ChaosMotorSport MKII Buggy Engine Swap

[ChaosMS]

Hi Guys, a bit of an update for you, finally got the next batch of laser cutting done, 8mm 304 stainless parts for the exhaust (manifold flange, and 6 3 bolt flanges to put the system together), 3mm steel for the rad /intercooler mount and the oil cooler mount, 8mm steel for the front hubs, and 3mm aluminium for the rad fan mounts! here are a few pics of the all the lovely bits ;D

304 stainless 8mm thick;

3mm thick steel;

8mm thick steel;

3mm thick Aluminium;

And a few pics of the Rad and Intercooler mount going together and clamped in place on the buggy;

and then roughly mounted - still needs a little work but getting there ;D

All the rubber bushes have been 3d printed and work really well and the top rad mounts use a 3d printed insert too!! ive been very busy!

so need to finish off and seam weld the rad mount then build up the oil cooler mount for the other side and fit that then I can crack on with the front hubs!!!!!

Getting there very very slowly ! ;D ;D ;D ;D

 

[ChaosMS]

Another quick update guys got the fans mounted up, fitted like a glove!! needed to move the oil cooler about a bit but new location should be fine and due to the oil cooler move the external oil filter mount needed to move, here are a few pics:

Firstly the rad fans and ally mount plate:

Oil Cooler mounting:

external oil filter mounting:

And finally hit a few issues with the short drive shaft when at full droop so will need to change the driveshafts to increase the max angle on the inboard shaft (I think I've kind of figured it out) anyway suspension at the rear at full droop note angle of inboard joint on passenger side which is sitting at max angle and is miles out!!

 

[ChaosMS]

Been busy again, finally got the driveshafts measured up -

here they are off to have the centre tubes cut to length and fitted ready for welding.

Got the lower part of the exhaust tacked together

made the exhaust mounts and fitted both top and bottom so time for a full trial fit !! (top mounts are not shaped yet)

 

[ChaosMS]

Quick update time guys... the knock on effect of this engine change is just madness!! so Ive now finished the new front hubs, modified the steering rack and fitted new rosejoints to it, so here are the new front hubs:

Parts layed out for a single hub:

parts built up:

tacked together:

fully welded and fitted:

then I took a look at the ket barrel and tried to fit it to the suzuki column....... total fail! so had to get a new vw golf column and change the suzuki one out whilst keeping the suzuki rack - almost there with the change now but once again the knock on effect strikes again, as I have now changed the column, non of the switch gear fits so now I have to fit the vw switch gear for lights and indicators and move the Hazard (which was on the top of the column) to the main dash!! I have also had the 3d printer working non stop and printed the gauge pod for the turbo pressure and oil temp gauges and also the mounting frame for the standard rotary light switch!!

Here is the mounting hole for new light switch:

mounting frame for the switch:

frame installed in the dash:

and light switch in place:

gauge pod mounted to dash:

Ill take a few shots of the new column at the weekend when ive got it fully installed (still waiting for the new wheel mounting boss so I can line it up)

 

[ChaosMS]

So had some time off work, and as we cant go anywhere at the mo I got the chance to work in the garage again!

I got all the disks and calipers mounted both front and rear

Which then meant I could get the wheels on.. woohoo!! looking nice in a black

Then set to working on the steering, had to swap the suzuki column for a vw golf one (which now means its adjustable) as needed the ignition barrel, had to make a bush as i now have an extra UJ in the path to the rack

The bush is mounted on the front bulkhead and holds the first section of the column in place its made of a steel 32mm od tube and a 3d printed insert with a grease nipple to fill the void with grease.

Then whilst I was sorting the steering I decided to get the seats aligned and whilst I was at it I wanted to lift the front edge of the seat a little to make the driving position a little better, so I modified the seat frames and lifted the front edge 45mm

I've got both sets of seat frames modified now and Ive ordered all the bits to sort the intercooler and cold air feed for the engine along with a larger 380lph fuel pump which I will get at some point! - Next job is to final weld the column mounting and add a brace to one of the rack mounts as im seeing a little movement in it.

 

[ChaosMS]

a little update as got bored last night so decided to build an adaptor for the stock vw MAF sensor housing - one end of the housing fits into the silicone hose no issues but the other end would normally bolt into the airbox and therfore does not have enough space to fit a silicone hose and aftermarket air filter, so a bit of fiddling with Fusion360 and some 3d printing later I got this:

This gives me a good fitting for the 70mm ID hose joiner now, here it is fitted to the MAF housing:

And finally the full assembly with joiner and new air filter:

 

[ChaosMS]

Well been busy doing loads of stuff on the buggy, bot the cooling system plumbed in and the ECU fully remapped with all the crap removed!!

3d printed a new MAF adaptor with a 15 degree bend in it (Old and new below)

Did all the intercooler plumbing;

Plumbed the radiator;

plumbed the oil evap system with a small catch tank;

Stripped cleaned and serviced the injector rail (new seals on all injectors cleaned etc ) then swapped the 3bar fuel regulator for a bosch 4bar regulator (ECU is mapped to a 4Bar regulator now)

And this is what she looks like now ;D ;D

I've just finished 3d printing the ECU mount that goes on one of the old firewall sections behind the seats, high up out of the way!!, just prepping the looms to go back on the engine so i can get all the clips measured up and fitted - and slowly getting the AN10 oil fittings so i can do the oil pipework and fuel pipework.

