The GASWAGON (act III)

[Plasticman]

well i was looking at it as i was removing stuff and i think i can modify stuff so it will all fit nicely in there, will wait till i nget the exchanger and configure the outlets, also bearing in mind the various sensors to incorporate into the thing.. hehe
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[keith]

I think most chargecoolers are a tight fit....plumbing and pipework can be a squeeze.

Air to air presents the challenge of getting a good flow over the intercooler without exposing the scoop.....especially on a syncro

Interesting to see what you guys come up with.

[lloydy]

Yup.. My new motto = "less is more"
It'll get enough air, but will have the back up of a thermostatically controlled fan.

[Plasticman]

well onwards,
the front areai have removed the masking to leave the weldable areas clean

and have coated with weldthru

we then have this nice little lot removed and destined for a.n.other in a far off place

all the odds removed from in here

i give you 10/10 for stuffing it in here and actually securing it but the 2" long screws were a bit rough
not much rot ,just the start off it but it will be all chopped open this week so no worries
such a lot of busy stuff

ive cut the loom open as i need to relocate stuff

DONT secure earths with self tappers,it moves

would be nice to move the pas resevoir a bit tom the left then the exp bottle a bit further towards the front of the van and then relocate the battery in a longtitudonal manner also be able to fit a bigger one

never was going to be a straightforward paint job
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[lloydy]

I can't take the credit/blame for shoving that in there The big self tappers i though were a great way for mr futbus to secure it all, stuck right out into the wheel arches didn't they
Is moving the PAS res and coolant tank, battery ect to do with the air filter?
Oh, and anything related to me is never straightforward!

[Plasticman]

ah the butfus tappers ...ok ,the ones into the chassis legs went on forever , i had to keep cheecking they werent just turning on the spot....
i just dont like the battery where it is. i know the hassle you had and the reason for it and that you didnt have fab' facilities etc so i wish to move stuff to a betyter position and tidy it up a touch and allow for a bigger battery if req'd and so forth, the filter issue will fall into place after the main item which is the cooler and its associated parts, then we try to create space and neat runs for gear.
the turbo actuator v/v's will no doubt go on the ns bulhead and have there hoses etc shotened neatened, there is the issue with the main loom to ecu, this at present passes through the area i wam fittin the cooler, so need to rethink this as i dont really want it there,(ecu and loom)that is.
front panel repacked and on its way in the morning, i wont fit the dfo panel till i have the new front from the eu chap just a double check as if its a couple of mm in the wrong position it will look a F.
so next step it to peel open the rear 1/4 to allow good access to the area loads to do....
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[lloydy]

That all sounds good, dependant on length of loom it could be mounted to bulkhead under the bed?
looking forward to seeing behind that rear quarter

[syncroandy]

Lloyd, the JX airbox sits very close to the top of the inlet mani so that's your limiting factor. Even tighter on a 1.9 than 1.6 due to the taller block. The inlet connection would have to be on the side for clearance, JX-style, so either a JX or AAZ inlet mani I would say, TIG'ed appropriately. Harness/loom should reach fine to under-bed location along LH chassis rail.

[Plasticman]

thanks for that, i dont think were looking at the airbox to manifold side more the main airfilter arrangement
ref the loom and ecu thanks for that it sort of looked like it would fit there and will be better IMO
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[lloydy]

Thanks for the info Andy. Mike, Andy was just confirming that the air box won't fit in the standard place. Under the seat for the ecu is fine by me

[Plasticman]

Well, hmm
unpicking the few spots at the rear here

because for one reason

this is scrap,closer

not the worst but still no good

saving the bottom of the 1/4

but
its trash

need a new bottom making

something to work from now

i will remove no more metal until i have the cooler constructed and placed,then i will configure it and make a mounting
a little oil sir

so thgis lot has to go through the hole and back to the engine bay

not me

through and done

where abouts is the best route for this to pass from engine bay to cab


it does leave a nice space

note if you look you can see a crease the full length of the swage aand it has been fully filled with pod, very odd and there are no creases on the rest of the panel

removed the last of the F nR cooler pipes so they can be packed up and sent
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[Plasticman]

Andy, which is the neatest route through, following the leg would be fine but ive not run one of these through before and dont want to cut unnecessary holes
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[Aidan]

best route is probably to go the same way as the MV wiring loom, through the back of the sloping panel and the ecu goes where the short bit of seat belt is hanging down on the nearside - above the floor where the bulge is between the heater and the charger, loom runs along top of chassis leg where the front to back loom is, iirc there is a slight pressing mark where the hole would be cut, don't know if the stud for the earth/coverplate is fitted if van a diesel, I don't think so

[lloydy]

Blimey, rust, rust and more rust! And a crease right down that panel too and this only the near side!
Can't help much on the loom route, but what Aidan says seems logical.

[syncroandy]

^WHS, I'd suggest 'MV' style, needs a 52mm hole just above chassis rail (there's a little dimple on the panel for the hole centre), then the engine connectors are all passed through from inside to out. However its really up to Lloyd, its his van !