Project 'Deathwish'

[jason_l]

Well like i said before i wasn't planning on getting onything done to the Demon over the weekend but managed to order a few little parts. While my Lexus was having its MOT on saturday i went up and paid some money to TGT for all their hard work recently. While i was up there i test fitted a harness, fit ok so im happy! will look even better when the chassis is painted properly.

Then while the girlfriend was out of the room i got the AN6 fittings ordered for the fuel cell, some Loom tape, connector blocks for the fuel cell, grease nipples for the hubs and some cam locks for the welded in lock box im making. Just got away with it before she came back into the room

Its been a slow weekend of work on the Demon but don't worry guys, come tomorrow i will be back on it as usual

Jason

EDIT: Forgot to add, one of the guys at TGT had a Glanza that has now been written off and crushed but he managed to get the manifold off before it went. Its a JPerformance one, i hope its OK and not one of the dodgy ones that crack easily??? Anyway i only paid £20 for it so if it does crack i will get a Ram style one later!

[bucketep91]

when the girlfriend is out of the room haha

I've been doing that too recently but i failed big time! i forgot i have to get all my parts sent to our flat while im at work and she has to take delivery DUHHHH!!! shes going fucking nuts with all the parts i have here they are spilling out of the back room into the hall and even in the close hahaha.

im liking the harness! cant wait to see the frame painted/powdercoated, it will look amazing! and how dare you take weekends off we need to see this thing built just as much as u do

[lukerobz]

cant wait for this to be on the track its gna be nuts lol good work pal

[jason_l]

Thanks Guys

Girlfriend is great to be honest! She knows i spend a fuck load on the Buggy but as long as i put £350-400 in our savings each month she don't ask much more.

I had the weekend off away from the Buggy to enjoy the sun and while i was out and about i went past so many Chav's out in their shitty cars, made me want this done so much more. Don't worry it will come along this week. With some interesting updates over the next months.

Jason

[Steve GT]

you lucky git £20 quid? first refusal on that bad boy if you ever want to sell it dude thats my next buy got the de-cat just need the mani now lol

them harnesses look immense i am sooooooooooooooo jelous of your seats still to lol top work jase im very impressed

[jason_l]

you lucky git £20 quid? first refusal on that bad boy if you ever want to sell it dude thats my next buy got the de-cat just need the mani now lol

them harnesses look immense i am sooooooooooooooo jelous of your seats still to lol top work jase im very impressed

I take it the JPerformance manifolds are ok then To be honest i will probably switch to a Ram style manifold eventually as i have the room for one and i think they look awsome, but that won't be for a few years yet as i need other things first!

Jason

[Minorand944man]

Just wanted to say great project! Nice to see how your welding improved as you made the various brackets and I love the polishing! Only suggestions I can add is to spray clearcoat/ metal lacquer on the polished parts to protect them and keep them shiny, and I LOVE this design for the front end of the buggy!

I think you should just have that front end, an engine cover and the minimal rear wheel mudguards needed to pass the SVA. Leave the rest of the buggy bare tubing like on an Ariel Atom, no sides, no floor etc! Radical Atom Demon!

[bucketep91]

i like the styling too but its more wieght lol stick it on to pass the test then ditch it

[jason_l]

Thanks guys

I do like that design but think im going to stick to the one before that with just the nosecone and standard style wheel arch's at the sides. Was going to leave the sides open and not add any panels but i need room for sponsor decals and think it will be more aerodynamic with sides added. Still going for transparent sides though so people can see right the way through the thing.

Products have started arriving today so updates will be coming shortly

Jason

[jason_l]

*** Update ***

Well been cracking on throughout the week as usual and been concentrating on the fuel cell this week.

Monday my laser cut parts finally arrived at work, been waiting ages for these but finally have them so i can crack on with the fuel cell now

Firstly i got the flange for the filler cap drilled and tapped. The flange is 12.7mm thick and gets welded inside the tank to allow the filler cap to just bolt onto the outside, finished off the tethered part also so now the filler cap will be fixed to the fuel cell. I just need to chop the filler neck part down a bit and it will get welded to the flange.

Then started looking at the fuel sender itself, using the standard setup as a template i started looking at remaking the whole thing. I didn't want to just use the standard setup as it will look pants fitted to a nice new fuel cell, im aiming on using a uprated in tank pump and will be bassed on the original starlet setup.

Here's the original mess.........

And here's my own version.........

