Monday, 29 August 2011

Just when you thought the engine problems were sorted...

Another day, another time for running around trying to get stuff sorted out...  Today's opening photo, the passenger side!!

Cue very long story...  scroll to the pictures if you are easily distracted!!

First up Damian went for a spin in Booger Mobile to book it in for some work - specifically replacing the rear wheel bearings (which are pressed onto the axles).  He found the place he was going to book it in closed - he's not sure if it's permanent or not - he will ring the number to find out another time.
Second stop was Drift Bodyworx to book in Booger Mobile's respray of the door sills with stone-protection paint, only to find that Trent was away up north.  Third stop was a visit to one of last year's sponsors to enquire about sponsoring Booger Mobile again this year - times are tough, so he's going to have to give it some thought. 

After leaving that place, Booger Mobile played up a bit with the same problem as before (stalling), only not as bad.  Fourth stop was a visit to Autobarn (to find they didn't make the part that Damian needed, but got some good advice from John about an alternative solution), and went to the rubber store to buy a bunch of rubber plugs for the chassis rail (that will be a blog post for another day).

After leaving Autobarn, Booger Mobile stalled a couple more times (including once in the middle of an intersection - luckily it was a turnoff rather than the main thoroughfare) before getting itself sorted out again.

When he got home, Damian noticed that the temperature under the bonnet was still sky high - he actually burned his hand on the TOP of the air cleaner...  This was becoming beyond a joke... time for drastic action. 

Damian remembered that the original engine from Booger Mobile had a standard exhaust system... after sifting through the junk pile outside his shed, he located the original cast iron exhaust manifold (still attached to the original head).  Damian's brilliant idea is to remove the extractors and replace them with the cast iron exhaust manifold - the theory being that instead of having six burning hot pipes taking exhaust gas from the engine, there would be a single manifold and ONE pipe leading to the exhaust... the laws of physics would dictate that this MUST produce less heat by virtue of the fact that there's only one pipe, not six!!

Do you think that whoever put this manifold on didn't have a bolt the right size?  Look at the ridiculous number of washers!!

The manifold was removed, and looked to be in reasonably good condition (considering its age, and the fact that it's been sitting out in the weather for a couple of years).  Damian took it to the exhaust shop to see if the dude agreed that putting it on would be a good option to cut down on the heat, and if it looked in reasonable condition.  He agreed that it would, and it was, but recommended getting it faced (ie: having the face of it machined to ensure it was nice and flat).

And through the magic of the interwebs, the facing was done!!

As with all parts, it was time to clean and paint it!!  First, tape up the faced edges and paint the underside...

Looking pretty good!!

Next, flip it over and paint the rest!!

The mess of black pipes that you can see in the picture below are all going to be replaced by the above exhaust manifold and a single pipe leading to the exhaust...

So...  Booger Mobile is booked in to have the extractors removed and the cast iron exhaust manifold fitted...  Hopefully this will really, really, REALLY be the end of the engine saga...  Only time will tell!!

Footnote:  Damian's Patrol decided that it wanted to join in the exhaust fun today by splitting a hole in the rear section of pipe, causing it to rattle and clang...  He will have to get that sorted out in the morning before Booger Mobile!! 

Sunday, 28 August 2011

Engine is run in - time for an oil change!!

Today's blog post is brought to you by the shiny driver's side of Booger Mobile!!  With the engine run in complete, it was now time for an oil change, and to drop the water from the radiator and replace it with coolant.

First step - drop the oil...

While waiting for the oil to drain, Damian decided to investigate the damaged claxton horn (you know, the one that goes ahooga), which after several melting moments, decided it would rather not work any longer...

Pull it apart...

Oh, that bent bit on the base is probably what's causing the issue!!

The oil was now drained, and the oil filter removed... Time to put the sump plug back in and fill it up with proper oil (not running in oil).

And offloading the now-black running in oil...

With the oil full, time to poke Booger Mobile's nose out of the shed and drop the water from the radiator...

This photo courtesy of Jordan... water goes whoosh!!

After using the hose to flush the radiator (which is brand new, therefore it didn't take long), it was time for the coolant to go in...  Appropriately, it is green!!

This photo courtesy of Aidan...

Time for a bit more planning - this is the likely position of the cross-brace (the pieces of wood were to hold it at the right height so Damian could check if the bonnet could still close)...

There were a couple of more little annoyances that needed to be resolved - of course, they involve pulling up the carpet (hence Damian has been avoiding it)!!  Out with the kick panel and the door step panel...

The carpet was folded back and the access hole in the floor pan measured (so that a plug can be made/ordered/whatever), and the T-bar box screws were uncovered - one was catching slightly on the linkages when putting the transmission into Park.  This was removed and had the end cut off to give more clearance.

Damian also lay under the car to check why it was a bit tough to get it into Park even with the screw fixed, and found that it was just touching the end of the hole that was cut in the tunnel...  Working in very limited space, Damian gently adjusted the edge that was touching (with a hammer and long screwdriver), creating enough clearance for Park to be engaged easily!!  WIN!!

Busy times ahead for Booger Mobile... lots of blog posts to come!!

Saturday, 27 August 2011

Rainy test drive, and Nambour PCYC Car Show has been postponed!!

