Project Walle

Hi Folks,

Finally got off my arse & sorted out some photo's.

Before you view please bear in mind, i work approx 12 hrs a day, & may spend about 1hr a night on the little scamp. Neil doesn't exist on a saturday, i'm Daddy all day, & i get some of sunday to work on Walle. So with my lack of time i'm progressing V slowly. (Try buying more steel at 5pm on a sunday)

If i've got the hang of PhotoBucket, the following should link to my album ! Who knows................who cares?

https://s567.photobucket.com/albums/ss115/nhazelwood/

Neil

Excellent..... Keep going, dude.

I second that, once you get the urge you can't stop if you see what I mean, I wish I could get mine done but being 3500 miles way it aint gonna happen and I can't ask Nettie to do it and I never got Florence (her Mk1) back on the road like I promised but needs must, pictures look good, I have built two Mk2's, rebuilding a Mk1 and have the protoype Mk4x4 - I'll be back as Arnie said - look forward to seeing it finished

I like the rendered isometric drawings Neil.

From the pictures it looks like your only a few weeks away though. Keep pushing mate, it'll be great to see it at a Scamp event soon.

I'm not sure about 'A Few weeks', i've got shed loads of ally chequer plate, ally sheet, angle iron, door seals, polycarbonate to buy & scrounge on a very small budget...

The great thing with my job (Designing assembly machines for the plastic moulding & pharmaceutical industry) is that i get to play on very expensive CAD systems.
Having spent hours in the freezing cold & rain measureing up Walle, i can now make plans of what i want the little shite to look like, and save the cost of cutting disc's...

Seriously tho', if anyone wants to see what can be done in the virtual scamp world, ie. what this rollcage would look like. or how can i get independant rear suspension in, let me know.
I've got no problems modelling up parts, even creating full manufacturing drawings, it's what i do for 10-12hrs a day.

If i can help anyone out in this way, give me a shout.

Cheers Guys

Neil

Cheers for the encouragement guys.

More photo's uploaded to Photo-#uckit.

Got to try & save up for stage 2 of the suspension mod's, hi-lo's & Spax adjustables (stage 1 was painting the radius arms, got to be good for at least 25 bph in the Maxpower tuning guide).

Now the roof panel is nearly finished (just waiting on makralon & rubbers for the skylights) i can really appreciate the lovely british climate from inside without getting wet!

Got the rear panel fitted & sealed in, waiting on makralon & rubbers for yet another window.

Dropping the headlights down to 5 3/4" halogen ones, & fitting landrover indicators will mean i've got to remake the front grille panel. Sorely tempted to cut & shut the existing grille & fit 2 sets of headlights, outsides with side, dipped & main beam, then the inner pair with just main beam . Fit "non road use" rally bulbs & watch the night turn to day ( concealed switch to throw Mr MOT off the scent !! )

Still haven't got round to starting on making new doors yet...

In the process of making new arch extensions, in steel, prefer to have them welded up & looking smooth, unlike the bloody ally ones & pop-rivets.

Need to do more bloody wiring...don't want to finish looming it all up as i'll have to undo it all later when i do the engine swap.

Finally decided on what engine swap to do . Just need to start saving up ready for next winters project... Vauxhall 2.0l Redtop, vectra F20 g/box, R1 motorbike carbs & manual dizzy... should be good 200+ bhp . Torque steer anyone

At this rate i might have to little sod on the road in time to teach the munchkin to drive.......



........have to stick the a series back in for that tho', and paint the bloody thing PINK too.

Hope to see you at an event soon, Stourport definitely...

An XE conversion hey?

I wouldn't bother with bike carbs & dizzy. It seems like a lot of effort for about 175 BHP at the flywheel. You'd be better fishing around on fleebay for a MBE 900/901 series 2D ECU as it replaces the dizzy (they're old hat now but cheap as chips as everyone wants the latest 3D & 4D ECUs), use the standard coil pack and bolt on some 40 or 45 DCOE carbs.

Don't forget the ARP rod bolts! if you buzz an XE without them you'll have a slight electrical fault caused by a rod going through the alternator!