Started by drilling out the main holes for the parts........

Then drilled the weld in tank flange to match and made a rubber sealing gasket from some thick 3mm rubber we had lying about......

Then looking at the standard setup in detail it was clear i would need some sort of breather for the tank. There is a feed pipe, a return and a breather pipe. The standard setup has a small cylinder inside the tank that acts as a breather. I took it apart and had a closer look. I could get air to escape through the valve but i couldn't get air to go the other way. I don't know how the valve works and im not sure if its bust or is ok. Most of you know by now that im not the sortof person to just make do so i started looking for a better replacement. After searching for hours on the net i finally found what is know as a 'roll over valve' from Merlin motorsport. I thought it was quite expensive but i needed one so just bought it!

It gets mounted in the top of the tank and does 3 main things. 1: lets air into the tank as fuel gets used 2: Lets air escape when filling up with fuel and 3: If the car rolls over it seals itself to stop fuel escaping.

Added it to the sender plate along with the stealth black AN6 bulkhead fittings and dowty seals and even used a waterproof connecter block to finish it off.

And finally with the wires connected up for the fuel pump.....

The wires pass through some Nylon bolts so they don't touch the metal part and effect the connection. Ordered some standard fuel line for inside the tank and the AN6 connectors for inside as well. Just need to make some brackets for mounting up the fuel pump and connect wires inside and its pretty much there!

Then Today i went up to see James at TGT and measure up for the fuel cell (again, just incase i got it wrong the first time) and measure up for a steel lock box that im going to weld to the chassis. This will go next to the fuel tank and will fit my race helmet and stearing wheel for extra safety when im parked up.

Got a picture of the engine now it has a new cambelt kit and the adjustable cam pulley fitted........

Clear cambelt cover will really set it off

And also chucked the remote fill point on for the cooling system. This is the highest point of the system as the radiator sits alot lower at the front so had to put it here to ensure i get all the air out.

Thats it for this week. Tomorrow i will be at work doing a few little bits but nothing major. Im pretty strapped for cash now this month but will be able to buy a few pieces of alloy and steel to start making the pieces for the fuel cell and lock box and at the end of this month the engine will be going back in and the suspension setup at the rear will be done. James is on holiday for a few weeks but his first job back will be the buggy.

More updates soon..........

Jason ;)

[SiCaln]

custom brilliance my friend very impressed

[Steve GT]

awesome update jase.....whats the plan for next week then?

[jason_l]

awesome update jase.....whats the plan for next week then?

Got a few parts coming for the fuel sender assembly so i can continue with that.......

Got a few little things to do that won't cost me anything in parts. Need to make some weld in inserts for the bottom of the harness mounts and need to turn a reducer down for the fuell cap so that a diesel nozzle won't fit into it (part of the IVA regs ). Might work on making a couple more arch's to finish off the set???

Then im sort of stuck for things to do. I would love to get the fuel cell mocked up ready for welding but i have spent too much on the Demon this month so need to stop now till pay day! Bit of an arse as i never seem to spend 2 weeks working on the same thing i sort of jump around from part to part as i get time

I have SOOOO many parts here that all need work doing on them but they nearly all need the engine in the Demon for me to start fitting them. I must have nearly £2000 in parts just waiting to be fitted but can't fit them as i need other parts first

Updates will be slow now for the rest of the month as i just tinker with small parts and don't spend anymore money! Unless i sell some dial kits then i may have a few £ spare.

Oh and im still waiting on my knock off HKS SSQV, but there is no rush for it.

Jason

[jason_l]

*** Small Update ***

Well its been a pretty slow week as although i have loads of parts in my room, with the buggy and under my desk at work i don't have much to do till the engine is in! James is away on holiday at the moment but when he gets back he should be back on it and start working on the buggy. Also as its aproaching the end of the month i will have some money to pay him so this is when the majority of work gets done, when he knows he's getting paid shortly

Got my stealth black fuel line fittings and the only part of unbraided fuel line im using on the whole project, these look really nice and its a shame they go inside the fuel cell so knobody will ever know the work that went into making these parts........

Fitted to the bulkhead fittings...........

Connected up through sender plate........

Then started looking at mounting the fuel pump, im still missing a few bits but will have these when i order the uprated fuel pump at the end of this month.

These are the only parts kept from the original setup, the small piece of pipe shown was later binned as i didn't need it and the uprated fuel pump will replace the stock item later. So the only things that are used from the existing setup are the fuel pump connector block and the small piece of metal on the end to house the pump filter.........

