jason_l

I don't think it will be 500kg, would love for it to get to that weight but i reckon im looking more at about 550kg+. Was aiming to eventually 5E it but in all honesty i think it will be more than enough with the 4E in there. Decided a while back to just keep it running a CT9, they are so cheap as they are that i can easily get another one if i have any problems and replace it. Will eventually go for a aftermarket ecu but for moment i will just keep the standard unit and later on down the line sort that. Until i give it a proper drive i won't know what its like for acceleration but i imagine its not too shabby

Whats the difference with the CJ crank pulley and a standard one?

lol Would love it to be on a similar level to yours mate but not too sure if im going mental power anymore. Going to just start with a measly 200bhp and then maybe a few years down the line maybe go more??? Still not sure on weight though, 600kg maybe?!??

Is that sarcasm i detect Taggy lol.

Hi Everyone, I know i have these video's posted up in my build thread but makes sense to post them up here, i have them on youtube now so as i add more video's i will add the links here as well. Not much of a thrash yet as i need to sort a few things but will soon get there and i can give it more throttle but for now a few teasers....... http://youtu.be/g3X7MS_8gxg http://youtu.be/QB7F215tuN4 All comments welcome people Jason

PM on way mate

This sold?

Thanks Guys, feels amazing to finally have it running. I know there are issues that need looking at but everything else is just minor now and its just a case of a LOT of small jobs. @ Josh, i was thinking i get the side panels made in something simple like black ABS sheet and have a full graphic wrap done over the top. Needs to be something mental me thinks. Basically if you look at the side section, the panels will cover the lower part of the sides and extend up at the back slightly to in line with the coilover tops. Need to have a think of some designs?!?!?Best part is i can literally make the side panels, and send them to you to be wrapped, that is if thats cool with you? Jason

Sorry i didn't update this sooner but i got side tracked yesterday with the help of a bottle of Rum! But now the rum is all gone so its time to update this, although just typing this is giving me a headache (huge hangover!!!!) This week has been hectic, ended up staying late monday, tuesday and wednesday in the vain attempt to get the buggy ready to drive on Thursday morning and it was looking like a no go! Everything was going great until i started filling it with coolant at 8:30pm Tuesday evening and it was gushing out the back of the engine. At first i thought it was a hose that wasn't connected properly but after removing the inlet manifold it was clear that i had a NA inlet gasket fitted and one of the water channels that should be blocked on the race tech manifold was not sealed. Water way can be seen here..... There was no way i was going to get a new gasket before thursday so at the moment the inlet is sealed with hylomar but a new gasket is on order and is on its way from Japan as we speak. After a few more problems, including the fact i can't get the rear brakes to bleed i left work very late Tuesday evening with the thought that it just wouldn't get done for Thursday!!!!! Then after a early start wednesday and a late finish all had changed, or so i thought! We rolled the buggy out of the workshop and tried to start it up. Not good news, sounded like this...... http://i920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-20-17-43-44_zps6d179a46.mp4'> Was revving up without me touching the throttle, we tried franticly to fix it but ran out of light, so it was rolled back into the workshop. Then came Thursday and after my alarm clock went off i thought about going in early to try and fix the problem or just admitting defeat. Decided to go in early and try in a vain attempt to get it fixed. To be honest i thought it was pointless as it just wasn't going to happen. However after fiddling about with the throttle cable a little and the TPS i tried one last time to start it and it and i couldn't believe it! IT WAS ALIVE!!!!! http://i920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-21-07-30-04_zps8edb901d.mp4'> Happy can not even describe how i felt, really wanted to get it working for my 30th birthday and i had finally done it, so again it was wheeled out and started it up, sounds a little better now.... http://i920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-21-07-35-30_zps28133390.mp4'> Took a few pictures of it outside, always looks so much better when its outside the workshop and on the road.... And then a little drive, nothing too fast as it was the first time its ever moved around and just wanted to check everything works. Plus i only have front brakes so can't really go too crazy. http://i920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-21-08-18-15_zpsac0cec8f.mp4'> Looks so mean with the staggered fittment of the wheels and im actually really happy the back got widened now There is a knock coming from somewhere, its not engine related as if its out of gear and i rev it then its fine! Might be clunky cv or something but im not too fussed as i will get to the bottom of it. Its also leaking slightly on the clutch master cylinder, has a small coolant leak on the back of the water pump and there is alot of oil leaking out the side of the cambelt cover but again these will be resolved when the engine comes out and the frame goes to the powder coaters. and a little inside footage, sounds like the devil's tractor.... http://i920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-21-08-19-26_zps52e90c28.mp4'> This just made my birthday! Finally i feel like im getting somewhere, i know its only a little closer but it just feels more real now. After nearly 6 years of building it finally its been driven Girlfriend is taking me away for the weekend now just for a break but i will be back on with it next week. Any comments welcome Jason