We had 145BHP at the wheels from this spec.

An XE head is capable of around 220BHP without porting/big valves but all of the power is hidden in the cams. you'll need to change the cams and pocket the pistons to get any more than about 175BHP at the flywheel.

We rolling roaded the current engine at 198BHP at the wheels (about 215BHP at the flywheel). This is about the limit for hydraulic tappets, once you go on to solid lifters you loose the saftey net and holes in blocks become more of a risk.

If you ever want any help with XE engines give me a bell.

Just a little update, as i'm bored at work!

Right, apart from chequer plating the pick-up bit & inside of tailgate, the rear end is 98% complete & painted.
Got new Hi-Lo's & GAZ adjustable shocks fitted.
Radius arm & Hub all assembled & painted.
New arch extensions made, painted & fitted.
Rear lights rewired (again) & Tow Bar electrics all sorted out.
Rear & sides have had 3 coats of Craftmaster Coach Enamel.
Fuel Tank fitted, painted & plumbed in.
12" Weller wheels repainted in white poundland appliance paint! (Cheers dad, you loved painting them really)
Aluminium Rear panel fitted with huuuge rear window.
Roof panel made in steel & painted.
Roof panel scrapped & remade in Aluminium & fibreglass, awaiting delivery of acrylic for roof panels.
Windscreen rebuilt with all new retaining strips & sealed (i hope), painted & fitted.
Interior fully carpeted !!!!!!!!!!!!!!!!!!!!!!!!!! Should go well with the red mud at stourport, bring your slippers !
New Mountney 13" steering wheel fitted.
Instrument panel made & fitted. (dodgy subject, see below in to do list).

At this point the car is nearly finished from the windscreen back.

After voicing my concerns about the reliability of Walle's existing engine with Woz (Jolly), it would be just my luck to turn up at Stourport & watch the engine blow up 30 mins later. So i've bit the bullet & decided to change the engine before Stourport. Cheers Woz for sourcing the new donor, & cheers Mat for telling me every 10 mins that i'm bonkers & a ###king lunatic.

New engine :~ Astra 1.4 (C14NZ for the fellow anoraks) not the most powerful of engines, but i wouldn't want the old man (75) to drive a redtop powered Scamp !!!

All i've got to do now is graft it in. (new bloody instrument panel to make,fuel tank to modify,subframe to cut & carve,new gear lever to fit, pedals to modify, and a possible 4th rewire...etc...etc...).
Make new front panels after engine is in, to take new smaller headlights & indicators.
Oh, got to make some doors as well & probably a new bonnet too.
Then paint the front end.

And if i've got time a new front bumper to make...

Is it just me that does a job, then changes it 3 weeks later & has to start again !

Sorry for waffling on, bit bored today, it's like a morgue here while we wait to find out if the company is going to close or not. Still if i'm made redundant i may have loads of time on my hands.

Neil

nhazelwood wrote:
Sorry for waffling on, bit bored today, it's like a morgue here while we wait to find out if the company is going to close or not. Still if i'm made redundant i may have loads of time on my hands.

Neil

I hope you keep your job but if not look on the bright side, it's the right time of year, the sun is shining and there's plenty of jobs to do on the Scamp or in the garden.

After a good weekend, the week has turned to poo already... Administrators are due in at work tomorrow !

On the scamp side:~ Managed to drop the engine & subframe, & take the old A series out on friday evening. Saturday finished stripping the astra engine out of the donor car, Donor engine has been cleaned & painted, awaiting the fun of trying to get it into the engine bay.

1st impressions, i think i might need a power bulge (max power style) to get the rad in . Need to stock up on cutting discs on the way home too.

Going to see if i can manage to get the new engine in WITHOUT an engine hoist, hehe, i'm a masochist at heart .

Still i may have a bit more time to work on Walle than i want to...

Neil.

Hi Folks,

Just a quick update while i'm waiting to start work next week...

Astra engine is 90% fitted .

Jobs left to do.....

