Toyota Freestyle GT
Toyota Freestyle GT
Ordered a few more parts today, postman always complains about how much stuff i get delivered at work! He's going to complain loads this week
Thanks for the coments guys, she's starting to get there now
Ordered a few more parts today, postman always complains about how much stuff i get delivered at work! He's going to complain loads this week
Well been cracking on throughout the week as usual and been concentrating on the fuel cell this week.
Monday my laser cut parts finally arrived at work, been waiting ages for these but finally have them so i can crack on with the fuel cell now
![[Image: DSC01271.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01271.jpg)
Firstly i got the flange for the filler cap drilled and tapped. The flange is 12.7mm thick and gets welded inside the tank to allow the filler cap to just bolt onto the outside, finished off the tethered part also so now the filler cap will be fixed to the fuel cell. I just need to chop the filler neck part down a bit and it will get welded to the flange.
![[Image: DSC01290.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01290.jpg)
![[Image: DSC01291.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01291.jpg)
Then started looking at the fuel sender itself, using the standard setup as a template i started looking at remaking the whole thing. I didn't want to just use the standard setup as it will look pants fitted to a nice new fuel cell, im aiming on using a uprated in tank pump and will be bassed on the original starlet setup.
Here's the original mess.........
![[Image: DSC01274.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01274.jpg)
And here's my own version.........
Started by drilling out the main holes for the parts........
![[Image: DSC01276.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01276.jpg)
Then drilled the weld in tank flange to match and made a rubber sealing gasket from some thick 3mm rubber we had lying about......
![[Image: DSC01279.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01279.jpg)
Then looking at the standard setup in detail it was clear i would need some sort of breather for the tank. There is a feed pipe, a return and a breather pipe. The standard setup has a small cylinder inside the tank that acts as a breather. I took it apart and had a closer look. I could get air to escape through the valve but i couldn't get air to go the other way. I don't know how the valve works and im not sure if its bust or is ok. Most of you know by now that im not the sortof person to just make do so i started looking for a better replacement. After searching for hours on the net i finally found what is know as a 'roll over valve' from Merlin motorsport. I thought it was quite expensive but i needed one so just bought it!
![[Image: DSC01278.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01278.jpg)
It gets mounted in the top of the tank and does 3 main things. 1: lets air into the tank as fuel gets used 2: Lets air escape when filling up with fuel and 3: If the car rolls over it seals itself to stop fuel escaping.
Added it to the sender plate along with the stealth black AN6 bulkhead fittings and dowty seals and even used a waterproof connecter block to finish it off.
![[Image: DSC01288.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01288.jpg)
And finally with the wires connected up for the fuel pump.....
![[Image: DSC01295.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01295.jpg)
The wires pass through some Nylon bolts so they don't touch the metal part and effect the connection. Ordered some standard fuel line for inside the tank and the AN6 connectors for inside as well. Just need to make some brackets for mounting up the fuel pump and connect wires inside and its pretty much there!
Then Today i went up to see James at TGT and measure up for the fuel cell (again, just incase i got it wrong the first time) and measure up for a steel lock box that im going to weld to the chassis. This will go next to the fuel tank and will fit my race helmet and stearing wheel for extra safety when im parked up.
Got a picture of the engine now it has a new cambelt kit and the adjustable cam pulley fitted........
![[Image: DSC01297.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01297.jpg)
Clear cambelt cover will really set it off
And also chucked the remote fill point on for the cooling system. This is the highest point of the system as the radiator sits alot lower at the front so had to put it here to ensure i get all the air out.
![[Image: DSC01298.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01298.jpg)
Thats it for this week. Tomorrow i will be at work doing a few little bits but nothing major. Im pretty strapped for cash now this month but will be able to buy a few pieces of alloy and steel to start making the pieces for the fuel cell and lock box and at the end of this month the engine will be going back in and the suspension setup at the rear will be done. James is on holiday for a few weeks but his first job back will be the buggy.
More updates soon..........