It was a rainy Saturday.  Damian decided to take Booger Mobile out for a wet-weather test drive, and his son Jordan came along for the ride... Cruising down the highway doing 100kph...  Funny thing about this picture - the Max Speed shows 184kph...  This happened one day when Damian was using the GPS in his Nissan Patrol - he'd just switched it on and drove out of his driveway...  About 200m up the road, the GPS picked up a satellite or two, then the speed numbers went crazy...  Read 84 then 126 then 154 then 184, before going back down to 65 or so (the speed limit was 70)...  Obviously it was having trouble locking onto the satellites, and was getting erroneous position readings, making it seem like he was travelling much, much faster than he really was...

Damian thought it was so funny that he decided not to reset the Max Speed (just so he could tell this story)!!

Jordan took over the photography - heading down the wet highway...

Giggle was enjoying the trip as usual!!

Still some wiring to be sorted out under the dash...

Rain, rain, go away!!

Heading south...

And through the magic of the interwebs, heading north again!!

Onto the exit...

And playing "spot Booger Mobile" were Damian's friends Rachael and family...

Booger Mobile performed beautifully - the engine purred and idled nicely, stopped and started without fuel issues, it was a joy to drive!!

Please Note:  As the heading reads - the Nambour PCYC Car Show has been postponed to Sunday 11 September 2011.

Friday, 26 August 2011

Adjusting the accelerator cable

Today's blog post is brought to you by Lovells Springs and Suspension.  Booger Mobile is currently running a standard set of heavy duty springs, and Lovells are (hopefully) going to make a set of 2" taller custom springs in time for this year's esCarpade!!

So, after picking Booger Mobile up from the carby shop, and being excited that the carby problems seem to be over *touches wood*, Damian noticed that there was a bit of free play in teh accelerator pedal.  That space to teh left of the black ring near the silver ball shouldn't be there!!

Upon investigation, Damian noticed that the custom mounts for the cable had been removed and replaced with standard mounts (no doubt becuase of the switch back to the standard air cleaner), leaving the accelerator cable with no adjustment left in it and not tight enough... *sigh*

After discussing the options with a few people, Damian had a brainwave that putting a spacer in between the cable mount and the firewall would solve the problem...  But what to use?

Hopefully Damian's wife Tricia won't miss this breadboard... it's 10mm thick and made from some kind of tough plastic - perfect for crafting a spacer out of!!  First step, drill a hole...

Then cut it out, measure where the connector bolt goes, and drill another hole!!

After more measuring, test fitting and shaping, here is the completed spacer!!

Spacer held in place...

And with the accelerator cable attached!!

Before this photo was taken, Damian thought that it might be good (having adjusted the accelerator cable) to check that the cable was in the right spot...  He attempted to fire up Booger Mobile, only to set the carby ON FIRE!!  Not a little backfire through the carby with momentary flame, but an actual fire...  Damian leapt out of the driver's seat and extinguished the flames, before attaching the air cleaner - figuring it might be safer to keep the fuel contained!!

Damian headed down to Autobarn at Caboolture, who have come onboard as a Bronze sponsor by virtue of the discounts that Damian gets on the copious number of parts etc that he buys there...  funnily enough, after collecting a sticker, he didn't actually get a discount today!! 

Lastly, off with the air cleaner again to put a plug over the vacuum advance pipe - it's not required, and quite frankly looked untidy with the hose blocked off and tied around the fuel line!!

Booger Mobile back in the shed waiting for more test driving on Saturday!!

With the esCarpade now only 6.5 weeks away (well, 7 weeks till the esCarpade, 6.5 weeks till Damian and Jason leave from Brisbane to head down to the esCarpade), it's all systems go, go, GO!!

Assuming it doesn't get washed out, come and see Booger Mobile at the Nambour PCYC Motoring Jamboree on Sunday!!

Tuesday, 23 August 2011

Footage from Tommy's formal surfaces...

Stop press!!  Footage of Booger Mobile arriving at Tommy's high school formal (with Tommy inside of course) has surfaced on Youtube!!  Check it out!!

Monday, 22 August 2011

Back from the Carby Shop... but is it fixed???

Tonight's Booger Mobile post is brought to you by Kumho Tyres...  Booger Mobile is still running a set of slightly worn Kumho R700 rally tyres, and Damian is hoping that Kumho will come to the party with some new ones for 2011!!

Having received the call that Booger Mobile was now ready for collection, Damian went to pick it up.  The original air cleaner was back on it, a second hand distributor was on it to replace the brand new one that had died (and of course, can't be replaced under warranty as it had been modified), a thermal spacer placed under the carby to protect it from the heat and a bunch of minor tweaks performed (rejetting of the carby and extensive tuning and adjustment).

The trip home was uneventful - the engine is now whisper quiet - Damian is impressed!!

As you can see below, the return to the old air cleaner means that the air horns no longer fit where they are...

Off with the air cleaner for a well earned coat of paint...

Pretty...  Silver heat proof paint!!

The underside - as you can see, it didn't quite fit in the acid bath at the carby shop!!

And with some paint...

Damian rejiggered the air horns so that they would fit beside the air cleaner when it was reinstalled, and noticed that the modified brackets etc for the carby had been replaced with standard ones...  This means that there is really no adjustment left for the accelerator cable...   As per usual, fixing one problem creates three others!!

That's it for tonight... the engine is finally run in, and it's now time to drop the oil and replace the oil filter, filling it with proper oil (rather than running in oil).  He will also drop the water from the radiator and replace it with coolant, which should help the engine run even cooler... 

With just over seven weeks to go, Damian has to get some more kilometres on Booger Mobile's clock so that he's comfortable that the issues really have been ironed out, replace the suspension, install the kick-down cable, replace the rear wheel bearings, get a wheel alignment and brake adjustment and perform a whole bunch of minor tasks...  Plenty of time... :-S