This part then gets bolted to the alloy arm, all it needs now is the alloy arm welded to the top plate and the connector block wired up and its finished!

with the pump roughly in position.......

Payday will see the uprated fuel pump ordered and the alloy material needed to make the fuel pump. My bro has also said that he will probably stay in Japan now for good, and as he has some nice motorsport parts lying about i will be buying them hopefully. First to come is a nice Simpson race helmet, very similar to the stigs helmet

Next Saturday im planning on getting up to work on the Demon myself, im hoping James lets me do some welding work on it. Im sure he will if he's about so i will hopefully get the centre consol welded in and make up a few templates. Also with any luck i may get the seat rails made up and welded in. With any luck the engine will be back in the Demon around the end of the month and the rear coilover mounts will also be done :angry:

Jason

[Steve GT]

cooking on mother flipping gas now :)

[jason_l]

cooking on mother flipping gas now

Yes seems it, been really cracking on with it recently and im sure people have noticed. I can't wait for the engine to go back in as the updates will really start rolling along then! Just looked back through the folders and this time last year, to the day, the Demon was just having its rear end extended! Done so much since then although it doesn't look like it.

Off topic, Haven't had time to sort that vinyl out Steve but will try and get some sent out this coming week dude

[Steve GT]

shes come a hell of a long way few more weeks and it will start to look a hell of a lot better. cheers n all jase

[ro55ifumi]

Qualty piece of engineering going on here

[jason_l]

*** update ***

Well its been a slowish week but next week will be better.......as the engine is going back in! Whoop whoop!

Not been doing much during this week as i have been a bit strapped for cash but i have managed to do a few little things. Firstly i got some adaptors made as i need to modify one of the lower seat belt anchors to extend out slightly. Then yesterday i was passing by halfrauds and i thought why not i will give it a go.

Went in and asked about paint mixing and they said they can mix any colour if i have the paint code. Didn't think they would have the Porshe 'Viper Green' im interested in using but she checked the system and it was there.

Just bought a single spray can of the green to try out and see if its any good, all i can say is i flippin love this colour!!!!!

Had a quick test spray on a old lexus wing mirror cover i had lying about and i personally think the colour looks great! Doing the frame black and the rest of the bodywork will be this colour.....

What you think Sparkster....

Checked it against my bro's kawasaki jetski and its close but the porsche colour is alot deeper and looks loads better.

Then today i got up to TGT and got a little done, its flippin hard working in this heat but was going to crack on with it. Got the centre console welded roughly in place and it looks pretty good, will be adding a full cover to it later but its in now!

Then spent a little time welding in holes and grinding them flat. A few hours later and i was flippin nackered.......

Got a few templates made for a couple of parts im going to make during the week and payday is wednesday so i will be back on it more now. I need to get a solid piece of 2.5' alloy to make a reducer up for the intercooler pipework. It basically needs to go from 1' - 2.5'. Nothing like this exists so will make it from scracth.....as with the rest of the kit.......

Turbo flange and intercooler pipework.....

Also i made a cardboard template for the side pieces, still unsure if i will add them but i guess it will help channel air around the buggy and deflect the odd stone etc....

what do people think???

was thinking i could mount a few of the gauges in the drivers side one.....

Got to the point while i was working on it that i just had to walk away as i was starting to get really pissed off with it and started thinking i really can't be bothered anymore. Second i started driving home all those thoughts dissapeared! Its hard working on this thing when the weather is so nice outside, but the second im out in the sun i start thinking 'DAM, it would be awsome driving about in that buggy'

Jason

[Steve GT]

was following a kit car the other day while i was driving in this heat and i thought god i want one of them so i know how you feel lol will be awesome better than any car. i like them cardboard mounts think you should get them done and some gauges there will look good too

oh and that colour is pure porn deffo a must

[jason_l]

was following a kit car the other day while i was driving in this heat and i thought god i want one of them so i know how you feel lol will be awesome better than any car. i like them cardboard mounts think you should get them done and some gauges there will look good too

oh and that colour is pure porn deffo a must

Thanks Steve

I have seen a few kit cars today and have been shouting in the car at the top of my vioce 'AAAARRRGGGHHHH, I NEED THIS THING BUILT' people must be looking at me thinking im flippin nutz

Its catch 22 as when the weather is like this i want it done so bad but i can't be arsed sweating my nuts off working on it

[Sparky]

Mate, the coulour, its lush!!!