Tried fitting the 4efte engine into the mini subframe i have on the Demon but it was stupidly tight, don't get me wrong if you have plenty of time you can get them to fit but i decided to widen the mini chassis in the end to get it all in with a bit more room to spare. Glad i did as now i have a wide ass on the Demon and it looks alot meaner and should be a little more stable. Seen a few of them in a Mini though and yes they go Very well

Standard ecu. Also has race tech inlet, standard ct9, very short exhaust, hks actuator.

http://static.photobucket.com/player.swf?file=http://vid920.photobucket.com/albums/ad42/demon_buggy/video-2013-02-20-17-43-44_zps6d179a46.mp4

Hi Everyone, Well got the thing put together and rolled it out of the workshop. Tried starting it but it just revs up and down without me touching the throttle. I hope its a quick fix as i really want to drive the thing tomorrow morning, even if it is just around the carpark a few times at work. Will post up a video when i get in but does anyone have any idea's??? Have had a little look over the inlet manifold and everything seems ok. Im guessing its something like throttle position or timing or something. Any idea's would be masively helpfull. Thanks all, Jason

Thanks Iddy, You and me both mate, just having it running around the carpark it will really get me motivated to crack on with it. Im not going to give it death, just a gentle run to check it all works as should.

Right well I guess its time for another update then. Really been putting in the hours this week, its half term next week and work will go crazy but I have managed to do a few late nights and some extended lunch breaks to get more done. Plan is to try and have it driving around the carpark on Thursday morning, its my 30th birthday so its sort of like a present to myself. Not sure if it will happen as I have a mountain of jobs to do before it can drive. So first things first I got the exhaust removed so I could gain access to the clutch slave cylinder. The bleed nipple is very close to the exhaust so had to remove it and I managed to get another slightly shorter one bought. I still need to remove the exhaust to bleed the system but its not like it’s a huge system and only takes like 10 minutes to get the exhaust off. Got the clutch line all bled up with my new easy bleed kit and I have to say its so easy to use and can be done with one person. Now I have a full working clutch. Then I got the coolant system all put together, im still waiting on another 10 stainless jubilee clips but the coolant system is all now done and when the clips arrive I can get them installed and add the coolant. Parts delivered…. The front left side brake line is very close to the coolant pipe but its not a problem and I reckon I can twist the brake clip slightly to give a little more room. Then checked the fuel lines going into the fuel regulator, there is a small leak coming from one of the joins, not sure which one but added new seals to them all and some ptfe tape to be sure. Still don’t know if I have resolved the leak but fingers crossed. Then looked at one of the larger jobs on the list, driveshafts! Had these made up a while ago now and have been meaning to at least get them test fitted to make sure they are the right length but never got round to it. Finally got them in and can say they are perfect. Was a complete workup to get them in and then I forgot a clip on one of them so had to redo it but they are now in. Just have to rebuild one of the hubs when I get in tomorrow. All the parts awaiting fitment…. One put together….. And the left side in….. Right side put together…. Then the right side in, just need to put it all back together again……. Plan is to hopefully stay late a few nights this week to get it ready to drive on Thursday but I really don’t know if I will get time. The list is quite big, rebuild hub, bleed brakes, refit exhaust, fit actuator, re-do some wiring, fit seats and harness, add coolant clips and coolant, fit handbrake cable are just some of the things I have on the list still to do. With any luck I will be updating the thread with good news on Friday and maybe even a video or two. Fingers crossed! Jason

Nice cars these! I had one and loved it to bits, until i decided to change. Yes they are underpowered but they should keep going and going. If your looking for idea's for mods etc or even some parts then sign up to Outlaw Jap Club. Loads of IS owners on there! Tell them Demon sent you Jason

Morgey, none of the cv boots have any steering angle on them as its rear engined Wheelies lol

Thanks for the replys guys. it is quite far on the cups but thats because it just pops of as they are so loose. Maybe if i just clip them up i should be ok? Or i might just bite the bullet and buy some new ones.....

Hi Everyone, Just a quick one really. Bit of a random one but i got one of the driveshafts fitted today and i think i might have the wrong cv boot fitted. For those that dont know i have a starlet engined kitcar. The engine is a 4efte but the hubs are from a mini. I think the starlet cv boots i have might be outer versions as they dont fit very well on the gearbox side. Below is a few pictures of the starlet cv boots i have, does anyone know if they are outer or inner versions? Many thanks for your help guys. Jason

I sooooooooo want this but need the money for other parts.

