{"id":226,"date":"2016-08-18T10:30:58","date_gmt":"2016-08-18T10:30:58","guid":{"rendered":"http:\/\/wheeleyandtwooley.com.au\/?p=226"},"modified":"2016-08-18T10:30:58","modified_gmt":"2016-08-18T10:30:58","slug":"goecoccyx-part-2-from-assembly-to-debut","status":"publish","type":"post","link":"https:\/\/wheeleyandtwooley.com.au\/?p=226","title":{"rendered":"Goecoccyx Part 2 – from assembly to debut."},"content":{"rendered":"

Geococcyx from chassis paint to debut.<\/p>\n

\"Bonnet<\/a> \"Front<\/a> \"Front<\/a> \"Motor<\/a> \"Motor<\/a> \"Rear<\/a> \"RH<\/a><\/p>\n

Thursday 9-1-2014.\u00a0 Set up and finalised painting.\u00a0 Loaded everything into boot and trailer and brought it home.<\/p>\n

Tuesday 14-1-2014.\u00a0 Reinstalled pedals.\u00a0 Lowered chassis onto floor, and dropped motor into place.\u00a0 Installed engine mounts, and lifted it back onto trestles.\u00a0 Finished installing engine, most electrical components, and most cooling pipes.\u00a0 Installed electrical mounting board, and clutch master cylinder.<\/p>\n

Wednesday 15-1-2014.\u00a0 Re-painted exhaust manifold, and installed it onto motor.\u00a0 Installed steering rack, steering shaft and steering wheel.\u00a0 Installed dashboard.\u00a0 Painted clutch operating shaft.\u00a0 Painted gear linkages shafts.\u00a0 Installed warning lights onto dashboard.\u00a0 Installed switches onto dashboard.\u00a0\u00a0\u00a0 Glued acrylic labels onto dashboard.<\/p>\n

Thursday 16-1-2014.\u00a0 Painted gear lever handle, air cylinder for gearshift, coolant tubes, steering shaft, fuel pump mount etc.\u00a0\u00a0\u00a0 Fitted start \/ cutoff relay, tilt switch, fuse box, fan relay, fuel injection relay.\u00a0 Connected clutch operating rod.<\/p>\n

Friday 17-1-2014.\u00a0 Fitted gear lever and linkages.\u00a0 Works perfectly.\u00a0 Fitted air temperature sensor.\u00a0 Painted mufflers.\u00a0 Started putting RF suspension arms onto chassis.<\/p>\n

Saturday 18-1-2014.\u00a0 Finished assembling front suspension members.\u00a0 Installed first muffler, but not exhaust probe.\u00a0 Partly installed firewall.<\/p>\n

Wednesday 29-1-2014.\u00a0 Installed rear suspension arms, uprights etc.<\/p>\n

Sunday 2-3-2014.\u00a0 Installed side \u201cLexan\u201d panels.<\/p>\n

Tuesday 11-3-2014.\u00a0 Installed rear brake callipers for both foot and turning brakes.<\/p>\n

Friday 20-6-2014.\u00a0 Drained oil from VW Golf Gearbox, and removed outer housing.\u00a0 Removed Input Shaft.\u00a0 Removed 4th<\/sup> gear from Output Shaft.<\/p>\n

Sunday 22-6-2014.\u00a0 Removed Input Shaft.\u00a0 Removed 3rd<\/sup> gear from output shaft.\u00a0 Removed all gear linkages.\u00a0\u00a0\u00a0 Installed Input Shaft with new thrust bearing, synchros for gears, and installed 4th<\/sup> gear on shaft.\u00a0 Made 13 mm long spacer for selector shaft to stop selector falling all the way off synchros. \u00a0Installed chain sprocket on Output Shaft, and 4th<\/sup> gear onto shaft.\u00a0 Tried to install \u00bd\u201d chain of 24 links, but it fell short by one link.\u00a0 Checked that the sprockets were the correct number of teeth (12 & 15), and of \u00bd\u201dsize.\u00a0 Chain does not sit on 15 tooth sprocket correctly.\u00a0 It seems to sit proud of the teeth.\u00a0 It sits on 12 tooth sprocket correctly.<\/p>\n

Monday 23-6-2014.\u00a0 Took Input Shaft out to check on chain wrap.\u00a0 The chain does not sit correctly into sprocket.\u00a0 Took it back to Mergard Engineering, because 12t was \u00bd\u201d BS sprocket, and 15t was ASA sprocket.\u00a0 ASA chain does work on BS sprockets, but BS chain does not work on ASA sprockets.\u00a0 They cannot re-machine the ASA sprocket to be a BS form, so suggested using an ASA chain on the both sprockets.\u00a0 Found some old \u00bd\u201d ASA chain (used), tried it out over the sprockets, and it fits.\u00a0 Fitted a BS chain link to it, and re-assembled everything.<\/p>\n