Make new instrument panel & wire up,
Hope the exhaust still lines up & refit,
Rewire indicators & lights etc, to suit astra instruments,
Finish coolant piping,
Sort out Vacuum piping,
Modify clutch pedal AGAIN, (not enough stroke for clutch)
Run fuel lines to modified tank,
Make new brackets to secure front brake hoses (shiny braided ones),
New rigid brake lines to make for front end,
Driveshafts to sleeve (astra inners to mini outers),
Fuse box to tidy up,
New front panel to make with lights & indicators in,
MOdify existing front grill to suit new front end
Inner panels & trays to make for engine bay / wheel arch,
BIG hole to box in for gearlinkage in bulkhead,
Gearbox lever tunnel to make,
Assorted cover panels & fab's to cover more holes,
Put oil in engine & gearbox..........................................MUST REMEMBER THIS ONE,
Fill & bleed radiator,
Stick 5 litres of unleaded in tank,
Put gearbox in neutral,
Put key in ignition,
Turn Ignition key
Run like hell.............

Rewire engine again...

Start painting, (rain dependant).

Right back to my cold wet driveway....

Neil

Hi Neil

Looks like things are progressing nicely, well done

What about some pics please

Rob

nhazelwood wrote:Hi Folks,

Just a quick update while i'm waiting to start work next week...

Astra engine is 90% fitted .

Jobs left to do.....

Make new instrument panel & wire up,
Hope the exhaust still lines up & refit,
Rewire indicators & lights etc, to suit astra instruments,
Finish coolant piping,
Sort out Vacuum piping,
Modify clutch pedal AGAIN, (not enough stroke for clutch)
Run fuel lines to modified tank,
Make new brackets to secure front brake hoses (shiny braided ones),
New rigid brake lines to make for front end,
Driveshafts to sleeve (astra inners to mini outers),
Fuse box to tidy up,
New front panel to make with lights & indicators in,
MOdify existing front grill to suit new front end
Inner panels & trays to make for engine bay / wheel arch,
BIG hole to box in for gearlinkage in bulkhead,
Gearbox lever tunnel to make,
Assorted cover panels & fab's to cover more holes,
Put oil in engine & gearbox..........................................MUST REMEMBER THIS ONE,
Fill & bleed radiator,
Stick 5 litres of unleaded in tank,
Put gearbox in neutral,
Put key in ignition,
Turn Ignition key
Run like hell.............

Rewire engine again...

Start painting, (rain dependant).

Right back to my cold wet driveway....

Neil

Well that's today's jobs sorted out!

What's on for tomorrow Neil, an end to poverty and world peace?

I'll try & post some pics in the next couple of days, my broadband is off at the moment due to insufficient funds !! Next time i'm down at the mates i'll take my photo's on memory stick.

Seriously tho, the bl##dy rain is doing my head in at the moment . My new job start date has been put back to next week, so although i've got 3 1/2 days more to work on walle, i've got zero funds.

I haven't bothered to plan out what i'm going to do, i KNOW any plans will go tits up, but we should be at Stourport. I might still have bits unpainted, but i'm passed caring at the moment. JUST GOT TO GET IT MOVING.

World Poverty..........Hmmm.............leave it with me & i'll have a think on that .
World Peace............ Who knows ??

Right, Going home to work on Walle while its still raining....before the thunder & lightning start up again !

Still, No pain, no gain...

Neil

Hi Folks,

Sorry for such a short visit at IMM, the boss was a bit tired & wanted to go home....after being carried round most of the way on my shoulders. Must have been the 20 mins on the bouncy castle while i found the Scamp site...

Just a quick update of jobs left to do...

Bleed brakes, again,
Connect up fuel hoses,
Fit gearbox tunnel & gaiter in after painting,
Cut headlight & indicator holes in new front panel,
Take front panel out again & paint,
Sort out some wiring oddities,
Repaint fuel tank & fit back in,
Refit radiator & clip all hoses up,

Fill the engine up with oil,
Fill gearbox up with oil,
Fill & bleed coolant system,

Turn the beast over.....

Shout, swear & finally cry.....

The clock is ticking down, 11 days & counting, & so are my funds...

I'll try & get some teaser pics posted if i get time, but if not, i'm praying like mad that i'll be at stourport (to show his confidence in my work Woz (Jolly) has bought a recovery truck to be on hand to get the little scamp to stourport).

