Stage 3 - Countdown To Crank (Bocor Pulok!) Pt. 1.

Filling the radiator with the believe that we will be able to complete the water affair today.



Damn...! ani..! angkat kain jemuran...! hujan dah turun...!
Immediately we realised that the thermostat gasket was pissing water like nobody's business. Also the cut metal water line which "the boss mech" overlooked to weld. :/



water flowing from through the thermostat's gasket.



What to do, just remove the radiator fan to initiate repair work..



The easiest of the lot.. thermostat gasket repair is a relatively easy job... adik stopped the leakage in no time. But then we realised that there is a little drip falling from the underneath of the waterpump. Crap!



The date was 28 June 09. The crank-day looming but seems like it managed to elude us again. hehe. I and adik started tighten up water hoses clip at around noon with the believe that we can proceed with the final job before crank : filling the fuel tank. But we guessed wrong. This story comes in three parts. So, enjoy guys... waaaaaaaaaaaaa! hehehe

Stage 3 - Countdown To Crank (Bocor Pulok!) Pt. 2.

Water pump "kong" oredy. Hampeh!



Water pump inlet. "Berpasior yob!" shilaker.... :(



Hati panas pny pasal, post gambau pun senget! hehehe BTW, this is the new water pump by works engineering(not! hehe). I just found out that Silvia share the same water pump with Skyline. Kuek keto den sok kalo gitu! hohoho



The water pump inlet was cleaned by adik while i went out looking for the new water pump.



The new water pump installed.

Next : To weld the turbine water line which was overlooked by the boss.

Stage 3 - Countdown To Crank (Bocor Pulok!) Pt.3

Adik is clamping the overlooked and unused turbine water line.



welding it shut. Done by the "all talk-no walk" boss. haha



refilling the water for the last time before crank. Or so we thought.. huhu



But we thought wrong.. soon we noticed that the water started to drip thrugh the welded part.



after adik tried to clamp it, the drip turned to spray. You can click on the pic to see it clearly.

In short, it's a NO GO for the crank today. It was already 6.45pm and i and adik were dog tired already. Got to sambung tommorow. Damn...

Stage 3 - Steelbraided fuel line (Mari Berinzal... huhuhu)

Pandangan sisi.. ok dok?



Fuel regulator pun tumpang mengensemkan dirinya dgn kehadiran hose nih. hehe



Into the fuel rail..



Kipas radiator dh masuk semula dah..



Lagi satu kali pusing tengok apa macam...? huhu


So, why this fuel line is so special, u might ask? Because i follow the whole process of it's coming to being. Now i know how it was produced and where to have one made. Actually the process is quite simple and quick (if you have the clamp machine that is.. haha).

Stage 3 - Still here but almost there.. ;))

Now, the turbine's steelbraided oil return hose is fitted and ready.



Turbine oil return hose (engine block inlet side).



Fuel cap and new rubber holder. (original wo... tak caya? Tengok bawah. hehee)



Rubber holder pny packet. ZK, kan gua dh cakap original.. hehehe



The freshly painted fuel tank, hoses, rubber holder & metal cap are in place and ready to serve.

This afternoon, i and adik has prepared a new steelbraided fuel line to be fitted between the fuel regulator & Fuel rail. It's ready but i didn't take the pics. May be, tomrw i'll snap it & upload it to this blog. ZK & DV6, mmg inzal lah kalo lu tengok itu hose... Yummy! hehe

By the way, no. the engine still cant be started. waaaaa...

Stage 3 - Still There.. :((

Walbro, kalo tak cukup gak petrol, tak tau la nk cakap. hehe



Saja je.. nk tunjuk made in USA, biau ZK sakit hati.. kikikik..



Tersilap... tertebuk lak lubang dalam bonet blakang. hmmm



Paip petrol pegi & balik. Pakai copper pipe baru. Yg lama dh reput & tadak paip balik (carburator maa...).



Paip air blakang enjin (atas gearbox) di"bypasskan aje.. Copper pipe pun nampak kat situ.

Stage 3 - Fuel Tank Is Done... and then some..

The fuel tank is done. As i said, i sent it for welding job and relocate the fuel inlet. Now, it is already fitted in the car. Oh yes, i did the paintjob myself.