Wednesday 25-6-2014.\u00a0 Painted F\/R Gearbox with silver Hammertone.<\/p>\n

Thursday 26-6-2014.\u00a0 Weighed F\/R Gearbox without oil.\u00a0 Winched gearbox into chassis, and bolted it in.\u00a0 Installed right angle drive gearbox, and driveshaft.\u00a0 \u00a0Installed cover plate. Installed half shafts, and bolted up inner CV joints.\u00a0 Installed toe link rods.\u00a0 Installed rear damper unit mounting to gearbox and chassis.\u00a0 Installed rear suspension units.\u00a0 Installed F\/R air cylinder, and connected it to gear lever. Installed lower cross brace into roll bar.<\/p>\n

Friday 27-6-2014.\u00a0 Replaced air filter element and cover.\u00a0 Riveted air reservoir bracket onto chassis, and fitted air reservoir cylinder into it.\u00a0 Connected air lines up.\u00a0 Installed second muffler.\u00a0 Installed fuel tank bracket and fuel tank.\u00a0 Installed fuel pump and lines.\u00a0 Installed rear cover plate. Spray painted overflow bottle bracket, and installed it.<\/p>\n

Thursday 31-7-2014.\u00a0 Plumbed brake lines to foot brakes on 4 wheels, and from turning brakes to lever area.<\/p>\n

Wednesday 13-8-2014.\u00a0 Winched\u00a0 car onto concrete, and sat it on some tube to get the exact centre of gravity.\u00a0 Measured it at 886 mm from outside of rear bulkhead.<\/p>\n

Thursday 14-8-2014.\u00a0 Fabricated lifting lug cross frame and lug.\u00a0 Welded it into chassis.\u00a0 Painted it.\u00a0 Calculated 35% on Front Wheels, 65% on Rear Wheels, empty.<\/p>\n

Friday 15-8-2014.\u00a0 Winched car up with central lifting lug, and placed it on tables.\u00a0 Made 3 mm thick alloy plate for Turning Brake Mechanism.\u00a0 Drilled chassis tubes and inserted RIVNUTS.\u00a0 Bolted it to chassis, and bolted turning brake mechanism to it.<\/p>\n

Thursday 21-8-2014.\u00a0 Started wiring up Reversing switch from warning light, & to solenoid.<\/p>\n

Friday 22-8-2014.\u00a0 Finalised wiring to reversing solenoid.\u00a0\u00a0\u00a0 Works properly manually.<\/p>\n

Friday 5-9-2014.\u00a0 Mounted fuel pump \u00a0lower in chassis, then lowered fuel tank the same amount.\u00a0 Now fuel return hose does not touch spring\/damper unit.\u00a0 Ran hose from oil breather to overflow bottle.<\/p>\n

Tuesday 9-9-2014.\u00a0 Wired up fuel pump.\u00a0 Fitted front footwell side \u201cLexan\u201d panels.<\/p>\n

Sunday 14-9-2014.\u00a0 Trimmed \u201cLexan\u201d front side panels, and fitted tie bars to them.<\/p>\n

Tuesday 16-9-2014.\u00a0 Fitted throttle cable to system, and put heavier spring on return cable.<\/p>\n

Sunday 21-9-2014.\u00a0 M12 Rod ends in top front uprights.\u00a0 Checked fluid in clutch master cylinder.\u00a0 Brake fluid into turning brakes master cylinders.\u00a0 Brake fluid into foot brakes.<\/p>\n

Tuesday 23-9-2014.\u00a0 Replaced kill switch with Narva 60094BL push\/push on\/off 16A 12V red LED from Bursons.<\/p>\n

Wednesday 3-12-2014.\u00a0 Cut steering shaft shorter.<\/p>\n

Thursday 4-12-2014.\u00a0 Lowered car onto wheels, out into sunshine, and photographed it.<\/p>\n

Sunday 7-12-2014.\u00a0 Painted front suspension arms.<\/p>\n

Saturday 20-12-2014. Used vacuum device to drag fluid through lines to rear brakes, but it left air pockets at callipers and at the steel fittings at master cylinders.\u00a0 Swapped fittings on turning brake master cylinders to be on inside of car to clear the brake lever.<\/p>\n

Tuesday 30-12-2014.\u00a0 Fitted M6 Nutserts for Fire Extinguisher, and bolted the bracket on.\u00a0 Installed extinguisher.<\/p>\n

 <\/p>\n

2015.<\/p>\n

Thursday 1-1-2015.\u00a0 Sprayed steel mount for clutch master cylinder.\u00a0 Sprayed mount for turning brake lever and master cylinders.<\/p>\n

Wednesday 7-1-2015.\u00a0 Bought new seal kits for VW Golf Mk 1 Girling brake callipers, and fitted them to car.\u00a0 Bled system.<\/p>\n

