Project EXI

The building of a Marlin 5EXi kit car, using a Seat Leon 1.8T 20v Donor

Aug 15 2010

Radiator Mounts completed, Horn fitted, instruments connected


Again another busy weekend.
- Finished paint and prep on intercooler/raditor mounts.
- Fitted radiator and intercooler into A-Frame,
- Fixed radiator pipes through tunnel with 6x 35mm pipe clips, had to make hole in front bulkhead slighty bigger. Two clips on rear bulkhead, two on front bulkhead and two on tunnel cross member with spacers in front of gear change mount.
- Extended MAF sensor wiring and covered in wiring pipe.
- Fitted Boost pressure sensor into small lenght of 57mm pipe, and connected in line to throttle in take housing.
- Fitted Header tank and replaced feed hose with 15mm heater hose.
- Fitted horn to front bulkhead, and connected wiring to terminals.
- Fitted brake level wiring to reservouir
- Fitted Adjustable thermostat control wires to thermostat and radiator fan.
- Fitted 6 way instrument warning panel to wiring loom, ready for first electrical power on.

Posted by Steve | Permanent link | File under: heating and cooling

Aug 11 2010

Radiator Mounts painting


Preped the new metal work and applied one coat of Enamel primer.
Decided on enamel grey as this is going to be a tuff finish.
Updated the wiring diagrams to show a few more ECU connections

Posted by Steve | Permanent link | File under: heating and cooling

Aug 08 2010

Header tank mounted, Radiator Mounts finishing


The weekend was a very productive one!!!
I now have a header tank mounting bracket welded in place. With nylon spaces and grommets to mount to reduce the shock the aluminium tank will tank. The weld needs a small tidy up but is looking good.
The front raditor mounts, extension brackets on above the intercooler, Ive done some grinding and filing to tidy these up. Rounded the corners off, these need some cleaning before prime and paint.
I have some grinding and filing work to do on the radiator A-frame, then this can go to prime and paint.
Also have a bracket to support the intercooler pipe of the gear box, again some more grinding work and filing to be done here before prime and paint. The bracket for is recycled from the turbo downpipe fitting, the pipe clamps needed widening a little from 52mm to 57mm.
There is also a M10 25mm spacer which bolts into the gearbox and this holds the bracket away from the gearbox.
I want to prime and paint everything in one go for obvious reasons, once painted final fixing of these components can mvoe on.
Ive also made an aluminium plate that is bolted to the right hand side panel which supports the brake/clutch fluid reservoir above the inlets on the master cyclinder. This avoids fixing the reservoir to the front bulkhead, where space is limited, and height above cyclinder inlets an issue, due to the drop on the dahboard.
Also fixed the adjustable fan thermostat to the side panel, allowing easy access to for fan temp.
Have to say a big thanks to my neighbour for giving up his weekend and doing alot of the metal fabrication for me !!!

Posted by Steve | Permanent link | File under: heating and cooling

Aug 05 2010

Radiator fan controller

I ordered an adjustable radiator fan controller, a thermostat hose mount and union from CBS.
I dont know why, but the hose connector is a 10m thread, the union is 1/4" american thread. Not even UK one!! CBS sell these two parts as a kit, and not having them fit is stupid. They charge 5 pound to re-tap it!!
I didnt bother with getting them to re-tap it. My neighbour had a tap set that would work on it so he kindly done that, and it all seems to work together.
I also set about cutting out a new rectangluar aluminium sheet to make center console version III.
I dont need nor want two rows of switches, so now I will have a row of 5 switches in the middle, a power socket in the bottom left, a starter & kill switch in the bottom right, and if space allowed two 52mm gauges at the top.
I want to keep the dashboard recess for either a heater control matrix or GPS logger with screen.

Posted by Steve | Permanent link | File under: heating and cooling

Aug 04 2010

Radiator top Mounts


Moved forward again with the radiator mounts.
We made some small cap to fit over the plastic mount point of the intercooler, so then when bolted in the plastic cannot split. This should prolong the life of the mount points.
We decided to make some u shape brackets, one will bolt to the radiator and the other side will just hold it in place. It is bolted on one side so that should be sufficent.
I also started to cut the silicone hoses leg length down.
I need to tap out the hose adpater to 1/4" to hold the fan temp sensor.
I can then bolt the adjustable thermostat to the side panel, and get that wired up.

