I completed connecting up the fuel system, incorporating an inline fuel pressure gauge and high pressure filter. I've probably gone a bit over the top with filters as i have an inline one at the rear before the low pressure scavenge pump, the standard filter in the bike pump and then this inline high pressure one before the fuel rail. I managed to reuse the clip on fuel pipe connectors between the pump and injector rail
An exciting moment was the arrival of the carbon fibre spacer plate to enable the airbox to be turned 180degrees and miss the injector rail. I wanted to try and keep the seal between the throttle bodies and the airbox, plus machining off the profile from the throttle bodies would mean a fuel strip and clean of the them, something i really didn't like the look of. It also means that the other than the removal of a small bracket on the fuel rail and one small triangular extrusion on the airbox, the engine parts are completely standard, making replacement easy and also hopefully ensuring no running problems. The couple of hours spent drawing up, printing, laying the drawing over the profile, then modifying the drawing and reprinting numerous times paid off, and the spacer slipped on perfectly. A nice touch is that the guy who made it for me normally makes the Mclaren F1 chassis's, so now i have a bit of F1 car on my little Fury!! :-)
I should have made it up in MDF first as per the engine mount as few small modifications to the design would have made fitting the spacer a lot simpler, i.e. making it 5mm larger so that the outer most holes on the throttle bodies and airbox could be used and moving the 2 small holes into a central position, but if i ever have any more made i will incorporate this. But with a little thought and few blunted drills (carbon fibre is horrible stuff to work with!) it was attached to the throttle bodies and 4 holes taped into it to attached the airbox to it.
Another small job was some sort of prop catcher, as the prop was higher than before the existing straps couldn't be used. The straps would have also been pretty useless, as by the time the prop has hit them, the reverse gear would have been chopping itself through my leg, so i was keen to have a robust design. Dad had the the brainwave of using the metal support from a centre bearing, so with a bit of grinding and the addition of an aluminium bracket (with curved side just for Tim H ;-) ) a very effective catcher is no mounted as shown below.
Next up was thecam cover breather mod. The 5VY R1 has been known to pressurise the crankcase enough to eject lots oil out of the breather, causing the destruction of said engine. The well documented mod is to add a breather to the cam cover, and pipe this into the top of the catch tank, which then has a return line back to the crankcase breather. Some people block off the AIS valves and fit a breather to the came cover, but another way of doing it is to remove the AIS reed valves and use these as the outlet. I liked this idea as it seemed the simpliest and neatest plan. I got the info from HERE. To route the oil back to the catch tank i just used the standard hoses from the AIS system, removed the solenoid valve from the plastic T piece and cover it with an ali plate and the pipe that normally goes to the airbox now goes the catch tank. OK, i could have used a plastic T piece from anywhere, but this one was free and sitting in the garage, plus it pushed the pipes in the right direction.
The catch tank was mounted on the bulkhead just above the height of the crankcase breather, so any oil that finds it way in there should hopefully drain back in. The photo was taken before the return from the cam cover breather was attached
Next up was the plumbing. The oil cooler was pretty simple, reusing one of the hoses from the original install plus a new 6" longer one for the other. The only mod required around the take off plate was the main water inlet pipe had to be bent out and the mounting bracket back to the engine modified, all to allow the cooler pipes to attach to the sandwich plate.
The water pipes were also pretty simple once i'd gathered together all the info of where all the pipes went (see HERE). I only needed an extra couple of meters of hose, 1 x 90deg pipe and some extra aluminium pipe, which i was very pleased about, the price of silicon hose is criminal! There were a couple of places where hoses were required to T into the main upper and lower hoses, so we had these welded into the aluminium pipes.
With all the pipework in place it was time to bolt the exhaust back on, and get the pictures i promised earlier. Its not a shiney stainless system, but its beautifully made, and just slides together
A nice touch from Tony Law Exhausts:-
Finally the airbox needs some clean air funnelled into it. The intake of the airbox is under the airbox which is now above the gearbox. The addition of the 15mm spacer helps with the available space, but some kind of 90 deg bend was required to mate the triangular intake and bonnet scoop/air duct. Some hunting around in the garage and head scratching and we were heading towards making a fibreglass mould based on a shaped foam plug. That was until dad scurried off to the bathroom and returned with a toilet U bend
It was the start if a good idea, but i refused to have anything that is designed to have turds passed through it attached to my car!!! We have a famous situation in RGB involving underwear in an airbox, but i'm not ready to have crap in mine ;-) Anyhow it was slighty too bulky, but gave us the idea of using a standard 100mm 90 deg waste pipe with the end sliced off, and attached to the airbox with a fibreglass moulded adaptor
So while Dad makes that up i'll be refitting and tidying stuff up in a vain attempt to keep away from the wiring! The aim now is have the car running by the end of the month, ready for a mornings test at Mallory at the start of march, and a full trackday at Silverstone 24t March, so i'd better start looking ta that wiring diagram!
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