Rob's long term Supercharging project

Well I've made myself immensely popular at work as many different boxes arrived on Friday.

I've got hold of a pair of plasma cut exhaust flanges to go on the cylinder heads, 8mm steel. I've also bought 2 Freelander exhaust manifolds, having been impressed at the quality of the 4 into 2 section with integrated lambda sensor (so it senses all 4 ports). Primaries look to be about 1.5 inches dia, though I've not measured them yet.

Bought 2 over axle parts as well as 2 rear box RC40 silencers and Mini van centre pipes , the rest will be made of pipe I''ve found rootling about in dad's garage.

Theory is that the K series manifold is good for at least 120 bhp; there'll be one on each bank so potentially enough flow for 240 bhp before the exhaust might start to be restrictive. The RC40 is also good for around 130bhp according to my David Vizard A series book and (and there will be 2 of them too).

Current plan is to cut the 4 into 2 parts off, place them in an area of the car where they will actually fit, then join the head flange to the collector with appropriate bits of pipe. Then use two 2 into 1 K series lower manifold parts to get twin 1.75 outlets next to the gearbox. I'll then weld up a little H pipe section and go twin all the way to the back, with an RC40 mounted each side in the very back (after moving the battery box upwards a bit)

I'm attempting to make it out of re-buyable bits for longevity. The manifolds won't be! The K series manifolds leave you with a rather nice 4 bolt attachment flange with a gasket so I can work it so that the thing will bolt apart and back together in situ. Hopefully.

Having said that, there is almost NO space on the driver's side, particularly now someon'e been and fitted a clutch slave cylinder...
 
Well this is rather neat

DSC_0120[1] by 1275midget, on Flickr

K series manifold fits pretty much exactly onto some of the V8 exhaust ports. (cast range rover / discovery V8 manifold for reference and so I don't get the paring messed up)

DSC_0119[1] by 1275midget, on Flickr

or at least, 2 of them anyway.

The other side I'll chop the outside 2 off and fit in the same way.

Now I just have to see if they'll fit in the car like that, I'll feel very very smug if they do...
 
it's bonkers how small it is. Very light too. All the ignition drivers and suchlike are external in the EDIS module. There should be space for it in the space behind the passenger glove box.
 
Well that's stalled now, pre MOT checks have revealed a lot of play in the top ball joint at the front :(

Time to find the monster taper breaker that we made for doing the other side.

That's slowed things down a bit.
 
I like the exhaust manifold plan, very ingenious!

Now it's off the road it's the perfect time to get that supercharger fitted :wink:
 
Going downhill fast here. Battery box surroundings all rotten out. Sill covers are like paper. Sadly, I think a spell off the road is needed rather than another splash and dash minimum time off the road job.

Best to do things right I suppose. It's done the important job of ferrying the sister bride about so time for a proper job. And who knows, if I save hard it may well be back with charger. Yeaaaah.
 
Well, you wouldn't want it pulling itself apart once it's been boosted so probably for the best to get the welding repairs done. You can always get that blower mounted and figure out the plumbing whilst you're at it :D
 
Here's the battery box and surroundings. Might need a bit of a wiring tidy too...

DSC_0022 by 1275midget, on Flickr

Taken the rear wing off, valance is very crusty. Has anyone used a fibreglass honeybourne mouldings valance?

DSC_0023 by 1275midget, on Flickr

Mostly OK inside, though it's gone through a very thin bit between the arch and the shock mount.

DSC_0028 by 1275midget, on Flickr

Forgotten how lovely wheelarch muck in your hair is.
 
That hole is mended now, nice patch on it, lovely.

What's the best way to support the shell during sill mending?
 
Rust cut out (and central bit rewelded - oops, didn't realise there was another box section in there...)

DSC_0035 by 1275midget, on Flickr

Patch tacked in

DSC_0036 by 1275midget, on Flickr

gone all the way through :)

DSC_0040 by 1275midget, on Flickr

seam welded and seam sealanted

DSC_0042 by 1275midget, on Flickr

That there, is my very first patch. It's the first bit of welding that wasn't building a welding trolley I've ever done, which is why it's a bit lumpy. As I go I'll get better though!
 
on to the more difficult bit next then.

DSC_0043 by 1275midget, on Flickr

hmmm.

this is the rear of the sill. Looks like it's been repaired before

DSC_0047 by 1275midget, on Flickr

Sadly, if it's anything like the previous repairs then there will be layers on layers of rubbish.

I've counted 6 layers here under where the cover sill is welded on.

DSC_0048 by 1275midget, on Flickr

Crusty. And damp. Nice.

So I'm going to be cutting a lot of stuff off the back of the sill I think. Any tips?

I know the midget folds up like a banana when you do this to it, do I need to brace the doors? Where should I be jacking/supporting it from (it's like it is on it's wheels now)?
 
that's good to know.

Having a look back through some of the rebuild threads to get half an idea of what lives inside at the jacking points. Can't remember who, but someone strengthened them so that you could jack it 'normally', so that might be a job for inside the sill section.
 
aargh it's bad.

DSC_0057 by 1275midget, on Flickr

entire sill has been covered over with a single big construction. Which is why there's no intented circles on it. They are there, because they've been left in.

see

DSC_0055 by 1275midget, on Flickr

Oh dear.

DSC_0056 by 1275midget, on Flickr

At the moment, it's looking like it's going to need at least a new outer sill (plus the obvious cover)

The inner sill is rotten at the bottom, down by the rear seats. I've done that before from the inside, so that's OK, or will be once it's been tidied up when the rotten outer is removed.

It must have taken quite a lot of effort to build this new sill out of a flat plate.

Chop Chop!

but first, I need to find out what it actually is supposed to look like. Because it sure as anything doesn't look right now.
 
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