Posted by Steve | Permanent link | File under: heating and cooling

Aug 02 2010

Designing some Radiator Mounts


My and my neighbour have fabricated a mounting scheme to hold the intercooler and radiator in place on the front A Frame.
The feet of the radiator fit into some large grommets that are held in place by two metal plates welded onto the lower intercooler mount at 90 degrees.
The side of the intercooler is now held in place by two removal brackets which get bolted to the side intercooler brackets.
We have yet to weld brackets to hold the radiator, that is tonights job.
My Order from CBS has arrived, so I now have the replacment header tank, air horn and a few other nice things.
My additional hose from Viper should also turn up today !

Posted by Steve | Permanent link | File under: heating and cooling

Aug 01 2010

Wiring, ECU connections, Center console, Radiator brackets


I spent most of the weekend finishing off alot of the wiring,
I have connected the ECU to the switich / permanaent live.
Extend some wires for the center console, soldered in additional wires for the dashboard indicator dual lamps.
Connected Alternator warning lamps.
In doing all of this I also made a the hole in the rear bulkhead bigger so I could feed the ECU loom thorugh here, and cut some aluminium to allow me to close up the hole and fit a grommet over the cable ends.
I've started working with my neighbour to weld on some bracket to securly mount the radiator, above the intercooler. Work will continue on this tomorrow night.
My order from CBS should arrive tomorrow, so I can then get the horn, fan controller, header tank fitted.
I also found I was one silicone hose short for finishing the coolant plumbing, so have ordered the missing 35mm 90degree bend from Viper Performance.

Posted by Steve | Permanent link | File under: heating and cooling

Jul 29 2010

Aftermarket Header Tank


Ive decided to invest in a verticle header tank from Car build solutions. This should fit into a space above the RHS rear wheel, roughly where the pipework from the donor is. Alternativly a vertical mount tank can be fitted on the rear bulkhead.
Also on its way is an
adjustable fan thermosat, with 32mm in-line pipe housing and union
6 way dash panel warning light
Carbon S/S air filter with ducting
High temperature silicon selant (for exhasut system)

Posted by Steve | Permanent link | File under: heating and cooling

Jul 28 2010

Wiring loom additions, Fuel hose adaptors, Header tank


Ive identified two wires that was missing in my wiring loom, so have now update the wiring to version 5.15
The missing wires are all related to ECU power,
we need a permanent live from the battery fuse plate to the ECU
and also from switched live Ignition 15 through a fuse to the ECU. I have added this onto my wiring loom and just need to connect it up.
I received the 10mm to 8mm fuel hose apdapters order from EBay for £2.20 instead of £6.00 from car builder solutions. Great saving, I did order 3 but found I needed 5 in total, as the copper line provided is 8mm and all the connections on the fuel tank and swirl pot are 10mm. It would be good if all connections were 8mm. But that is joys of building a custom kit car from custom kit peices.
Im in two minds at the moment as to wether to replace the donor header tank. The main problem is where to fit it!!! There isn't enough room to fit it between the engine and the rear bulkhead. and fitting the round donor header tank to the chassis round bar on the right hand side is going to prove tricky.
I have seen the Horizontal header tank from Car build solutions, and at 150mm diameter should fit in between the engine and the tank. I now have to justify if the £94 + VAT expense is worth it. (I think it might be)

Posted by Steve | Permanent link | File under: electrical

Jul 25 2010

Intercooler connecting the pipe work, Fuel pipe fitting


I spent the weekend cutting the pipework so I can route the turbo output to the intercooler side pipes. I recevied the silicone hoses from Viper performance and have fitted the last remaing section to complete the intercooler circuit.
I also fitted some hoses over the orginal passenger heater connections and fitted a billet aluminium plig to block these off. I haven't destroyed anything in this aera in case i need to get access later.
I have bent the copper pipe work and temporaily fitted two runs down the driver side to complete the fuel circuit, also order 3 more 8mm to 10mm fuel hose adpaters as there is a mixture of 8mm and 10mm connections all over the place.
I also have the hoses to complete the coolant circuit, just need to get the raditor permantly fixed by welding some supporting brackets onto the intercooler brackets.
Work is not happening fairly quickly now I have the parts, and first fire day is approaching !!

Posted by Steve | Permanent link
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