Fuel Filter

Found on ebay for 99p! Just an injection filter for an Omega or Astra or something. Aluminium sheet cut to strips to make brackets, Rivnutted onto the pedal box.

From Zero 020511

Accelerator Pedal

The pedal didn't provide enough travel to fully open the throttle butterfly so I welded a piece of 3mm steel onto the pedal and also made a clevis out of 3mm plate and some nifty welding to allow for the rotation of the pedal.

From Zero 050611

Slightly tricky to see but there's the single strip of 3mm metal, roughly 12mm x 40mm with the first 10mm of it welded to one side of the top of the pedal, a 5mm hole in the top of that strip, a clevis which is really just a U-shape made from 3mm strip, all linked together with an M5 cap head and washers to space it out.

Throttle

After another lull in posting, we have some more progress to report!

Throttle cable action - used a bike brake cable, the barrel shaped nipple on the cable fitted into the original Saab throttle linkage. At the other end a cable nipple from ebay was purchased. The threaded adjuster is off an old bike brake lever I had in my stock of bits and pieces I've hoarded in the garage. You never know when things come in handy!

From Zero 020511

The aluminium plate bolted onto existing holes in the throttle body, to provide a cable stop. Shaped with a hacksaw and files, from strips of aluminum and aluminium angle, then low-temp welded/brazed again.

From Zero 020511

Seats

Not much to say, seats & harnesses fitted! Mounted straight onto the steel floorplan, driver's seat on sliding brackets from GBS.

From Zero Dec10

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.