Cheers,

Neil

Hi Folks,

Managed to get some more pics uploaded today...

Engine Change Album

As of dinner time today, things left to do....

Touch up paint on fuel tank & bolt back in,
Wait for front end to come back from the paint department (dad painting on the garden table), then refit lights & indicators,
Sort out some silly wiring issues,
Rebleed the brakes again,
Add Engine & Gearbox oil,
Get new Lambda sensor (didn't bother to take it out & managed to snap it off !)
Make front bumper,
Make new shockabsorber mounting brackets, (GAZ shocks are bigger diameter than orig mini ones & foul on the subframe)
Source new air filter & piping,
Work out if i REALLY need to fit side mirrors ?
Clean windscreen to minimise the weld splatter on it, (jewellers rouge & plenty of elbow grease),
Paint bonnet & other stuff.

Start the engine in safe mode..............................&...................

Cheers Folks

Neil

Hi Neil,

I had a look at the photos. Very impressive, I like how you've modified the Mini subframe. Simple and neat.

I'm also amazed that you've made it all fit. Superb!

I can't wait to have a proper look over it at Stourport.

Looking forward to seeing it at Stourport.

Elaine&Richard J.

Good work. Cracking job.

come on son you can make it

by the way if you smash it to pieces can i have your steering wheel?

....does asking this make me a bad person?

just like top gear when they have a challenge i'll be following wallie in the 'you have to use this all weekend if you fail ' vehicle.

pity its a 7.5 tonne recovery truck, not sure how you'll get on through the bomb holes AND i want it cleaned before you give it back.

If you're after a small mountney wheel, i have a spare. It does need a little bit of restitching, but nothing serious even i could do it.. if i were to become less lazy ;p I
ts shirt button size makes it so cool, if hard as hell to get used to however...

If you're going to stourport, i'll bring it with me and you can see if you want it.

Hi Folks,

Just a quick update, some teaser pic's to follow...Hopefully i've reached the peak & am on the nice easy run down of work ready for Stourport...

Jobs done...

Fuel tank stripped & repainted (again), new sender unit fitted & calibrated
Brake master cylinder changed to later front/rear split type & brake lines remade,
Wooden panel the pickup floor,
Made new side opening tailgate,
95% of interior now complete,
New radiator fitted,
New air filter fitted,


Jobs left to do...

Chequer plate the inside of the new tailgate,
Get new bulbs & get the number plate light working,
Make new hinges & rigid tonneau cover,
Change rear brake cylinders (is it just me that hates the bl@@dy spring clip that holds the cylinders in...),
Fit new front disc's & kevlar pads,
Finish paint & assemble drivers side door,
Make passenger side door & sort out storage trays for the munchkins sweets.
Fit some mats onto the chequer plate floor,
Sew the new gearstick gaiter up,
Make new hinges & bonnet,
Fit new speedo cable,
Make 3 wheel arches,
Get new wheels shotblasted & powder coated, then sprayed,
Get new tyres,
Get engine back out & repaint,
Modify engine mounts,
Paint all engine bay ancillaries,
Paint from end,
Set headlights,
Get MOT, tax & insurance.................

Need to drive Walle around a bit to give him a shakedown & then load up the tent & head down to stourport...

Cya at Stourport................................i hope...........

Neil,

Now you are really going to far..................................................


...................................having a calibrated fuel guage........ ............



...............its all supposed to be guess work and keeping your fingers crossed in the Scamp Club


I thought you were finishing it, it sounds more like you are just starting

Well when i say calibrated.....

When the tanks full, the fuel gauge shows 50 litres...(only 19 litres tank tho')...
When the tank has got 3 litres left the pump stops sucking...so when i get down to 5 litres left the fuel gauge is just going into the red......result...

Looks like i might get about 90 miles to a tank !

Most of the stuff i've got to do are not really necessary, but my list of "Tarting" up has grown...

In my defence i've been working 14-16hr days for the last month so progress has been v slow.

Neil

I did find out once that the "E" on the guage does not stand for enough