1268 replies to this topic

[Doctor Ed]

Astra J OPC (A20NFT) For TÜV i need to use the oem cat for that engine. Conveniently it's a big 3" in/outlet cat

[Doctor Ed]

for reference, the starting point... from an Astra J OPC with A20NFT

[Doctor Ed]

2016 Ford Focus RS 'Frozen White'

[Doctor Ed]

So... time to make a to-do list! Small fiddly stuff to do first: - retrace the ABS (FL) and DRB (RR) cutout wires, and mark the switches (memory is failing) - rerun thermostat sensor wire and fan control wires down the sill to the back of the car - replace one dodgy dash switch - refit the heater control panel and heater piping/valve assembly. set the cable in final position - wire up and finish installing the 6sp reverse lockout mechanism - pull the shifter and handbrake cables through the chassis in preperation for the engine/gearbox install - replace the airbag and pretensioner control module (bought a new one as itll suck to find the one ive got doesnt work once other sh*t is finished) - mount new driver seat mounts and enjoy the newfound legroom Medium sized fuckaround stuff: - Swap the ABS control module for the 4chan Deawoo one I got (S108196010 C) - Bend up new brake cross-over hardlines and fit to the ABS pump - mount the brake fluid reservoir and hoses to the master cyl - Finish the fueltank/pump wiring and speedflow hose assembly, and remount the tank - Finish the speedflow lines to the 044 and surgetank Large stuff that i need to do properly: - Fit and bond new crashbox - Fit and bond new windscreen surround - Jig up and reweld the hardtop mounts to the rollbar - design and make a new rear Firewall section to enclose the W2A intercooler core - design and make the W2A core mounting brackets - reweld the W2A core water fittings to suit 25mm ID hose when thats done... get the goddamn motor in... - flywheel is in production at TTV and due for completion on the 20/08 - need to mount a new clutch slave cyl to avoid that sinking feeling of a leaking clutch once all assembled - i busted the reverse switch on the box off. oops - need to get me some reinforced motor mount bushes - intake pipework - exhaust pipework

[Doctor Ed]

Not good enough to really brag about, but my birdshit welding is actually starting to look like it could hold water.

[Acidpopstar]

One hell of a project dude. I wish I had 100th of your knowledge to sort mine. Can't wait to see the final result Sent from my iPhone using Tapatalk

[Doctor Ed]

Thanks mate It's 1000 little projects come together all at once, will be good to see it all working together!

[Mopeytitan]

Not good enough to really brag about, but my birdshit welding is actually starting to look like it could hold water.

Be fair to yourself mate that's not bad at all! Only thing I can see wrong is it's not straight all the way around but unless you have a jig that rotates you will never get it perfect. Love your project can't wait to see it finished! I know the feeling of it's not just one it's a 1000 jobs mine is the same!

[Doctor Ed]

so... direct swap eh...

either the daewoo wiring loom has the FR + RR wheel speed sensor inputs swapped at the ABS plug, or the control solenoids/outputs/brake lines are swapped (compared to the Lotus ABS unit).

so which is it? anyone have a Matiz wiring diagram with the pinouts of the ECU control unit?

[Doctor Ed]

well, ill answer my own question Matiz pinout/wiring diagram here: http://www.autocats....M2_5_25.en.html vs VX220 pinout/wiring diagram here: https://www.speedste...el-Vauxhall.pdf now dont let the different numbering of the plug pins confuse you (as they did me), and youll see the Matiz uses a COMPLETELY different pin assignment for the wheel sensors. i wont list them as its futile, but a quick look at the diagrams and youll see what i mean. the ECUs are 1 model number different, so hard to fathom that they are completly and utterly different, but wow, the wiring diagrams sure have them hooked up differently. theres a lot of unused pins, so maybe itll take a variety of inputs utilising different pin combinations, but be fcuked if im human trialing an ABS system swap with this many differences. (and even then, the ambiguity with the different brake line outputs isnt resolved) so, im putting the VX ABS back in, and will wait for someone else to human fireball this swap i think

[Doctor Ed]

Airbag ecu swapped out for new. PITA to change once the windscreen is in, so do it once, do it right.

[Nev]

Is that the sensor that detects excessive G to trigger the bag ?

 

[Doctor Ed]

Yep. Also has the system controller, system check/error memory etc. if the car's been crashed and the bag or seatbelts deployed, the ecu becomes bricked. My donor had been in an impact, but to my knowledge the bag and seatbelts remained undischarged. Would suck to find out otherwise later though, hence doing it now. Liz has them cheap, so it's a no-brainier

[Doctor Ed]

So, due to fondle's machine going into meltdown, I ended up getting a small bunch of laser cut and folded parts made in the U.K. (Essex Laser). Awesome quality and finishing. Actually sent me duplicates of all the parts at no cost, they were just there when I opened the parcel. A couple of bits needed welding (which I wanted to do myself) which I hooked into after breakfast this morning. Pre and post welding and hitting with a lick of paint...

[Doctor Ed]

Gearbox-end shifter cable termination/mounting bracket. Adapts the standard 5sp shifter cables to the M32 box, including height and offset to the linkage joints...





Particularly happy with the welds on this. 4mm Steel, at least 3mm gap to jump. Did some killer rolling 8's and came up neat as pie.

[Doctor Ed]

Bastardised a Toyota Avensis lift-to-shift reverse lockout shifter collar, spring, gaiter etc. got it fitted up well with a small welded anti-rotation stopper-collar under the sleeve, and bodged up a microswitch. Have yet to wire it up, but it all sits spot on

[Doctor Ed]

annddd... got the mechanics of the reverse lockout installed and finished. Test run hooked straight up to a power supply and it works really nicely. Makes a solid and satisfying metallic click and engage, and the 1-2 gate endpoint is solid as nails

[ChrisS1]

Enjoying reading this, keep up the great work!

 

Far beyond any skills I could even hope to have.

[Doctor Ed]

Thanks mate! I hope it's an interesting read. I'm enjoying just plugging away at it and posting as I go

Meanwhile... I finally got the design for my OEM seatmpunt modification sorted

Simply replaces the intermediate mount plates between the seat rails/base and the seat fixtures themselves. Incorporates the standard seatbelt anchor fasteners etc.

Drops the seat absolutely on is ass on the floor plan, and inclined the seat back further, matching the incline of the fuel tank bulkhead. The head of the seat tucks in nicely under the rollhoop and sits around ~20mm from the glass (so plenty of room for flex without contact).

I'm 6'4" and now have about 3-4" between top head and top of roll bar. Short of a vac-formed custom seat, I'm not going to fit much better I don't think.

Doesn't work obviously with the vx220 headrests, so need to cut those out. Or use an S2 rollbar. Would obviously also work for elise and exige models fine. Can make some to order in case anyone is ever interested.

[Doctor Ed]

Powerflex Black Series motor torque-mounts procured and installed...