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Thread: Dubai Mk1 Duratec

  1. #201
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by Retromotorsport View Post
    Does A2B want a fabricator ...
    Well Gary, if you ever want to escape the Winter, there is always a busmans holiday available out here

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  2. #202
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Well Gary, if you ever want to escape the Winter, there is always a busmans holiday available out here
    Gary hates the heat of an English summer let alone a Dubai winter!!!

    Good work Neil, like Gary says you'll be putting paint on it soon

  3. #203
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    Re: Dubai Mk1 Duratec

    they got air con.. ?

  4. #204
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    Re: Dubai Mk1 Duratec

    Well it does get quite chilly here in winter, average daily temps are around 18-22'c
    Give it a month or so and I will be wearing a jumper while working on the car

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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Well it does get quite chilly here in winter, average daily temps are around 18-22'c
    Give it a month or so and I will be wearing a jumper while working on the car
    Sounds like a normal winter in Norway.....

    Car is looking good! Cage is looking fantastic

    Remi
    (Norway)

  6. #206
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    Re: Dubai Mk1 Duratec

    18°c...brrrrrrrr......defo jumper time!!!!!! it's 39°c here today.....I LOVE SUMMER

  7. #207
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    Re: Dubai Mk1 Duratec

    yeah finally worked in my garage yesterday with the A/C off for the first time in 6 months, will be good for the next 5 or so

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  8. #208
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    Re: Dubai Mk1 Duratec

    Decided to have a go at making my own caliper mounts, the Honda mounts that I was given with with the calipers and discs are made of steel



    So after chopping off the Honda strut mounts with a cutting disc, I had this



    A bit of 5mm steel, a few steel spacers and a mig welder and I had this



    Not the prettiest thing in the world, but certainly strong enough


    Here is the end result, fitted up with the new bells, so for a grand total of £60 (for the bells) I have a lovely brake set-up





    And it just keeps getting better as me old mucker, Spencer has promised to get my steel mounts converted into billet alloy at the local machine shop.

    Finally got my training on the 380 finished and my check ride just happened to be up and back to Heathrow, so it was time for a bit of shopping
    A quick visit to see Peter McKewan at Raceline and one very nice internal pump Duratec dry sump joined the fray.



    The sump is Peter's own design, as the Cosworth one caused no end of troubles for Caterham. It has been widely used by all the Caterham Racers in the various race series this year, with no issues, so is well tested. As you can see it is a pretty complete kit, although I do have to supply my own gasket compound

    Here is the sump pan, I will have to raise the engine up a bit to get clearance, or drop the rack mounts some more in the WCXM, as I need to find about 18mm or so.



    The block needs a little die grinding to clear the new pump's casing



    Old standard Duratec pump on the left, new Raceline designed internal scavange and pressure pump on the right



    Note the in and out engraving on the ports, almost idiot proof that is. So the whole thing just requires one scavenge pipe to a dry sump tank and one return feed back, pretty neat



    Final bit of shopping was a nice set of perfect condition 2nd hand Arrow rods, a lightweight steel flywheel and a modified chain tensioner, all in all not a bad days shopping.



    Plan to get the block/sump/engine mounts/X-member sorted out and fitted to the car over the next couple of days

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  9. #209
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    Re: Dubai Mk1 Duratec

    Its been a while since i read this thread
    Cracking work as usual and that sump looks luuurvly
    Cheap brakes too

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    Re: Dubai Mk1 Duratec

    Nice work neil, should see some quick progress now your messing with shiny bits Cant fault the brakes at that price!!

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    Re: Dubai Mk1 Duratec

    Cars coming on a treat impressed with the brakes, its certainly warm in Dubai today, unfortunately im stuck in the airport waiting for a connection to Dehli. One serious place!!!

  12. #212
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    Re: Dubai Mk1 Duratec

    Thanks for the comments lads, well managed to get a couple of days work done. Got the drivers side seat mounts welded in and the Sparco seat all mounted up, just forgot to take any pictures...

    Anyway on to the interesting stuff. I did a trial fit of the Raceline Dry Sump and bu**er me if it went on with no BIG clearance issues. The design of the sump means only the middle channels get in the way of the rack. As it was fitted up to the Retro Ford World Cup Cross Member (WCXM) with zero clearance, i.e, just touching.



    Here you can see the rack resting on the oil channel and Raceline logo



    But most importantly the clamps are all clear



    I had planned changing the car to LHD, but the steering box of the LHD rack fouls the scavenge ports



    So scrub that idea, RHD she remains. To get some clearance on the sump, I could have lowered the rack a bit more, but instead decided to raise the engine by re-drilling the mounts. The engine has heaps of clearance between the head and strut brace and the 2.3 engine is 13mm taller, so initially went for a 10mm raise on the mounts.



