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Gazzar

2.5 petrol rebuild and conversion to EFI thread?

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Watching this is getting to be like watching Binky...

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Without the lucrative product placement.

Yet?

  • Haha 1

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Make no mistake, if you want to have your product placed prominently in the rest of the build, please get in touch! All family friendly products considered, fees reasonable!

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1 hour ago, Gazzar said:

Simples!

Now, what to fit in place?

You mean what to fit in place of the choke cable?

 

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1 hour ago, Gazzar said:

Yes, I'll work on that after some food. I've next week off and aim to be engined then.

Yeah, stop slacking Gazzar 😉

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3 hours ago, Bowie69 said:

You mean what to fit in place of the choke cable?

 

Yes! Curry hook? Off road MS fuelling map switch?

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Bracketry playing was successful.

Without much measuring I sort of estimated the location of the holes in the bracket.

And drilled them.

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That left the sensor ever so slightly too far away.

Any closer meant that the hex head bolt would not fit.

So cap head bolt was required:

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And a bit of hand filling and the sensor was quite good!

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The bracket is too close to the alternator mount for the sensor to line up with the trigger wheel, so it has to be moved out, I chose to thicken the base to do this.

I found a nice piece of 5mm and welded it to the back, played with the grinder a bit and had a very nice bracket  as a result.

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Etch primer, zinc, primer and satin paint follow.

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Time to align the trigger wheel.

I've set the pulley at TDC, according to the pointer ( I do hope that's right! I think it is).

 

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The gap is nine teeth ahead of the sensor, with the sensor on the ninth tooth.

 

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I then clamped everything with a variety of clamps, and removed, gingerly, the pulley.

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Lost of marking, stamping and scribing followed.

I used the lathe to index the three rings.

I've decided on a M5 bolt, purely as that's the only tap I've got in the workshop.

I've drilled the three rings, through in the places and I'm through in over place on the pulley.

I'm going to tap the pulley before I drill any more, but I've a busy day tomorrow, so decided to stop for the evening. Mainly as I'm a bit tired and I knows I'll mess it up if I hurry.

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Excellent !  
 

The bracket looks great following the shape of the alternator bracket, makes it look more factory.

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Thank you, it worked out well in the end.

I was afraid that it would end up with a lot of welding and strange angles, but that was okay.

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20 hours ago, Gazzar said:

It did occur to ask you, but I knew this series was very original, so it was, to my mind, they best starting reference point.

Plus it was an excuse to get in the LWB, and enjoy that lovely TDI torque! I'll kill the gearbox soon, if I'm not careful.

Yes, please do. Let me assure you, more than most  I've every incentive to seeing this project to the finish. I give you info where I can. By virtue of when I got them, I fall over three and a bit 17H lumps here, thus can supply firsthand pix etc. I've said before, you're lucky to have a 17H. Reckon if most want such things, they're going to have to cobble one together using TDi cranks and 5MB 2.25 lumps. Until you came along, I was reckoning to have the best incarnation, thus more than happy to work in datum.

17H electrics: For others reading this, the 17H needs a 12V supply to the Weber carb. Without it'll not idle too well. Before my time, mine was a sixer. Can't be too hard to convert what was a diesel.

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Thank you.

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Am I worrying too much about the grade of bolt I'll use the hold the trigger wheel on? It's a cheap low grade bolt x3. I'll use Loctite 660 on the layers as well.

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Yes - you are 😍

There are no shear, compression, or tension forces on that bracket that would justify much more than cheese to hold it on.

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I know. The bolts are made from cheese, though, which is why the Loctite will be used.

On a related note: is the pulley made from cast iron, not steel, if the drill produces grey dust, rather than silver coils?

Thanks.

 

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Trigger wheel all tapped, fitted, stuck with Loctite in many places, tested for alignment and painted.

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Sensor bracket fitted too!

I think it doesn't look too out of place.

It would look better if it was cast steel, but good enough.

 

 

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Management permitting, I hope to have the pulley on and keyed up tomorrow.

Again, management permitting, lifting brackets, off engine stand, flywheel and housing fitted. If I can find the bolts!

I might be able to get the clutch fitted, but that's optimistic.

 

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