Inlet Manifold

We used a Saab 9000 manifold as it has the inlet on the end rather than the 900's original one that went over the top of the engine and was way too high to even consider using. The issue was that the inlet faced into the bulkhead so we cut off the ends and rewelded the opposite way round. Was tricky to get it all lined up but made an MDF jig to help matters. We used a low temp aluminium brazing kit from ebay (£15) and a plumber's type propane torch - it worked for the manifold cutoff onto the flange but was not powerful enough to heat the mass of metal of the manifold to get the solder to flow properly so we enlisted the help of someone with Oxy-Acetylene, the bodged up the leftover holes with JB Weld. Fingers crossed it works.

From Zero Dec10

Ends cut off.

From Zero Dec10

Rough position it will end up in. Used 70mm OD aluminium pipe to extend mounting position.

Intercooler

We bought an Intercooler for a Toyota Mr2 Turbo off ebay and used 1" angle rivnutted to the chassis. There wasn't enough room to put it in front of the radiator with the fan fitted, the rad sits very far forward in the Zero. We will add a lot of ducting to channel cold air to the cooler.

From Zero Dec10

From Zero Dec10

More engine installation work

So, nearside rail removed, turbo now fits, but we turned it round 180 degrees on the manifold flange.

From Zero Dec10

Will mean some replacement of oil and water hoses using banjo fittings (M12 I think) and high temp oil/water hose. Also the bit turbo inlet hits the block so that will need trimming back.

Engine mount, sump

Top view showing n/s engine mount and chassis rails

From Zero Sep10

Close up of engine mount spacers, turned from aluminium

From Zero Sep10

From Zero Sep10

Shows how much the sump sits below the chassis.

From Zero Sep10

As can be seen, that chassis rail will have to go.. a quick look on the net shows many 7 kits only have 1 rail so we're not too worried about chassis strength.

From Zero Sep10

Long time, no blog

Due to Mike's laziness the blog hasn't been updtaed for ages so here comes some brief updates to where we are now.

In summary, the damn Saab engine doesn't really fit!

Fitting Radiator

Radiator was positioned roughly in the right place, the top about 4" above the chassis top rail, then we drilled 2 3mm holes in the top of the brackets on the chassis and used zip ties to hold it in the right place before putting the nose cone on to check for clearance. Once ok, we drilled 6mm holes in all 4 positions and used M6 cap head screws to bolt it in.

Engine Mount

Engine mounts were made using a piece of 5mm mild steel drilled to suit the holes in the block, with some 3x 1.5" box section with a cap welded on the end. In this cap an 8mm hole drilled, and some heavy duty Capri engine rubber mounts used, these have an M8 stud sticking out each end.

On the other end of the rubber bit, I had some mounts left over from I think a mk2 Escort RS2000, probably from Rally Design. The Zero chassis was then drilled to suit, and all bolted up with nylocs.