    This combined with buffing off the raised Raceline logo gave me a solid 12mm clearance, a bit much I think.



    So when I welded up the mounts, I put it back a few millimetres, end result is a nice 8mm gap as demonstrated by the 8mm Allen key, you can just see slid into the gap



    Still a solid 25mm under the strut brace



    Minor problem to tidy up, is the bottom of the gearbox, will need to make up something to blank the hole. Note this is the MX5 box, there is a filler/skid plate solution available for Type 9's etc.



    Finally got the steering column mounted, had to hack the original column mount off, then shorten it and re-weld to suit the bracket I fitted to the cage cross bar. Nice and solid now.



    Here is a picture of my purchase from Mark in BKK earlier this month. I took off all the trim bits, as they look superfluous on a race car



    Very happy with the wheel and an absolute bargain at the price
    Last edited by dobuy; 18-11-2009 at 17:06.

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    Re: Dubai Mk1 Duratec

    beautiful car mate keep up the good work

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    Re: Dubai Mk1 Duratec

    Neil,
    Just read through all your project thread. Very impressive.
    Are you doing a complete dummy build before painting the shell?

    John

  15. #215
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by quantumjohn View Post
    Neil,
    Just read through all your project thread. Very impressive.
    Are you doing a complete dummy build before painting the shell?

    John
    Thanks John, would like to do a dummy build, but the problem for me is getting all the parts to Dubai in time, so unlikely, except for the mechanicals. I want to paint it while it is still cool here in Dubai, as the paint might go off to quickly if I do it when it is 35-40'c

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    Re: Dubai Mk1 Duratec

    What a great update, plenty going on there........do like the Dry Sump Kit from Raceline

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    Re: Dubai Mk1 Duratec

    awsome build. I salute you
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    I want to paint it while it is still cool here in Dubai, as the paint might go off to quickly if I do it when it is 35-40'c
    Funny, it's the other way round here. I didn't completely dummy build mine because I was rushing to paint it before it got too cold!

  19. #219
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    Re: Dubai Mk1 Duratec

    OK, well me old mucker Spencer managed to get my cobbled together brake brackets, scanned and cnc'd in alloy for me, very nice they are to





    Had to shave a bit of the back to clear the pads with a soft flap disc and also the cut out for the steering arm



    Decided I needed to cop a bit off the right hand engine mount



    So I could get my new mild steel SBD supplied headers to fit



    Still a bit tight, bit worried about vibration, but I might just weld a tag onto the manifold to pin it to the engine mount



    Nice bunch of banana's



    I had to chop away a bit of the chassis brace to get them to fit as well, but simple enough to plate that with a cut-out.
    Picked up some 2.5" mild steel tube in Auckland on holidays and a silencer, so currently making up the exhaust, will mount it under the axle as it will only be used on the track.

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  20. #220
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    Re: Dubai Mk1 Duratec

    It's coming along really well mate

  21. #221
    Pit Crew Decade Plus User 105Ian's Avatar

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    Re: Dubai Mk1 Duratec

    looking very nice and comming along well

  22. #222
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    Re: Dubai Mk1 Duratec

    dude, if you wanna bring any standard duratec parts back to the uk, lemme know, i'm only down the road from heathrow

    once again, this build is looking great

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  23. #223
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post


    Still a bit tight, bit worried about vibration, but I might just weld a tag onto the manifold to pin it to the engine mount



    Nice bunch of banana's



    I had to chop away a bit of the chassis brace to get them to fit as well, but simple enough to plate that with a cut-out.
    Picked up some 2.5" mild steel tube in Auckland on holidays and a silencer, so currently making up the exhaust, will mount it under the axle as it will only be used on the track.
    Looks very familiar

    I guess it's touching the mount as most installs use chassis mounts where you can get more clearance with the tube style mount.

    You shouldn't get any movement between the manifold and engine mount.

    Mine has been superb with no problems at all

    Build is looking great

  24. #224
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by cossie matt View Post
    Looks very familiar
    You shouldn't get any movement between the manifold and engine mount.
    Thanks for the logic check Matt.

    Adam, thanks for the offer, although it looks like you want me to bring you parts!! Hopefully I will get up to the Autosport show and pick up a load of stuff. Still have to decide if I stick to Emerald for the ECU or get something else

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  25. #225
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    Re: Dubai Mk1 Duratec

    OK, well too many distractions like holidays and the Autosport show, but finally managed to getting down to a bit of work

    First off knocked together an exhaust sytem from some tube and a silencer I picked up in NZ on hols



    Put it under the axle, but think I have given it too much clearance, so will wait until the car is on it's race wheels and tyres and adjust the bend to suit the ride height



    Got bored one day and decided to make a GRP top to the gearbox. Was going to weld something up but as the angles are all over the shop because of the 10 degree cant on the gearbox, GRP seemed like a better option.



