One week ago I was thrashing away clipping back together the final pieces on the build of the Willys for a test run at the Point of Ayre Lighthouse, Isle of Man. Well all seemed OK until it was time to run the engine.
The engine had previously run without problems using a fuel can on the floor and the fuel line dropped into it. So you would think with all new fuel lines, mechanical pump and fuel cell in the car there would be no problems. Not the case as no matter what we tried the pump would simply not pull the fuel through even after the fuel had been forced through to the pump using compressed air into the top of the tank.
The original pump was reinstalled but this also did not work.
6am Sunday morning and by midday we would be at the Lighthouse with the Willys running or not.
After a quick read of the Ford book I found that there are 3 types of cam wheel [used to drive the pump diaphragm] mounting methods used to the attach the cam wheel to the timing sprocket. One of which can come loose therefore no drive to the pump.
So strip down begun at 6.15am. 7.15am the timing cover is removed to find NO PROBLEM with the cam wheel.
Bol#o>ks, it has to be a problem between the tank and pump.
So it,s off to the Lighthouse on a trailer as we still have a couple of minor airline leaks in the air suspension to tackle.
Wednesday 8-8-07 three days to D-Day
Plastic flexible conduit is routed through the body from the boot to the front air bags, taking care to keep bends as free flowing as possible.
The route takes it up through the rear bulkhead and follows the cage in the roof, then down the door pillars to the front bulkhead.
After drilling through we are into the inner wing area under the arches. Following the top chassis/cage leg to the centre of the air bag, the inner wing is drilled and the conduit run through to line up directly above the air bag fitting.
The 1/2" plastic line was then fed through back to front and terminated into the push fit 1/2" fittings. Although the pipe was difficult to push through for the first time [no draw wire used] installing conduit DOES mean if for any reason in the future the air line has to be changed it will make the process much easier, not forgetting off-cause to attach a draw wire to the pipe before removal
After laminating a layer of fibreglass over the bulkhead and tidying of the floor area around the servo/pedal/master cylinder, the body is ready to be refitted.
With the body back into position and bolted down, the hand brake is coupled up along with the steering column and air bags.
Seeing as the electric power steering [Citroen Saxo] is coupled up and ready for action I decided to run a couple of temp wires from the battery to test. First attempt failed miserably fluid burst out of one of the hose barb fittings. Why? well inlet/outlet pipes on the Volvo rack, which is which? 50/50 chance of getting it right yes? Guess I don't win the lottery this week DOH!!
After reversing the pipes the system worked perfectly with no leaks YES!! All that remains is to road test.
More pictures of the rolling chassis.
Tomorrow we will be lowering the body back down ready for the radiator, air bags, air lines and wiring to be undertaken.
All that will be left to do then is add coolant, trans oil, fuel and fire it up!!!!