Lauren's 1985 Kouki Trueno

[Lauren]

Detail on oil cooler (Tom's post):
Well it got finished off on Friday morning ready for the trackday :+:

Test fitting the sandwich plate:



The compact male / female elbow fouls the block :-: There is a different fitting that it is even more compact but I simply couldn't source it in Manchester on the day :-: (but I can get it through Pirtek special order). There wasn't time so it was time to modify:



The sandwich plate test assembled:



And test fitted:



Once this was done I could measure up for the lengths for the additional pipes. Here's the dummy pipes marked up:



And back off to Pirtek to get the pipes made up. The pipes were made up with HiTemp 305 convoluted PTFE pipe with stainless steel overbraid. It's top stuff :+:

Crimping the new hoses up:



The new components:



The connections onto the oil cooler are aluminium and welded onto the cooler (so are not replaceable). Unfortunately Lauren damaged one of them (it's easy to do)



I decided to carry on regardless and worry about that later.

But then I hit another problem. Tried to fit the sandwich plate for the final time and couldn't understand why I couldn't get a socket to fit . It should be 24mm AF but that didn't fit and 27mm AF was too big Then I worked it out. It measured 25.4mm on the Vernier, 1" AF, furking merkinians! :-:

So it was out with a file to reduce it from 25.4mm AF to 24mm AF





It finally fits :+:



Initial components ready for final fitment:



Relieved compact elbow now clears the block :+:



First pipe fitted:



Second pipe fiited:



Exhaust manifold finally fitted:



Or so I thought.... :-: I wasn't at all happy with the exhaust manifold bolt hole on number 1 cylinder so off it came again and I ran a tap down it to make damn sure it didn't get damaged any further:



With exhaust manifold finally fitted, distributor needed to go back on exactly as it came off. Marks realigned as they were:





Once that was done there was nothing else left to do than to tackle the damaged thread on the oil cooler itself. I must admit I wasn't too hopeful that it could be recovered so while I was attempting to repair it I advised Lauren to have a look on the internet for a replacement.



But after a hour with a needle file it was looking reasonably okish:



Finally finished



Well it got finished off on Friday morning ready for the trackday :+:

Test fitting the sandwich plate:



The compact male / female elbow fouls the block :-: There is a different fitting that it is even more compact but I simply couldn't source it in Manchester on the day :-: (but I can get it through Pirtek special order). There wasn't time so it was time to modify:



The sandwich plate test assembled:



And test fitted:



Once this was done I could measure up for the lengths for the additional pipes. Here's the dummy pipes marked up:



And back off to Pirtek to get the pipes made up. The pipes were made up with HiTemp 305 convoluted PTFE pipe with stainless steel overbraid. It's top stuff :+:

Crimping the new hoses up:



The new components:



The connections onto the oil cooler are aluminium and welded onto the cooler (so are not replaceable). Unfortunately Lauren damaged one of them (it's easy to do)



I decided to carry on regardless and worry about that later.

But then I hit another problem. Tried to fit the sandwich plate for the final time and couldn't understand why I couldn't get a socket to fit . It should be 24mm AF but that didn't fit and 27mm AF was too big Then I worked it out. It measured 25.4mm on the Vernier, 1" AF, furking merkinians! :-:

So it was out with a file to reduce it from 25.4mm AF to 24mm AF





It finally fits :+:



Initial components ready for final fitment:



Relieved compact elbow now clears the block :+:



First pipe fitted:



Second pipe fiited:



Exhaust manifold finally fitted:



Or so I thought.... :-: I wasn't at all happy with the exhaust manifold bolt hole on number 1 cylinder so off it came again and I ran a tap down it to make damn sure it didn't get damaged any further:



With exhaust manifold finally fitted, distributor needed to go back on exactly as it came off. Marks realigned as they were:





Once that was done there was nothing else left to do than to tackle the damaged thread on the oil cooler itself. I must admit I wasn't too hopeful that it could be recovered so while I was attempting to repair it I advised Lauren to have a look on the internet for a replacement.



But after a hour with a needle file it was looking reasonably okish:



Finally finished