    Still needs a bit of fiddling with, but is largely there. It will screw into the tunnel top which has rivnuts inserted to hold



    Some shopping arrived from the US



    In case you are interested it is this one here £121 on eBay

    Also Rally Design sent me a nice little delivery



    and my DS tank



    Which of course means it must be time to cut another hole in the car



    Then a few bits of steel



    Welded it all up, then realised I had no idea if the front wheel would rub on it at full lock, so on with the crossmember and suspension and lo and behold, its all good. Even room for my 15"-ers



    DS tank fits in a treat, had to cut off the square base and need to find some suitable securing strap, but it's all good





    Tidied up my chassis strengthener that needed to be chopped to clear the manifold as well as chamfering the compression strut to clear the exhaust



    So that is about it for the last few days work

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  26. #226
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    Re: Dubai Mk1 Duratec

    coming along nicely

  27. #227
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    Re: Dubai Mk1 Duratec

    Always like to read this thread. Love those brakes

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    Re: Dubai Mk1 Duratec

    always lurked in this tread.....what a cracking job your doing on this car.....will be savage when done.....keep the pics coming

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    Re: Dubai Mk1 Duratec

    Love those 2 Rally Design bananas. Great idea for the Dry Sump Tank, Good Luck.

  30. #230
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by smicker View Post
    Love those 2 Rally Design bananas. Great idea for the Dry Sump Tank, Good Luck.
    Wondered who would comment on my Bananas

    Can't say the DS tank position is my idea, it was stolen from one of Gary's mods on andypipes car I think.
    I had to cut mine in a bit deeper than Gary did, as I needed lateral clearance on my radiator.
    The great thing it it is relatively economical, as will need bugger all hose and the tank only cost £95 from RD.

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  32. #231
    Way too much free time Decade Plus User Retromotorsport's Avatar
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    Re: Dubai Mk1 Duratec

    Not really my idea, but yes, we've put a few tanks there, mainly because Arron at HT insists on the tank being in the front

  33. #232
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    Re: Dubai Mk1 Duratec

    Coming along nicely...

  34. #233
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    Re: Dubai Mk1 Duratec

    Has most definitely been a great thread to follow. Great work happening there!!
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  35. #234
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    Re: Dubai Mk1 Duratec

    Another quality piece of work you are doing a cracking job

  36. #235
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Some shopping arrived from the US

    Tell us about this gizmo. 8 fuses but seems to be alot more wires than that. Is it a more cost effective way of re-wiring from scratch? Are the 2 silver canister looking things and black box between for indicator flashing?
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  37. #236
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    Re: Dubai Mk1 Duratec

    Yeah it is 8 circuit, so for example one circuit will be the lights, so you have head, side, tail, fog lights and all their associated wires for switches.
    If I lived in civilisation with good (accessible) supplies of car electrical stuff I would do it from scratch, but this seems like a reasonable way to go.
    The good thing for me is that all the wires are labelled, numbered and of the correct rating for the job, will let you know how I get on.

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  38. #237
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    Re: Dubai Mk1 Duratec

    Price probably doesnt seem all that bad......will be interesting to know how it goes!
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  39. #238
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    Re: Dubai Mk1 Duratec

    Well, lots of little stuff done this week like filling grommet holes in the floor and welding the dashboard to the roll cage cross bar. Also did a little repair around the dash top were the roll cage comes down, as I cut a bit too much away when installing the cage


    Decided against going the silly money to a Stack or Race Technology Dash and instead just go for the bare necessities. So for £120 all in, Auto Gauge Rev counter, oil pressure, oil temp and water temp gauges and a bit of Carbon were sourced off eBay, here is the cheapo version







    Doesn't look too bad, but not sure about the vinyl top in a race car, shame it is mint and I know lots of purists would kill for it


    but my angle grinder kind of slipped and




    The sanding flap discs on the angle grinder a brilliant for shaping the foam, so a bit of GRP layered on top


    Then a bit of filler to smooth it out


    Just needs a lick of paint now

    Managed to pick up a FIA (FT3) Fuel Cell off eBay in the USA for a reasonable sum, so availing myself of the company's discounted courier service




    Securely bolted to the Floor




    Plan to use an internal pump and a built in swirl pot, to cut down on all the hoses and unnecessary bling.

    Tidied up the gearbox hole surround, ready for paint


    And finally got my flap discs out and cut off the big lump of engine mount on the front of the Duratec's chain-case

    Two of the holes were tapped and filled with blanking plugs, as one mounting bolt will be plenty

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  40. #239
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Dubai Mk1 Duratec

    Nice work there
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  41. #240
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    Re: Dubai Mk1 Duratec

    Once again....fantastic!!! Makes me wanna fly out there and take a look.
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