As some of you probably know we're two petrol heads called Dave (Welder Dave & 3D Design Dave) that decided to set up a design & fabrication business called DaveFab.
We've both had a few 5's in the past and we use the current one (we've named it the D52, because of the whole stealth bomber thing) to develop parts.
So here's the story so far...
This is the car in all its glory at a recent ring trip (more on that later), it's a 1997 Mk1 1.8 Harvard
We started out making a few bits in our spare time, we were proud at the time, they were very very shiny. Some titanium, most aluminium though.
We were quite proud we'd made a few bits, but they were all a tad raw. Not the understated, functional and clean look we were after, so after countless hours making bits in our spare time and loads of different finishes the engine bay looked like this.
The engine was mostly original at this point, we developed our own scuttle intake that uses the stock size panel filter, a radiator cooling panel and it had a cobalt cat back exhaust.
For the other bits, we developed a tower brace, a rear jacking bar/chassis brace and a brake master cylinder stopper. The car also had Koni suspension, and some sticky tyres.
So it all was pretty sedate at this point.
We did a few track days at Castle Combe which were great fun. Attended a couple of local meets
And then in April we took the car to the ring.
The place amazes every time - Car Friday on the Easter weekend is mental. Lots of German beverages were consumed, many laps were done, and lots of plans were chewed over.
From this point on things started to change in terms of what direction we wanted to go with the car...
So not long after we got back from our road trip (about 4 days to be exact) packages started to arrive.
We decided to go Turbo, we've done TD04/05 in the past. While it was great and we love those set ups, we decided we had to use some modern technology. We've designed bits in the past for these turbos on other cars, and we just couldn't resist.
We had rough power figure in mind for the car so after reading many compressor maps we decided a Borg Warner EFR 6258 in 0.64 trim was going to provide the desired wizzbang we wanted with good response.
After spending an unusual amount of time staring at it, making turbo noises and spinning the compressor we turned our attention to the car.
We had to get a few last pics of the car before we took it to bits.
We couldn't wait to get rid of this.
Quick compression test while we could, all seemed ok.
We then had a long long day. One Dave started to remove bits off the car rather rapidly while the other finalised the turbo location for the manifold.
Got everything ready..
Bit of jiggery pokery..
And its out!
The following morning we got stuck back into it, removing the old 5 speed box getting the engine onto the engine stand.
It's a great small package when you get it on the stand. Looks like the important bits have been cared for too. No sludge here!
The next steps we have to take (the best bit) is to fabricate all the components required.
Starting with the exhaust manifold..
So after a few weeks this turned up:
We've decided on a full 304 Stainless Manifold, all 3mm thick wall, with a billet collector and CNC ported head flange. Primary diameters are 1.5" ID. A lot of people turn their cheeks at stainless because of its bad reputation for cracking. There's a lot of reasons this happens, but it's usually improper gas coverage combined with a lack of turbo support.
We started a 3D model of the design, and then designed the weld fixture around this.
While we wait on laser cutting for the fixture, we started the color change on the D52. We decided on a vinyl wrap using Hexis HX2000 material.
It's certainly different, and seems to vary hugely depending on the angle and lighting.
And that pretty much brings you up to date with where we are at the moment. We'll post more as we get on in the next few weeks - we're hoping to get it ready for JDM Combe so fingers crossed we don't have too many hold ups!
Marc at Skuzzle says if that's for a BW you might find the stud for the brace might interfere with the IWG.
It is for a Borg Warner, you'll have to tell him he need not worry so much. Unless we run 80mm+ studs I don't think it'll be an issue. That's with the actuator & rod clocked round as far as allowed by Borg Warner towards the turbo flange.
In other news, we're pretty much there with the intake/radiator/intercooler/oil cooler design.
We decided to go with a slightly smaller radiator core and use a Garrett intercooler core with our own end tank design to optimise the route. The rule of thumb is every 90 degree bend claims half a psi of boost.
We'll do an update shortly..
