I leak tested the sump with some screen wash. I mainly just wanted to leak test the hose fittings which are an O-Ring seal. They are the weakest point really.

The leak test was a go – no problems with the sump. In fact, nothing at all leaked, so hopefully this sump will actually be dry!!

No problems with leaking here! So after the leak test I made the hoses up. It surprising how much room JIC hoses can take as the minimum bend radius is quite large and the fittings are huge. But after a while I came up with this:

So long as the sump misses the cross member and steering rack, and the hoses miss the cross member, and engine mounts it should be good. They only way to find out is to fit everything onto the actual engine and get it in position to find out if anything interfere’s…

et Voila! Nothing appears to be interference fit. It is also pretty close though! I call it precision engineering, but other’s might refer to it as luck! Anyway, the engine mounts are fitted and it appears to all line up okay. Just got to fit the spherical joint spacers in the mounts and I can start fitted everything else that was removed for re-painting the engine bay. Seems like there is quite a lot left to get done before Germany!!! Got to get this thing MOT’d again soon.

Shortened the pipe leading into the Silencer and added a lambda bung

The other end is quite tight.

I’m going to leave it like this, as I can always shorten the silencer body to get more space, or it might be that I need to add another silencer to get the noise levels

Overall, it looks fine.

So the face mounting options available are:

• 71 frame is 4 holes M6 on a 85mm PCD
• 80 frame is 4 holes M6 on a 100mm PCD
• 90 frame is 4 holes M8 on a 115mm PCD
• 100 frame is 4 holes M8 on a 130mm PCD
• 112 frame is 4 holes M8 on a 130mm PCD

…and I’ll probably need a new pulley for it (unless it happens to have the same size). Machine mart do a fairly decent range of pulleys:

http://www.machinemart.co.uk/shop/range/guid/38ED3488-DAAD-4081-A62A-16554351AF21

The original Orac motor is a 71 frame motor.

The silencer is held on with a vclamp – I hate slip couplings. They always get stuck, leak and generally annoy me.

Silencer is 1m long, lol, and they’ll exit out of the sides in front of the rear wheels. The silencer length is because I’m not running a balancer pipe. This is needed as the engine has a 90 degree crank, and therefore uneven firing on each bank of 4 cylinders. This means that the scavaging will be poor, and basically, it’ll be very noisy.

Internet forums* think not to run a balancer pipe will cost me approx 25Bhp (400 as stock, so I think I’ll live with 375) , but the long term plan with the car is get it set up/reliable with the engine as stock, and then it gets 2 turbos. These will naturally quieten the engine.

Next, I’ve got to add the lambda bung, build the silencer up properly and support both it and the manifold properly.

And then the other side needs doing.

It’s come out well. My feet fit the pedal box well enough. The last thing I’m going to do is add an indentation in the left hand bulkhead as a clutch foot rest.

The rest of the bulkheading is coming along nicely.

Tuesday should see the dash fitting better (and being easily removable), and the beginning of the bulkheading on the passengers side. The floor will wait until I’ve extended it out to the full width of the car.

Machining

I machined the scavenge channel out of the flat plate:

Also changed the scavenge fittings from hose + jubilee fittings over to be -10 JIC/AN fittings:

I bought some 4mm aluminium plate to weld on as the base, so I started profiling it so that it’ll fit. I’m leaving the material in place this time which sits in front of the flywheel. It’ll offer it some protection. Previously the flywheel was easily visible and could easily take a battering!

On the bottom of the sump will be the channel that I milled out to perform the scavenging…

So really the next step is a bit more profiling of the plate, maybe a bit of bending too in order to get a slope into the scavenge channel (I didn't have that in the last sump) and then it’s just a case of weld, weld, weld…

I also started work on the new dry sump setup, which hopefully will be leak-free! The old sump pan always leaked a bit. Well, weeped really, but it’s still annoying!
I milled out the main scavenge channel, which took a while to do manually! Oh how I wish for a CNC mill! But the result is pretty good. All I have to do now is machine off some excess from the bottom (under the channel) and the holes needed for the scavenge pipes.