Cosworth 2.9litre in my Crewwy

[dickspanner]

OK, I have taken delivery of my LPG kit and have the following question, Is there anybody on here who fits LPG conversions who can give me some advice? PM me your contact number and I will call you for a quick chat.

Cheers

Dickspanner

[Aidan]

Steve at gasure is away on holiday this week, and he probably won't notice this thread, neither will headley who used to be steve's man down south

[dickspanner]

Not been on for a while and not done much work on the crewcab for a while.

Started work on it over last couple of days so small update as follows:-

Had to, believe it or not, strip my engine cradle again and reweld it up as could not get M12 bolts in final mount. The thing is now set, the engine is sat central and it is fully welded up. (However, even though the engine and box are dead central the rear of the crewcab deck now slopes to passenger side - going to empty everything out jack it up and let it re-settle to see if this is a perm problem).

Both driveshafts are now fitted - Centrally.

I have started all the fuel install which includes the modifed tank etc. Lost the grommit for tank and filler neck, new one on order. Phah.

Going to go work on the thing tonight and hopefully get a few jobs completed.

Gas system is staying off the Cosworth engine for the moment as I am going to get it fully up and running and do a few thousand miles on it first before I try and modify all the plenim chambers etc of the cosworth engine.


The thing needs to be completed and up and running as soon as possible so I can shake it down before a trip to France. May even take it to a VW event mentioned to me earlier today.

Will hopefully post an update into the progress after tonights work. List of things is getting smaller.

Dickspanner

[hairyuk]

glad to hear your back onto it. i've been checking for updates for ages and cant wait to hear what it goes like, once completed

[dickspanner]

There was a short break in the progress of the Crewcab but spent the night at my lock up and put a few more lines through my list of things to do. The list is getting shorter.

Fianlly got oil in the engine last night and it is now wet, I should of had a wetting the engines head celebration and had a grown-up shandy or two.

Clutch is now installed and working, but did however shear the bleed screw off. Bugger. The clutch appears to be working so when it goes to be MOTed I may just get my mechanic to fit a new one for me while he has it on his ramps etc. (I hate hydrolics)

Started on the electrics as well. It is going to be a real slog to get these sorted, but I am aiming to try and get the thing fired up by next weekend.

I still can't understand why the back is sitting low on the passenger side, jacked it up a couple of times and let it resettle, managed to get the bed at 90cm each side, bounced it a few times and it has gone down 1cm again. Going to have to hae another look through it.

Overall it was a productive night and the thing is getting closer to completion. Really looking forward to firing the thing up and listening to see how loud the exhausts are, Oh I hope they are not too loud. LOL. (They may even spit fire with the loud pedal at full).

Will keep posting now hopefully over the next couple of weeks.

Dickspanner

[dickspanner]

Well I managed to cross a few more things off the list of things remaining tonight.

I managed to get the fuel tank in after a lot of faffing about with trapping pipes as I was trying to get it in. At the end of the night I have basically got the tank bolted up with all the fuel pipes in place connected up. Once the pipes are connected at the engine side then all the fuel system is place.

I took some more pictures tonight but have left my camera at my lock up so no update piccies at the moment.

Will post some pictures later in week.

Dickspanner

[dickspanner]

Rightly or Wrongly I have now booked the crewcab in for an MOT next Thursday.

My list is about 20 items now and I intend to get them all finished by Thursday, if not the mechanic who is going to MOT it is going to finish off the list.

I will post some more pictures up over the next couple of days in relation to the progress etc to getting it ready for its MOT. If all goes well and it goes for the MOT then hopefully within the week it should be on the road, albeit not finished interior wise, but atleast I will be shaking it down before its Trip to South France at the end of July.

I may even go down to Bug Jam in it, but will resist running it a quarter of a mile as I would probably end up scattering my gearbox over a quarter of a mile. LOL.

Dickspanner

[dickspanner]

Well folks today is pre-MOT day where I have a list of around 30 jobs to complete prior to MOT tomorrow.

Most jobs are simple except 2.

Intalling the full electrics to the engine (Biggy) and getting the engine to run and shortening the gear linkage. This involves grafting the full cosworth modified harness to the VW one.

The list is a full A4 sheet of paper, but working through it should allow me to get it all done.

I will post some pictures of the final works today when I get back from my lock up tonight.

FIngers crossed I get everything done and get this engine up and running.

Dickspanner.

[dickspanner]

Its far too late for me to start posting pictures at this time of night but a brief outline of todays events are as follows.

My list was in excess of 30 items, but slowly and surely I worked throught them all. Each item being ticked off when completed untill all jobs were done except electrics and I started on the task. The majority of the work had been carried out prior to this point so it was a matter of final wire up and testing each part of the install. After completing all the tests the time had come to try firing it up. Turn turn splutter splutter then bingo she ran/ fantastic a fully running motor, tick over fast, but erratic but she runs. Upon trying to get all the airlocks out of the water system, the front shockers were installed to allow the back end to sit high and as I was installing those, we noticed a dripping from the engine. I thought a jubilee clip had not been tightened fully but upon close inspection water was leaking from the head gasket on one side and coinsidentally there apppears to be a crack in the block.

I am totally gutted, and a call to my engine builder is happening first thing in the morning to get him down to look at it, as in my opinion he should of spotted this when he re-built the engine. Maybe it is just coinsidence and the head needs a final torque down or something, but all the wind has been knocked from my sails in the whole project as if the engine has to come out again I am going to be livid.

But basically all that is needed to finish the crewcan now is to taape up the electrics, replace all the fly leads that were installed to pu earths and positives here and there into the harnes. Got all the dials working all the stuff on the dash works and all lights etc. If the engine was not leaking, I would of spend another couple of hours on the project and it would be going in for an MOT tomorrow.

I will keep you posted on tomorrows evens if I can get the engine builder to come look at the engine.

Dickspanner

[dickspanner]

Got to admit not done this before but below is a link to a video I took with my camera last night of the engine running.

http://s110.photobucket.com/albums/n103 ... CF2044.flv" onclick="window.open(this.href);return false;

Sound quality is very poor but at least it is a bit of evidence that the engine ran.

Will try and post some pictures tonight.

Dickspanner

[windysurfer]

Well done on getting it running.

Hope your leak turns out to be an easy fix

[Aidan]

tough break on the leak after all the work, fingers crossed for you

[dickspanner]

Went and had a chat with a friend who builds rally cars and he said K Seal will sort the problem out, so going to give that a try tonight and hopefully it will be going in for an MOT on Friday.

Fingers crossed.

Aiden, we have spoke several times but the time is looming for the gearbox we chatted about. When the crewcab is up and running I will give you a call and pop over for a brew and chat.

Dickspanner

[jamesc76]

Defo crossed for you buddy im away all weekend but keep us informed on here ill be loggin on on my phone!!

[jonno]

Got everything crossed for you today.
I have really enjoyed this thread.
Good Luck with the MOT