will test if I can shoehorn the steel lines around the engine (can the engine go in without the plenum, then install plenum once engine is in chassis?). If so, existing hardware is kept, system can be half-bled off car, installed, then do the final connection and bleed on car. If the steel lines can't fit around the engine, then fork out for new plumbing, complete the system externally, and attach once done in a few weeks.

Anyone have suggestions or feel strongly either way?"

Plans for this week?

From Chris Ward, 30/03/09:

"So are we going for pre-engine install tomorrow night (or Wednesday?) And then engine in on the weekend?"

Oil system O-ring

From Mike Claffey, 27/03/09:

"I might be able to pick something up at lunch if you give me a part number? And place to purchase in Osb. Park. "

From Greg Chapman, 27/03/09:

"I need to get my thesis off the ftp to work out what size I need. From memory its -015, but I would need to confirm.

Worst case I'll just use 3Bond.

Its only for the inlet to the scav pumps so it doesnt matter if it leaks a little."

Engine parts

From Greg Chapman, 27/03/09:

"Got most the parts I need for the engine. May need a new part for the oil system turned up. Will see how I go with the old part. I might be able to machine it back into shape myself.

Need a helicoil to be redone, but that wont affect engine going in.

Also need to replace an o-ring. Anyone know a place thats open over the weekend that will sell a viton o-ring?"

Costs so far

From Jonathon Lowe, 26/30/09:

"I’m happy with either. If people are free for a Tuesday session then I’ll be there. Otherwise we’ll have to come in on Saturday or Sunday to finish what we can.

I plan to send Angus an email tomorrow regarding paying of stuff we can’t get from the lab or for free. The current list is,

Nitriding of spindles ~$250

Throttle cable ~$80

Please populate this list and fix any figures."

Engine in schedule?

From Stuart Saare, 26/03/09:

"I will need to install Kinetics before the engine goes in. I plan to bleed everything off-site, and just the rear valve unit -> steel hose coupling through the rear cowling will be done on-car. If the engine is definitely going in Wednesday night, will Jono or Locky be free Tuesday night as well for pre-engine-in work? Or will Wednesday night be a preparation night for engine in? i.e. get the engine back, attach oil system and drivetrain and exhaust, do Kinetics and wiring work on rear cowling and so on; then plan another session to actually get the engine in?"

More sensors

From Morgan McDermont, 24/03/09:

"OK great.

Re: fuel pressure sensor. It's not required for a map or anything, but we do actually have our original sensor so it seems stupid not to refit it for troubleshooting etc... especially since the rest of 06's sensors are now complete.

BTW: Jono, can you grab the spare 100bar pressure sensor (its in a red foam bag in one of the cardboard boxes) from Codexa before Wednesday's meeting? Or get Locky to bring it? It appears its 08's spare brake pressure sensor and Nigel needs it back ASAP because one of his has failed."

Kinetic sensor

From Stuart Saare, 24/03/09:

"Did that yesterday afternoon. 07 now has the plug that was in an 06 accumulator, and 06 has an 07 transducer. Incidentally, the transducer I took from 07 also has a dissolved label, so I scratched "40" all over it."

Sensors

From Morgan McDermont, 24/03/09:

"The fuel lines are in the car. They were connected to the rail without the T+sensor, so i would assume its a male fitting on the rail then.

We are still missing one Kinetics pressure sensor. If we can't find it, we should buy a plug for 07 and borrow one of theirs until a new one can arrive, so we can bleed and check 06 as its built.

I had a look in the brown cupboards for the throttle cable with no luck."

Re: radiator and prop valve

From Pete Marsh, 24/03/09:

"I think the radiator bleed nipple is M6. A quick check of the thread with a regular M6 bolt will confirm.

The prop valve internals have been passed from car to car as the 06 ones are the only ones that work correctly. More pistons will need to be made (correctly) to get everything going. Or we can delete the UWAM mod and run standard valving or delete the prop valve all together?

Does the car need the fuel pressure sensor? Is it a map input or something?"

Fuel system - 23 March

From Callan Bleechmore, 24/03/09:

"After a quick perusal of my old mate, the Goodridge catalogue, I’ll have a stab at the parts we need for the fuel rail.

AN825-04 JIC TEE NPT ON LEG 7/16 JIC to 1/8 NPT

AN910-01 FEMALE PIPE COUPLER

CPL-04 ADAPTOR SWIVEL FEMALE COUPLING

I’m reasonably confident that these are the parts for the fuel rail as you can’t get a JIC/NPT tee in anything but an all male affair. A quick check of the fuel rail will confirm/or not, that it has a male thread.

Is the fuel line gone from 06 as well?

I have no idea about the radiator bleed.

Wardy, do we have invoices from Comp Friction that will tell us what we need?"

Brakes update - 23 March

From Chris Ward, 23/03/09:

"I've been trying to work out what to do about purchases but I can't get a hold of Angus and [he] won't reply to my messages/emails. If anyone sees him at uni, punch him in the nuts for me.

There's a few bolts and fittings that the brakes need. I will try and get to uni on wednesday to search for them and the f$*#@g prop valve internals. If I don't find everything I'll place an order at Comp Friction and get the fuel rail tee as well. Can anyone confirm that the sensors are 1/8 NPT and the fuel line is -04? So according to the attached pic we'll need a -04 tee with a 1/8 NPT in the middle (and a npt coupler). What connects the rail to the tee and is it male or female? It's obscured in the pic.


