ZX 16v

[welshpug]

Right then, last picture of the ZX being bunged in the garage was taken back in June 2013, fast forward to July 2014 where progress starts up once more.

[quote name="welshpug" post="1426254" timestamp="1406490999"]
whoah, time flies!

its been sat outside the garage for a few months again as I stuck the 205 inside, not dome much to it really, I sorted the weeping brake unions and bled the brakes again, and more recently just been waiting for a friend to have some spare time to weld it up for me, we did think of making a start on it today but he has a house he's painting for his dad which is dragging on a bit unfortunately, so I took it to bits again...




Unplugged the engine loom...



Faffed about with the auxillary loom adding a few plugs and wrapping it in tape, then added the DTA loom I had made, made up the last few connections to mate it to the car temporarily, then bolted the bodies on...



yes, I do have a rusty looking rad, but it doesnt leak, AND I have an alloy ordonez rad spare I can fit to it if needs be.

I then thought, errr, all I need is to bung a coilpack on and it "should" run....

so I did! https://flic.kr/p/ocNe87 (video link)



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[quote name="welshpug" post="1426659" timestamp="1406806035"]
Progress!

borrowed Antons trailer!



though when I pulled up Anton was making funny faces looking at the trailer, I hadn't realised the nearside rear wheel was steaming away, what with Dan sticking his arm in the way of the mirror all the time, and Diesel smoke going down that side of the car too



looks like a lining had detached itself and got wedged, cooking all the grease from the wheel bearing too!

in the workshop jacked up already

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[quote name="welshpug" post="1429174" timestamp="1408655845"]
A few weeks have passed, Anton has waved his weldy torch over the grotty bits, a new windscreen fitted, and finally this evening he dragged it back for me, he'd lashed up a quick throttle cable bracket from some wire to aid moving it

Thought I'd best make a proper bracket and see if I could get full travel without lifting the pedal too far, or having to bury it in the carpet.

a bit of steel angle, a rivnut, a threaded adjuster barrel and a 90deg v-brake noodle and I have myself a £90 saving on a Jenvey linkage kit.

20140821_204632 by WELSHPUG, on Flickr

20140821_205738 by WELSHPUG, on Flickr

20140821_205802 by WELSHPUG, on Flickr
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[quote name="welshpug" post="1429235" timestamp="1408736891"]
more progress after work this evening, as my bodies are short and I have long trumpets, and normal length Weber gti6 injectors I needed a stepped backplate, these are usually over the £50 mark, but inspired by Kristian (Black_Mi16) who had made his own stepped backplate from some sheet steel, I cracked on with some C.A.B.A.D*

20140822_174904 by WELSHPUG, on Flickr

(*Cardboard And Beer Aided Design)

20140822_181739 by WELSHPUG, on Flickr

20140822_183116 by WELSHPUG, on Flickr

20140822_183507 by WELSHPUG, on Flickr


Bolted the centre piece under the trumpets to figure out where the injector securing bolt reliefs needed to be.

20140822_190223 by WELSHPUG, on Flickr


Transferred the design onto some steel sheet.

20140822_191317 by WELSHPUG, on Flickr

chopped it out.

20140822_194531 by WELSHPUG, on Flickr

carried on chopping and a bit of holesaw action, had nothing to hand to do the radius cut unfortunately, but it wont hurt to have some flat edges instead of curve.

20140822_202131 by WELSHPUG, on Flickr
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[quote name="welshpug" post="1431124" timestamp="1410353193"]
I did finish off the airbox, not 100%^ happy with it, I haven't much experience of welding tin and I put a bit too much heat into some parts so its not as flat or pretty as I'd like it to be.

[url=https://flic.kr/p/oQgZzG]
20140823_084153 by WELSHPUG, on Flickr


20140823_121759 by WELSHPUG, on Flickr

You'll notice it now has more black panels on it now, I am thinking of making the whole car black as with the old shell.


20140823_134811 by WELSHPUG, on Flickr

Found a few of my trim clip bags though I still need a few more, some parts will need sticking on with some structural automotive adhesive.


20140909_183209 by WELSHPUG, on Flickr

moved the radiator fan across to the left side and fitted an Alloy Ordonez radiator I'd got hold of, then had a fiddle about with an oil cooler to see if I could make it fit without spending loads on new pipes, gentle persuasion of the steel hard pipe and shifting some brackets on it means that no longer fouls, but the low pressure feed from the reservoir needs re-routing a little so its not rubbing on them constantly (I plan to retain the standard heat exchanger as it aids warmup, and using the thermostatic control on the oil cooler to stop it over cooling at the same time as adding extra cooling capacity)


20140903_190109 by WELSHPUG, on Flickr


20140903_194332 by WELSHPUG, on Flickr



rear seats and cards fitted.


20140905_163733 by WELSHPUG, on Flickr
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[quote name="welshpug" post="1431125" timestamp="1410353769"]
got hold of some Clio 182 Weber Pico IWP 042 injectors, flow 250cc/min @ 3bar, decent spray pattern I hear, and most importantly shorter than the IW204 gti6 units.


20140905_171609 by WELSHPUG, on Flickr

which means this fits


20140905_171915 by WELSHPUG, on Flickr


20140905_171931 by WELSHPUG, on Flickr


though with the trumpets I have the filter doesn't fit, so I still need a stepped backplate, or if possible some Satchell trumpets with the backplate bolted to the back of the radius of the trumpets.


20140905_173035 by WELSHPUG, on Flickr

then I took the inlet and loom off, made up an extra bit of loom for the other injectors, seeing as the ecu and the bodies have capacity for twin injector's why not?



20140907_150538 by WELSHPUG, on Flickr



Stuck the standard loom ecu and inlet back on for now, as I want to get it MOT'd, looks a bit like this.


20140907_170047 by WELSHPUG, on Flickr



got my set of part worn Michelin PE2's and C5 wheels fitted up with new valves and balanced.


20140910_113539 by WELSHPUG, on Flickr
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[quote name="welshpug" post="1433163" timestamp="1411930933"]
progress since the last post has been that I fitted a standard 24mm rear arb, and stuck on the drivers side front arch trim, also got hold of an 075 battery off a mate scrapping a mk4 golf in exchange for one of my dead batteries.

and the V5 finally turned up, so its off for an MOT on wednesday (1st of october)
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so, Wednesday came...

this happened....












20141001_131837 by WELSHPUG, on Flickr