The fuel regulator has found it's new location.


Adik (the mech's employee) did an awesome job hiding the injectors' wires, dont u think?


The steelbraided oil cable is in place.



Basically, this week, nothing much is done. But adik has been doing his best sorting the wiring & a some placement & fitting works in the engine bay. i have found someone to finish up the whole wiring for the car. the car should be able to start TOMORROW. Amin to that but we'll see... hehehe

Stage 3 - Looks like i gotta finish the fuel tank my self...

Remember this tank? Yes. The Kelisa's tank (RedGiants & ZacKapcai luorg jgn gelak ah?! hehe). Just arrived from Indon last night and shot straight to the workshop and guess what? Forget the pedals. Even this tank (which i helped in making the frame) wasn't welded yet.

2mrw, i will come again and do it my self. And believe me, u! I will deduct whatever cost incurred from this mechanic's upah. And i will find that ever elusive Ford Maxi Van pedals 2mrw myself and bring this %^&$%# mechanic to the "kedai potong" and make him show me the money that i gave him for the pedals.

Yeah. sorry (again). Coz i nagged (again). Hehehe

I go sleeping2 first ah Labi?

nk caghi pedal... nk caghi pedal... nk caghi peda..... huhuhu

Tommorow

Mekanikku "BerbuaL" lagi

Sekadar Gambar Hiasan _ takde kena mengena dgn ini cerita. Hehehe

Do u guys remember that my mech promised me that the throttle-brake-clutch pedals would arrived yesterday? They didn't. actually this is not the first time this thing has happened. This pedals story has dragged for about a month now (since the day my ic piping fabrication completed).

That time, my mech asked for RM500 for the ic piping cost & to get the pedals (and the pedals, according to him is ready and available). I made the payment via cheque bcoz i realised long2 ago that for this particular mechanic, everything must be recorded & documented. huhuhu...

Once the payment made, his attention shifted to other cars, eventhough at that time my airflow piping still not done yet. Then do u guys remember the "air-flow piping incident" in my previous posting? the one that i made the measurement & sent for welding myself & get it don within 30 minutes? - Yes? Only that time i found out that the welder didn't get his money for the ic piping job.

And from then on, this pedals kept on eluding my poor mechanic. The excuse? The old, "barang tak complete la bro... Aku malas nk ambik barang tak complete nih, bukan apa, nanti kang ... bla... bla... bla..." Then, where did the money go and why did the welder didn't get his money for the job done? no need to answer la... hahaha

So, for today, i dont want to 'petir' him. I'm going to Bandung, Indonesia later today for two days. I will bising and corner him abut this matter when i come back. I will let u guys know how far his "bebual" will go. hahaha

By the way, this mechanic that i been refering to is NOT that "Adik" fella. "Adik" is only an employee there.

And now i think u guys have a rough idea why this project has been dragging for the last 9 months just for CONVERTING the engine (the original plan was two months, at most! "berbual" punya kaki.. hampeh!).

By the way, sorry guys. Didn't plan to whine in here. but i did. :(

Stage 3 - custom-fitting the fuel tank.

Cut off the top of the amazon's tank.


grind off sharp edges.


marking the border.


cutting... by the way, i helped by standing on the sheet; see the white shoe? hehe.


No more gaps. yeay!

By the way, the mechanic promised me (again) that the throttle, brake & clutch pedals will arrive tommorow. We'll see about that.

Stage 3 - Fuel Tank Issue

The original tank. all rusty


The new fuel line. It has been waiting for 2 days now for the tank to be ready.


the kelisa's tank. Too many gaps.. :s



The original tank has rusted. Furthermore it doesnt have the return fuel inlet which is needed by the fuel injection system of SR20. Solution? buy a perodua kelisa fuel tank for RM250. Now time to think on how to install a kelisa'a tank into an Amazon.

Stage 3 - Getting up to date

ic silicone hoses tied up.



the wires are less messy.



fuse box - passenger side.


fuse box - driver side. Hidden yet easily accessible.

The date is 7/6/09. I sent this car to this workshop in september 2008 (for engine conversion). This is the current state of the project. When will this project finish for real? only God knows... Sigh... :((