Callan, was the radiator bleed nipple metric or JIC/UNF? Are there any sensors that we won't actually be running with and thus need some sort of plug to replace them?

Anybody spotted a throttle cable in their travels?"

Electronics update - 23 March

From Morgan McDermont, 23/03/09:

"Wed 1st sounds good to me if the engine has a crank in it.

An update on EE stuff:

I have got all the 06/07/08 lipos and charging gear, which 08 no longer requires. This means we have a new charge regulator the same as 07's (ie: it will not charge below 4000rpm, but works great above that). This will do until a better solution comes along, only possible issue will be re-packaging the monster-box behind 06's seatback...

I found the fault in the 06 powerboard (which 07 killed on the morning of their US enduro) and I've got enough bits to fix it.

Re: rear wheelspeed magnet rings: are you sure the one you have was a spare Jono? I was looking for these last year when I did the torque sensors, and I found (what I thought was) the 06 spare then. I *think* it is still in the box with the rest of Slobodan's stuff in the lab. Is it possible that we actually found 06's LH and RH rings and the spare is still AWOL? Or have we both re-found the same ring?

I've found the original 06 fuel pressure sensor. However the blue anodised t-piece that holds it to the fuel rail is missing, and is unlikely to be found (read: it's in the lab). Callan/Pete: can we buy another? I looked for it and noone knows where it went...

I still can't find that extra driveshaft with the 07-spec inductive torque sensor on it. This means we have to use 08's spares, but that is cool with 08. They aparrently will fit.

It looks like the barb on our second waterpump was butchered/murdered by 08 to fit to the dyno for a pump comparison test. However we only ever had 2 pumps because we were worried about reliability of the new pump type. 07 only had one and ours never broke so I suggest we modify the return pipe and just use one. If we want two we will also have to re-make the L-fitting between them as its still missing. All we will need is a longer blue silicone hose. AFAIK there was some spare in the fluids crate but its prolly gone by now. Stu, have you seen any lying around?

I borrowed the front linear pots from 07 as it turns out they are relatively easy to replace there, and the wire lengths are ok. This way we can fit them to 06 before the engine goes back in, and give the new ones to 07 if/when they finally arrive. Miller, did you dig up the invoice for those? Most other bits should be ok to use. If we can get a good idea when we are likely to want to first run engine/ drive it, we can give 08 some warning and borrow the ADL/telem for troubleshooting.

Engine update - 23 March

From Greg Chapman, 23/03/09:

"Haven't had as much time as hoped to play with the engine. Apart from the oil pump, a big end bearing, and the internal pieces which are missing, everything seems to be in reasonably good nick. I'll see what I can grab from uni during the week. Spoke to Luke who said there is a box of F4i parts for me to go through.

I wasn't planning on taking the head off unless anyone convinces me otherwise. Need to check valve clearances still.

Won't know if 1st April suits until Wednesday. I will look to have the engine assembled for that day, however being April Fools' Day I may leave out the crankshaft."

Regarding rear spindles

From Jonathon Lowe, 23/03/09:

"I’m not sure what the deal is with money. I would suggest running it by Angus if you can find him. Maybe he would let us throw it on the Motorsport account. If it really doesn’t have a huge effect on the life of the spindles then I’m all for something like zinc plating.

How does Wednesday April 1st sound for a rebuild evening?

Let us know if there is anything outstanding that wont be ready by then that is a major component. I’ll bring the bbq down again like last time."

Jonathan

Rear spindles - 23 March

From Pete Marsh, 23/03/09:

"The new rear spindles are machined. If there is no money for nitriding of them shall we just get a light zinc plate or something similar at done at AAEP for free so they don't rust?"

Progress update - 18 March

From Jonathon Lowe, 18/03/09:

"Greg looked at the engine over the weekend. Oil pumps have some damage but he recommends that only the oil pressure pump be replaced, scavenger pumps should be ok. Not sure about the cylinder walls but will try and inspect them without removing head. Nothing else major to report.

07 water pump was returned so I assume 06 still needs another second water pump.

Nando pressed out the rear spindles. No Belleville springs or speed sensor rings were inside. I did find one speed sensor ring in a box but it appears to be a spare, should check dimensions. Have the originals one been stolen or lost?

Wardy got rotor hat spacers laser cut.

I’m still yet to get a set of diff internals from Locky and insure they suit 06.

Also Locky said Tim Slako is happy to provide oil for old cars but would prefer only dealing with one person so best to go through the current team. I’ll chase both of those things up."

Engine Out - 4 March

The engine was removed from the chassis on 4 March, along with the rear suspension, drivetrain, electrical system and Kinetic suspension system. Engine-out is a relatively straight-forward procedure, and will allow closer inspection of subsystems. Any minor repairs will be conducted on the subsystems and then the car can be reassembled.

The engine being removed from the chassis

Rear suspension and drivetrain components

Iron Chef Jono Lowe cranked out a UWAM cook-up, supervised by Chris 'Kenny' Ward

Greg Chapman's workshop attire resembled a mullet hairdo - party up the top, business down the bottom

Stu Saare and Morgan McDermont (unsuccessfully) attempt some fine 'recalibration; of expensive precision linear pots