Project Custard - Gearbox issues

[custardavenger]

Ok so I'm starting to to a load of mods and thought it would be best to keep it all in one place.

So a bit of background. I had a dyno run at Janspeed with just a Che manifold and a K&N filter. I got 124BHP and 113.5 Torque. A week later it turned the big 100K miles and I fitted a janspeed system. It also has TTE springs and roll bars and team dynamics wheels.

So I have 3 weekends to spend time on mods while my Mum is away.

Weekend 1
Cut bumper where it had melted from the janspeed. Removed the dash to install gauges (more about that later) and removed gearbox to install RPS flywheel and MWR/RPS clutch. First problem was that I think MWR sent me the wrong flywheel bolts as they are 5mm too long and stop the motor turning. Then (Shame) I stripped a thread for the front engine mount. Then with gearbox fitted back on it came to bleading the clutch. Lots of swearing and about 1 litre of fluid later and it still won't opperate properly.
I have installed the extended push rod and a speedsource clutch line and ACT release bearing. I have used Halfords Brake/Clutch fluid (Not sure on which Dot will check). I have tried to adjust the free play to the corect setting. At best I have got it to engage 2 but grinds in reverse which is the gear Toyota recomend to set up with.

Can anyone tell me how far the slave cylinder moves on full stroke of pedal or suggest a solution?

Really don't want to spend next weekend taking it out again

[custardavenger]

Hello anyone out there?

Am I the first to have this problem?

Well as it seams no one can help me and I won't get near the internet for the weekend, weekend 2 will probably be spent removing the clutch again to check to see if there is anything obvious.
I will also (if all goes well with the clutch) be removing the brake calipers for painting as well as a few of the rusty brackets I can remove. Test fitting the guage mount and refitting the dash. Getting new tyres and getting tyres taken off my standard rims ready for powercoat and some track tyres. And if I get all that done and still have time then its stage 1 of fitting the supercharger.

[spit]

Patience Rob  s:lol: :lol: s:lol:  ! I'm measuring the throw of the piston for you tonight - got a friend stopping over who can stomp on the pedal while I'm under the busy end.

I tried doing it single-handed last night but wasn't quite quick enough  s:lol: :lol: s:lol:

[custardavenger]

Cheers mate. I know your there to help me. Just really suprised not one else was.

Will check back here later tonight then.

[DannyN]

Patience Rob  s:lol: :lol: s:lol:  ! I'm measuring the throw of the piston for you tonight - got a friend stopping over who can stomp on the pedal while I'm under the busy end.

I tried doing it single-handed last night but wasn't quite quick enough  s:lol: :lol: s:lol:

You should've shouted matey, I'm only 10mins away and can usually always pop over

D

[spit]

Didn't wish to disturb ... I had you down as a pre-stressed Groom awaiting the big day Danny  s:wink: :wink: s:wink:

Anyhoo, we're trifling in the Custard thread .... back o/t.....

[spit]

Rob -

pedal movement (measured with ruler horizontally from top of footpad on the pedal): 130mm

pedal travel to the start of piston movement: 10mm and you could feel the resistance!

Piston measurements were taken from the lip of the cylinder (once the boot was removed)

Cylinder edge to piston end at rest: 22.5mm
Cylinder edge to piston end on full floored clutch: 34.0mm
Piston travel therefore: 11.5mm

Good luck   s:P s:P    s:wink: :wink: s:wink:

[aaronjb]

Slave cylinder is a pig to bleed (pretty sure that's posted about somewhere - I forget if it was Mark, Stu's or Phil's car we were doing it on), ended up having to use an E-Z-bleed (pressure bleeder) to get the air out.

[markiii]

was mine after we did teh trd clutch line

[custardavenger]

Cheers Ste will have a measure as soon as I get back.

Cheers too Aaron. Had thought of this. Got a mate who owns the garage where I'll be getting my tyres so will ask if he's got a pressure bleeder. I have a bad feeling looking at Ste's measurements thats it's gearbox off time as I recon i was getting something close to that movement.

[custardavenger]

Ok so I'm back in Nottingham after weekend 2 and it's been a mix of good and bad.

I have realised that due to things taking alot longer than hoped I'm not gonna get everything done and have dropped doing the brakes and another couple of things that I'm keeping secret for now.

So first job trying to sort the clutch problem. I checked the movement with Ste's measurements and was getting the same travel on the slave cylinder. So I dropped the gearbox again and found nothing wrong. Refitted, blead clutch with different fluid and vacuum bleader. Was good enough to get into gear but clutch point is about 1/2" from the floor and the gearbox has become very clunky. I'm gonna contact MWR to see what they advise but at least it's drivable. Took it up the road to test it. was a mile and a half away when my mate text me to say he could still hear me (thats how load a janspeed is for you folcks that haven't heard one).