Jason
*** Update ***
Well been cracking on throughout the week as usual and been concentrating on the fuel cell this week.
Monday my laser cut parts finally arrived at work, been waiting ages for these but finally have them so i can crack on with the fuel cell now
Firstly i got the flange for the filler cap drilled and tapped. The flange is 12.7mm thick and gets welded inside the tank to allow the filler cap to just bolt onto the outside, finished off the tethered part also so now the filler cap will be fixed to the fuel cell. I just need to chop the filler neck part down a bit and it will get welded to the flange.
Then started looking at the fuel sender itself, using the standard setup as a template i started looking at remaking the whole thing. I didn't want to just use the standard setup as it will look pants fitted to a nice new fuel cell, im aiming on using a uprated in tank pump and will be bassed on the original starlet setup.
Here's the original mess.........
And here's my own version.........
Started by drilling out the main holes for the parts........
Then drilled the weld in tank flange to match and made a rubber sealing gasket from some thick 3mm rubber we had lying about......
Then looking at the standard setup in detail it was clear i would need some sort of breather for the tank. There is a feed pipe, a return and a breather pipe. The standard setup has a small cylinder inside the tank that acts as a breather. I took it apart and had a closer look. I could get air to escape through the valve but i couldn't get air to go the other way. I don't know how the valve works and im not sure if its bust or is ok. Most of you know by now that im not the sortof person to just make do so i started looking for a better replacement. After searching for hours on the net i finally found what is know as a 'roll over valve' from Merlin motorsport. I thought it was quite expensive but i needed one so just bought it!
It gets mounted in the top of the tank and does 3 main things. 1: lets air into the tank as fuel gets used 2: Lets air escape when filling up with fuel and 3: If the car rolls over it seals itself to stop fuel escaping.
Added it to the sender plate along with the stealth black AN6 bulkhead fittings and dowty seals and even used a waterproof connecter block to finish it off.
And finally with the wires connected up for the fuel pump.....
The wires pass through some Nylon bolts so they don't touch the metal part and effect the connection. Ordered some standard fuel line for inside the tank and the AN6 connectors for inside as well. Just need to make some brackets for mounting up the fuel pump and connect wires inside and its pretty much there!
Then Today i went up to see James at TGT and measure up for the fuel cell (again, just incase i got it wrong the first time) and measure up for a steel lock box that im going to weld to the chassis. This will go next to the fuel tank and will fit my race helmet and stearing wheel for extra safety when im parked up.
Got a picture of the engine now it has a new cambelt kit and the adjustable cam pulley fitted........
Clear cambelt cover will really set it off
And also chucked the remote fill point on for the cooling system. This is the highest point of the system as the radiator sits alot lower at the front so had to put it here to ensure i get all the air out.
Thats it for this week. Tomorrow i will be at work doing a few little bits but nothing major. Im pretty strapped for cash now this month but will be able to buy a few pieces of alloy and steel to start making the pieces for the fuel cell and lock box and at the end of this month the engine will be going back in and the suspension setup at the rear will be done. James is on holiday for a few weeks but his first job back will be the buggy.
More updates soon..........
Jason
Well its been a pretty slow week as although i have loads of parts in my room, with the buggy and under my desk at work i don't have much to do till the engine is in! James is away on holiday at the moment but when he gets back he should be back on it and start working on the buggy. Also as its aproaching the end of the month i will have some money to pay him so this is when the majority of work gets done, when he knows he's getting paid shortly :lol:
Got my stealth black fuel line fittings and the only part of unbraided fuel line im using on the whole project, these look really nice and its a shame they go inside the fuel cell so knobody will ever know the work that went into making these parts........
![[Image: DSC01301.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01301.jpg)
Fitted to the bulkhead fittings...........
![[Image: DSC01302.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01302.jpg)
Connected up through sender plate........
![[Image: DSC01303.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01303.jpg)
Then started looking at mounting the fuel pump, im still missing a few bits but will have these when i order the uprated fuel pump at the end of this month.