Friday 9-1-2015.\u00a0 Coolant into radiator, gearbox oil into VW Golf box.<\/p>\n

Saturday 10-1-2015.\u00a0 Oil into motor.<\/p>\n

Monday 16-2-2015.\u00a0 Made another new 20 dia steel brake fitting for LR brake.\u00a0 Ran air injection breather hose into overflow bottle.<\/p>\n

Tuesday 10-3-2015.\u00a0 Hoisted car down onto its wheels, and did wheel alignment.\u00a0 Almost no movement vertically with 100 kg applied to chassis, so maybe the rockers need to be re-engineered.\u00a0 Put it in gear and pushed it along to unlock motor, and it turned over OK.\u00a0 Right angle gearbox seems to make a lot of noise.<\/p>\n

Thursday 12-3-2015.\u00a0 Connected battery, and turned on ignition.\u00a0 Tested forward\/reverse light and it works.\u00a0 Fan does not turn.\u00a0 Took fan off and tested it, and it works.\u00a0 Deducted there is a wiring problem to the fan.\u00a0 Hit starter without plugs fitted, and motor turns over well.\u00a0 Soaked up \u2018Redex\u2019 from cylinders with rag, and fitted plugs.<\/p>\n

Thursday 19-3-2015.\u00a0 Removed throttle bodies complete, and cleaned them with WD40.\u00a0 Suddenly they work, so must have been stuck with dried fuel etc.\u00a0 Reassembled throttle bodies, and then ram tubes and air filter.\u00a0 Connected accelerator pedal, and it now works the throttle.<\/p>\n

Saturday 21-3-2015.\u00a0 Rewired fan and ignition through new fuse box, and now fan works.<\/p>\n

Tuesday 24-3-2015.\u00a0 Tested power at coils and leads, and it is OK.\u00a0 Could not find the trigger sensor that Yamaha had told me about.\u00a0 Built towing eye, painted it, and installed it.\u00a0 Charged battery.<\/p>\n

Wednesday 25-3-2015.\u00a0 Onto trailer and taken to Team Moto Yamaha.\u00a0 They checked wiring, and asked if I had power at the coils.\u00a0 We checked all that, but there is no sparks.\u00a0 They then asked me to take out the trigger sensor, while they stole one off a police bike, and we swapped them over.\u00a0 Still no spark.\u00a0 They tested circuits, and found some were earthed correctly, and some not.\u00a0 They could not work out why.\u00a0 So we made a common earth for lots of circuits, and tried the starter, and we got spark.\u00a0 Connected them better, and tried to start.\u00a0 They advised that my fuel pump is only 4psi, and I need 40 psi for fuel injection, and so it would not run properly with only that much fuel.\u00a0 So they got some aerostart, and sprayed it into the intakes, and the car fired up and ran.\u00a0 Even revved up a little.\u00a0 Took an hour and a half to find the problem.\u00a0 We then swapped over my trigger for the police unit, and mine works perfectly; so it was the earthing problem causing it all.\u00a0 They also advised that I do not need such a long set of ram tubes, and they work quite well with pod filters on the short tubes.\u00a0 The air temp sensor does not need to go inside the tubes, just hanging about in the area of the intake.<\/p>\n

Tuesday 31-3-2015.\u00a0 Bought new fuel pump, 12 mm to\/ 8 mm hose tail, \u00bd\u201d hose and clamps.\u00a0 Made bracket for new fuel pump.<\/p>\n

Friday 3-4-2015.\u00a0 Made recessed aluminium mount for 40 psi fuel pump, and fitted it.\u00a0 Fitted new fuel pump.<\/p>\n

Saturday 4-4-2015.\u00a0 Wired up new fuel pump.<\/p>\n

Monday 13-4-2015.\u00a0 Made new right angle drive gearbox with welded on bearing holders.<\/p>\n

Sunday 3-5-2015.\u00a0 Iron Man Motorkhana.\u00a0 DEBUT OF CAR.<\/p>\n

 <\/p>\n

 <\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

Geococcyx from chassis paint to debut. Thursday 9-1-2014.\u00a0 Set up and finalised painting.\u00a0 Loaded everything into boot and trailer and brought it home. Tuesday 14-1-2014.\u00a0 Reinstalled pedals.\u00a0 Lowered chassis onto floor, and dropped motor into place.\u00a0 Installed engine mounts, and … Continue reading →<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[1],"tags":[],"_links":{"self":[{"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/posts\/226"}],"collection":[{"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=226"}],"version-history":[{"count":1,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/posts\/226\/revisions"}],"predecessor-version":[{"id":234,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=\/wp\/v2\/posts\/226\/revisions\/234"}],"wp:attachment":[{"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=226"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=226"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/wheeleyandtwooley.com.au\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=226"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}