So next it was fitting the supercharger. The kit is the guinnee pig one built by TTS and fitted to Prolex-uk's car. I picked it up on my birthday after a failed atempt at picking it up before.

Fitting meant taking apart even more of my car. And drilling holes in it too. Aarg!

To make this more interesting I'm currently loading the pics taken.

[custardavenger]

Ok Some pics then


Flywheel



Clutch



Issue with flywheel bolts (MWR ARP one on the right)



And as a little tease on an in progress mod I've done this



Just so I could do this



Will be mat black once finished

[custardavenger]

So supercharger. You can all search if you want to see pics of the full kit, They are on here somewhere.



Ok SC fitted. There are a few issues I need to sort out with it. I am not happy with the way it bolts on so have some parts on order from Mr T, The pipe that is lagged need a support making as it is not possible to tighten the supercharger end enogh to get rid of the wiggle room and finally you may have noticedthe duct tape, There is a hole on the pipe which will get replaced when I can source some. Other than that lot its all good here.




The intake mounts on original fixings (with longer bolts) Had to remove the lower heat sheild. I may look at making some custom sheilds for various places later on.




The SC oil cooler. This was a pain. Had to file and enlarge the holes to get it to fit. Very snug. To fit it I had to remove the inner wheel arch. Also found the plastic inner air scoop didn't look right. In the wheel arch I found this.



Staightened it


And everything fitted alot better. Must have had a bump to the rear wing at some point. Also took this opertunity to run various cable into the drivers side storage bin through a new hole and a gromit (gave up trying to get it through the original gromit)

Next fitted the tank and filter.




Note Innovate LC1


Then came the injectors. I know some may say that the connectors should be soldered into the loom but I couldn't bring myself to cut into a OE loom so I made some connectors


And fitted the injectors.


It seams I haven't taken a pic of the intercooler fitted (probably because the wiring is temporay and I'm too ashamed to show that.

So only one thing more to do. Fire it up. After a couple of turns it roared into life. Then we pushed it outside as it is running so rich we were dying from the fumes. I should have taken a video and will do soon but the sound is very interesting. Mainly because the fans are on constant and sound like a hovercraft. Let the PFC settle then gave that throttle a blip and we have boost.
Then stopped car to callibrate the Innovate. It was then when the injectors started to leak. And thats the situation it's currently left with. I have all the seals on order from MrT as I have refitted the injectors 4 times now and each time they leak but I can see nothing wriong with them. Frustraiting.

[custardavenger]

OK car is booked into TTS on Tuesday for a dyno.

Does anyone have a guide to installing injectors. I'm worried that just replacing the seals may not be enough. I have tried drianing the rail of fuel, drying it then pushing the injectors into the rail and then fitting this to the engine.

Anything else I should try?

[aaronjb]

All you should need to do is unbolt the rail, remove the old injectors, push the new ones in (with new O-rings - use Mr T ones, the ones I had from the injector rebuild place leaked) making sure you don't snag an O-ring and then sit the injectors down into the lower isolators and bolt the rail down.

No need to empty it, or dry it, or anything else.. Just make sure it's all properly bolted down or it'll leak like a sieve..

[custardavenger]

Ok then. Well I guess I'll have to hope that new o-rings work then as I tried a few times with the same result.

Cheers

[custardavenger]

Ok after a lot of lunchtimes spent machining, my custom guage and commander mount are almost finished.

Have yet to try them in the dash yet but it will hopefully turn this


Into this


On the left is the PFC commander screen (If it works) Tomorrow I will start painting them matt black so the blend in a little better














Hopefully if all goes well I will get these fitted at the weekend. If not I have a hard decision on whether to put the dash back on or not.

[custardavenger]

BTW update on the clutch. I hacve spoken to MWR and they said they didn't know there was a problem with the blot length. As for the clutch the told be to adjust the pedal.
Now I have already had a go at adjusting the pedal and believe it is currently on its maximum but will have a go again before I contact them again.

[Wabbitkilla]

Nice work there!  s8) s8)

[kanujunkie]

nice machineing is more to the point

[custardavenger]

Cheers Nick.

You know once I've got the guages done the next project I have is something the I think will interest you alot.

[Wabbitkilla]

I'm all aquiver with anticipation - looking forward to it mate.

[custardavenger]

nice machineing is more to the point

Yeah I am quite proud of it. Like one of the guys at work said its a shame to paint it, but they're just too shinny.

[aaronjb]

That does look nice  s:) s:)

Now can you make me one of these:

 m http://www.youtube.com/watch?v=LJ4UmtD15UE m

 s:) s:)

[kanujunkie]

nice machineing is more to the point

Yeah I am quite proud of it. Like one of the guys at work said its a shame to paint it, but they're just too shinny.

why not just spray it with a matt laquer then?