Ok scrap that! After a little more work dodging i have found the youtube video, now to buy more gearbox oil as i don't have enough..... ha

Hi All, This is going to probably sound really dumb and im sure its going to be a simple answer but does anyone know where the fill point is for the gearbox oil and roughly how much oil it will take? I haven't had a real goodlook yet but thought i would simply just ask while im sat at the computer. Its a standard LSD box if that makes any difference? I reckon im about 2/3 weeks away from its first drive since i have started building it nearly 6 years ago!!!!! Thanks, Jason

Thanks Buddy. Well its time for another update. Really been cracking on with it now as its really starting to come together and the thought of driving it around the carpark at work is getting very close. Not going to give it death on its first drive but just check brakes, oil etc and just make sure everything works as it should. As the weather has been sort of hit or miss this week I have had limited jobs I could do on the house so I have had a few days of work on the buggy. My main job this week was to try and get the coolant lines as complete as possible….. Started by removing the front radiator and drilling 2 large holes in the front chassis roughly where the coolant lines will be going. Used a 43mm hole saw to start with….. Then filled out to match and added some trim. Later had to go back and open it up some more as the hoses are at a funny angle but it will work. Im going to add some extra bracing here later as the frame will have weakened from the large cutout and having the hubs near it I don’t want it twisting. Then using the 2 civic top radiator hoses I have I roughly marked the location for the holes on the bottom of the main cabin and again with the 43mm hole cutter made some holes…. Which meant the hoses fitted like this…. Front….. In between chassis…. And inside the cabin…. Also while I was drilling the holes it meant I could see roughly what it will look like when I pull away at the lights and the thing launches into the air. Haha You can see how the coolant lines will go and means they are mainly housed in and not left open to the elements or running under the buggy as I don’t want them getting damaged by speeding bumps etc. Then refitted the radiator and continued with the front joins. Fitted a takeoff adaptor near the radiator, its perfectly located to run a short cable straight to the dash for the water temp gauge… Refitted radiator.. Added the front hoses… You can see that space is tight here but this has since been open up slightly and is a better fit and shape. Then continued with running the coolant lines down the inside of the buggy. Have finished soldering the copper pipes. Im still in 2 minds if I should use them or get them remade in alloy. Im sure copper will be fine but a part of me won’t be happy until they are remade in alloy. I guess I could send off the copper lines and get someone to remake them in alloy using the existing ones as templates, or am I going to be fine with the copper lines? What do people think? Anyway, got some 28mm pipe clips to hold the pipes in place and after a little test it was clear I was going to need a spacer to lift them up slightly. Laser cut some 10mm white acrylic spacers and then cut out some rubber spacers as well, these will help with vibration and also spaces it up the correct amount. So got the buggy jacked up, holes drilled and the clips all fitted in place… Then after smashing my knuckles up a lot I got the copper pipes in… And added the silicone hose to join the 2 parts together… Its very close to the battery and also the clutch pedal but as long as the cover I make is very low down I don’t think it will effect the clutch and my foot.. I also had some heat protective covering arrive from Merlin Motorsport. I ordered the 50mm stuff as I thought it would be like heatshrink and be measured in its flat form but its not so its huge, however its still useable. Plan is to wrap the coolant lines to prevent heat transfer. Slightly too big…. But can be wrapped up nicely… Did consider sticking both coolant lines in one covering but I want to ideally keep the two lines separate as one will be, or should, be cooler than the other. I’m close to finishing off the coolant lines, I’m just waiting on a load of clips, connectors etc to finish it all off and then add the coolant. As you can see I have put a few hours in this week and plan is to do as much as I can over the next few weeks. Its coming up to half term so its going to be mental at work and we are down 1 man for the next few weeks but will try and get a few more updates soon. Its very close now to a test drive, just need to fit driveshafts and connect everything up and then add fluids and its on! Already working on the next update as we speak, postman ain’t going to be happy with me with all these parts on the way. As always comments very welcome J Jason

Yes shouldn't be too shabby. Aiming for 220bhp to begin with and i reckon should be below 600kg. I can pick the front up off the ground by myself and im not exactly strong so it should be ok. More and more i think about it the more i reckon it will need a wheelie bar I would like to achieve 500hp/ton but im not sure if im ever going to need that much power, just be nice to have it i guess lol 5E, hmmmmmm......

Its so close to a test drive now its getting serious, all i can think of is driving it out those doors for the first time! Not going to give it death. Just going to try and keep it simple. Start up, little drive around to make sure everything is as it should be. Test lights, brakes, gear linkages etc. Its going to be hard not to just floor it from the get go. Need to be carefull though as hubs etc all need checking etc before i give it beans. Couple more weeks of work and i reckon i might have a few video's to share