These are the only parts kept from the original setup, the small piece of pipe shown was later binned as i didn't need it and the uprated fuel pump will replace the stock item later. So the only things that are used from the existing setup are the fuel pump connector block and the small piece of metal on the end to house the pump filter.........
![[Image: DSC01305.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01305.jpg)
This part then gets bolted to the alloy arm, all it needs now is the alloy arm welded to the top plate and the connector block wired up and its finished!
![[Image: DSC01307.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01307.jpg)
with the pump roughly in position.......
![[Image: DSC01309.jpg]](http://i920.photobucket.com/albums/ad42/demon_buggy/buggy/DSC01309.jpg)
Payday will see the uprated fuel pump ordered and the alloy material needed to make the fuel pump. My bro has also said that he will probably stay in Japan now for good, and as he has some nice motorsport parts lying about i will be buying them hopefully. First to come is a nice Simpson race helmet, very similar to the stigs helmet B)
Next Saturday im planning on getting up to work on the Demon myself, im hoping James lets me do some welding work on it. Im sure he will if he's about so i will hopefully get the centre consol welded in and make up a few templates. Also with any luck i may get the seat rails made up and welded in. With any luck the engine will be back in the Demon around the end of the month and the rear coilover mounts will also be done
Jason
*** Small Update ***
Well its been a pretty slow week as although i have loads of parts in my room, with the buggy and under my desk at work i don't have much to do till the engine is in! James is away on holiday at the moment but when he gets back he should be back on it and start working on the buggy. Also as its aproaching the end of the month i will have some money to pay him so this is when the majority of work gets done, when he knows he's getting paid shortly :lol:
Got my stealth black fuel line fittings and the only part of unbraided fuel line im using on the whole project, these look really nice and its a shame they go inside the fuel cell so knobody will ever know the work that went into making these parts........
Fitted to the bulkhead fittings...........
Connected up through sender plate........
Then started looking at mounting the fuel pump, im still missing a few bits but will have these when i order the uprated fuel pump at the end of this month.
These are the only parts kept from the original setup, the small piece of pipe shown was later binned as i didn't need it and the uprated fuel pump will replace the stock item later. So the only things that are used from the existing setup are the fuel pump connector block and the small piece of metal on the end to house the pump filter.........
This part then gets bolted to the alloy arm, all it needs now is the alloy arm welded to the top plate and the connector block wired up and its finished!
with the pump roughly in position.......
Payday will see the uprated fuel pump ordered and the alloy material needed to make the fuel pump. My bro has also said that he will probably stay in Japan now for good, and as he has some nice motorsport parts lying about i will be buying them hopefully. First to come is a nice Simpson race helmet, very similar to the stigs helmet B)
Next Saturday im planning on getting up to work on the Demon myself, im hoping James lets me do some welding work on it. Im sure he will if he's about so i will hopefully get the centre consol welded in and make up a few templates. Also with any luck i may get the seat rails made up and welded in. With any luck the engine will be back in the Demon around the end of the month and the rear coilover mounts will also be done
Jason
Dark Samurai Yes, this plans to be at JAE this year.
LOL would love to get it along to JAE but they won't let me in as its not a JAP car :glare: I have already spoke to John Fuggles about it and he said its a no. Would love to get it to some shows this year but its in bits so not really any point. Im aiming to have it road legal at the beginning of next year ready for show season :thumbup:
Dark Samurai Yes, this plans to be at JAE this year.
LOL would love to get it along to JAE but they won't let me in as its not a JAP car :glare: I have already spoke to John Fuggles about it and he said its a no. Would love to get it to some shows this year but its in bits so not really any point. Im aiming to have it road legal at the beginning of next year ready for show season :thumbup:
yes, but its not a jap car on the V5c so they won't let me in! Apparently a lotus with a Honda engine tried to get in last year and they wouldn't let him as its a lotus. Mine is technically a kitcar so they won't let me!
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