Will be paying Halfrauds and my local bodyshop a visit

Loving the updates that I have missed mate, that custom stuff is nothing short of awsome I love it

[jason_l]

*** Small Update ***

Well i have been paid this week and the parts will start rolling back in again

Got some alloy turn up this week and have made the top for the fuel cell. Has the cutouts for the filler cap and for the fuel sender. Just need to order the remaining stock and cut it to size, then comes the fun of welding it up

Then got a 2.5' billet of alloy arrive as i need to make a alloy reducer for the intercooler pipework.

I have started drilling the thing and its all mounted up in the lathe for when i get back to work on monday morning. Going to waste a load of it but i just can't seem to find a 1-2.5' alloy reducer. So means a custom made one from scratch, like the rest of the buggy.

Want to say a big thankyou to Luke for the vinyl's he sent me, they are great and i really can't wait to get them on the thing. Just can't yet

I picked the RHD and Pedo bear up from Modified Live last weekend.

Then after seeing this picture get posted up i have decided to make one of these as well.........

Going to make something similar but use it to mount on the rear of the buggy and it will be used as a spare wheel mount. Just going to build it as and when i can't do parts on the buggy and i already have a seat from a old chair i can butcher up. Its not going to be on the Buggy most of the time but will just fix it on the back for shows etc.

Monday i am going round a mates house to begin machining the hubs to accept the new uprated brake calipers i have and the rest of the week i will be cracking on with it as i usually do

Oh, and forgot to mention the engine is currently going into the Buggy! Will get pictures next weekend but expect work to really move forward soon

Jason

[jason_l]

*** Update ***

Well, what a difference a week makes ;) Been working a bit more on it this week and im sure the pictures will help to show that.

Monday and tuesday i spent the evening round my mates house machining the hubs to accept the new sexy callipers. Took ages as i didn't want to feck them up so spent a while machining a little and testing them, then a bit more and so on. Second calliper was a bit easier as it was then setup to machine the correct amount. Tomorrow i will be going into work to weld the holes up and redrill them in the correct position, then hopefully get them reskimmed during the week.

Here's how they currently look.........

While i was at my mates i remembered about a turbo that he has lying about in his workshop, was thinking about fitting it to the buggy but i think it may be a little small? What do you guys think? LOL

my mate......

Tiny intake......

next to my size 10........

WIN!!!!!!!

My nice HKS (fake) SSQV arrived on Tuesday as well, looks pretty good, has a few marks on it but will look good on the pipework. Already started filling down the adaptor to be welded to the pipework as i don't want to use a silicone adaptor.

Then spent my lunch breaks throughout the week machining the 1-2.5 inch adaptor from the solid piece of billet, took flippin ages as i could only work on it a little at a time but came out just perfect.

Just finished.........

on the turbo flange.........

with pipework.........

and after a quick 5 minute polish...........

Looks 100 times better than some of the intercooler pipework i have seen on the market.

Then today i got up to TGT to spend the day doing a little bit and measuring up for more custom parts i will be making over the next few weeks. When i finally got round to getting out of bed and getting to the workshop i was greeted by this..............

HELL YES!!!!!! The engine is in!!!!! Im so happy its really starting to look like a buggy now, not just a pile of parts and some scafolding.

Bomb proof engine mount..........

Then spent the whole day adding parts so that routing can be worked out. Inlet manifold will come back off later when the frame goes to paint so i can polish it up, and rocker cover is not on as its currently being polished. It looks so much better with a few parts added and that inlet manfold looks amazing on show at the rear of the buggy. Exhaust was just placed on the back but will be at a lower angle when its fixed in place.

starting to route the coolant pipes........

With fuel rail added.......

Going to spend next week making all the new parts that i have measured up for and i will update next weekend as i usually do. I have loads more material now so i can finish the fuel cell and it will be getting welded up next month. Also bracket for induction kit, exhaust and fuel pressure regulator.

comments welcome as always

Jason

[Bluebear]

Holy pictures batman!

Ricky's inlet mani looks badass and really at home there. Its a shame on the starlet engines, as the RaceTech plate would be facing the bulkhead, but on that it looks brilliant.

THE ENGINE IS IN! Yeaaaah!!

Cannot wait to see this terrorising the streets, shame you're not allowed to have it at JAE ;)