3D Design, Fabrication & TIG Welding We have upgrades for your 5 at www.davefab.com
wannabe: What's the punishment for a lapsed MOT nowadays? Diary commitments and the need to still put it back together suggest missing my MOT date but needing it before I can get one sorted...
Jul 2, 2019 21:41:31 GMT
Zed.: used to be a ~£30 fine BUT I believe its income related....... (or it was 9 years ago when I got done )
Jul 2, 2019 23:46:11 GMT
Crumpets: "Standard cost" is £54.85 - (That's the highest VOSA will allow a garage to charge for a standard car test) most garages usually do it for £30-£50 to be competitive.
Jul 3, 2019 7:05:46 GMT
JamesMk3: Issue with no MOT these days is as soon as the test elapses, insurance won't cover you. If the old bill catch you, it's 6 points and £300 FPN, or court, which can be anything up to a ban and unlimited fine.
Jul 3, 2019 15:58:45 GMT
wannabe: Is that actually true?? What happens if you're driving to an MOT without a current MOT, which the law permits you to do?
Jul 3, 2019 21:28:13 GMT
Crumpets: You’re only allowed to drive your car when its MOT has expired if you’ve booked an MOT and are driving to the test centre. If you’re stopped by the police on the way, you’ll have to be able to prove that you have an appointment.
Jul 4, 2019 7:51:01 GMT
Crumpets: If your car fails its MOT, you can only drive it if the previous year’s MOT is still valid (i.e. the test took place on a date earlier than last year’s). If your vehicle is deemed ‘un-roadworthy’ the above doesn’t apply and you can’t drive it on the
Jul 4, 2019 7:51:58 GMT
Crumpets: By 'Un-roadyworthy' - I mean if it has failed its MOT on a "Dangerous" defect as per the changes applied on the 20th May 2018. Sorry to spam the chat, just a little difficult to explain in 256 letters haha.
Jul 4, 2019 7:55:23 GMT
wannabe: Info is always welcome I thought that a Fail is a Fail is a Fail now - so you lose the ability to drive on the previous MOT in all circumstances?? It also is not clear if your insurance is invalid without an MOT?? I thought it was valid!
Jul 4, 2019 10:17:58 GMT
FFS Corders: Ask your insurer about that, they will be able to give a definite answer over if they'd pay out or not. The fact you need insurance to take it to an MOT and not tax should be a good indicator
Jul 4, 2019 12:39:38 GMT
Crumpets: Alarm keeps going off in the night - Getting annoying now & I wasn't popular at 4.30AM. Gurrrrr
Jul 6, 2019 7:52:12 GMT
wannabe: This is why I think alarms are a bit of a waste of time nowadays - everyone ignores them, gets annoyed by them, and thieves will take the car if they want it anyway... lol May I suggest a steering wheel lock?
Jul 6, 2019 11:49:04 GMT
Zed.: ~20 + years ago, I used to remove the battery, gearstick & steering wheel from my 2L ford engined Chevette (was living in a dodgy area of Swansea)
Jul 6, 2019 15:27:16 GMT
FFS Corders: Gearstick is a new one for me lol
Jul 6, 2019 16:10:20 GMT
Crumpets: Battery is good, I've jkust installed a battery isolator to stop it, only does it once ever so often - Might remove it down the line and keep it for the central locking aspect.
Jul 7, 2019 13:27:22 GMT
FFS Corders: Yaay MOT passed. Now got a few niggles to fix soonish
Jul 9, 2019 16:11:17 GMT
Zed.: niggles? is that a word for friendly advisories? always a feel-good moment when you have that pass paper in your hand, 12 months to worry about fixin the next problems
Jul 9, 2019 20:44:03 GMT
FFS Corders: Only one of those was tempermental hazards. The others are genuine niggles such as a couple of tired hoses and calipers that are on the way out. Getting a proper MOT means I find out what to prioritise
Jul 9, 2019 20:52:53 GMT