 

[ChaosMS]

So a little more work on the buggy, got the oil system plumbed in, from sandwich plate to external oil filter then through a thermostatic oil valve and finally through the oil cooler and back to the sandwich plate.

Here are a few shots of the oil system:

Also been working on the wiring loom, all of the coil pack wiring had to be replaced along with the connectors, done a major chunk of it so far:

Next job is to plumb the fuel system back in and finish the wiring !!

 

[ChaosMS]

Hi All, not a massive amount of changes since last time but thought I would share a few pics anyway, got the fuel system plumbed back in with the new pump etc and modified the stock fuel rail:

just removed the push on ends and fitted hard line AN adaptors so now it will connect to the rest of the fuel system.

pump and filter mounted to the fuel filler neck case

and everything in place and hoses attached

Manifold tacked together (with flexi and o2 sensor mounting

And the backbox supports tacked in place

So the exhaust is ready for a full weld now and its on with the next job - I need to sort the water hardline from the water pump with needs a few modifications then i need to do a compression test before doing the engine service and start up!

So I now have a queue of tig welding to be done which at the moment is going to take a while seen as how we are in lockdown!

Anyway fingers crossed my mate will be able to come round in the next few weeks to finish off the tig welding for me!!

Rich

 

[wagon_1.0]

what's the wee filter for?

 

[ChaosMS]

what's the wee filter for?

Ha ha keen eyes Wagon, its the tank breather ;D

 

[wagon_1.0]

actually the detail on the coil pack is epic! I wanted to "personalize" mine like that too, but I havent got a logo

yamaha logo is a bit stupid, a fancy "F" for freestyle? an "R1" ..... what if next week i need to put a Suzuki engine in

 

[ChaosMS]

actually the detail on the coil pack is epic! I wanted to "personalize" mine like that too, but I havent got a logo

yamaha logo is a bit stupid, a fancy "F" for freestyle? an "R1" ..... what if next week i need to put a Suzuki engine in

Well if you think of anything let me know happy to print them ;D

 

[ChaosMS]

OK So time for an update as its been bloody ages!

The jobs left to do are getting smaller in size but take a lot more time, Ive finished the cold air intake side, the 3d printer has been getting a real hammering printing parts and templates out recently so let me walk you through whats been going on so far:
Cold Air Intake pipework and brackets:

so this is the very odd angled mounting frame to hold the top of the turbo input pipe and MAF
it mounts onto the tube that runs down to the engine mounting outrigger

this is the same bracket mounted just need to print the elbow pipe now

a little bit of a clean up and it fits like a glove

elbow and bracket in place there is also a top support now that mounts onto the angled fan surround to support the air filter

 

[ChaosMS]

Next thing to tackle was the driveshafts that are backfrom the driveline specialists (wanted them spun up to check they were true!)

they just needed a bit of tough black paint and re-assembly (the re-assembly bit took ages as one of the joints was being a total git and wouldnt go on - the clip just kept getting stuck!) anyway after a lot of colourful metaphors everything went back together and I test fitted the shafts - and they fitted perfectly, so I printed a couple of mounting templates for the new top mount of the shock, took the wheel off the short drive shaft side and made sure that when in full droop the driveshaft does not lock (and no it does not )

 

[ChaosMS]

now cast you mind back to the previous engine installation and the huge gear shift mech i had to make - to take the rod change out the back of the suzuki gearbox, and then send that forward to a MR2 gearstick assembly - which was a cable shifter. Skip forward to the VW gearshift assembly shift mechanism and now the gearshift needs to be a golf one so I can lock out reverse gear

So this is the vw shift mech, it has cable output at the front, that needs to change to the rear!

This is one of the shift cables im going to use, its a marine outboard control cable with about 70mm travel and they mount via a small groove in the end finishers - so i had to come up with a threaded body that could be laced over the end and would lock onto the cable, i cam up with these:

then with a bit of messing about and more printing I came up with some threaded mounts for them that fit inside the shift casing:

which fit in like this:

the reversing arms needed extra support as there was just way to much play;

the extra support works like a charm and gets rid of all the play, so just a little paint full strip down and all new bush kit and its ready to go in the buggy;

printed some templates to cut the holes and match up the mounting holes:

and this is it finished:

seems to work really well and if anything fails i can always reprint them!!

 

[ChaosMS]

And the final part of the update is the new lower front arms - the old ones are cracked so I decided to beef them up (not as mad as the rears but..)
So I started with this 60x40x3mm wall

then drew out what the cuts and angles were going to be and chopped it all up

this is what they look like just prior to welding

and after welding

just need to weld in the end plates (need to get them laser cut first though )

 

[ChaosMS]

Hi Guys, update time !! - yeah I know its been a long time coming but a lot has happened since last time

So following on from the initial build of the arms above , whilst waiting to get the laser cutting done (and finishing the design for the laser cutting in the first place) i thought I would sort the wiring loom and put in a couple of multi pin connectors so I can extract the engine - so the 3d printer got to work with a couple of mounting plates and shrouds

and a back cover

Then a little work on the alloy plate behind the passenger seat

now you can see the idea the curved shroud goes in behind the passenger seat to protect the sockets and wiring

and the mounting plate bolts on the other side with the connectors in place

Then there was a hell of a lot of wiring too do and I decided to ditch the now almost empty fuse box in favour of a small after market one
Lots of wire arrived

and new fuse box wired

then making up the extension to the bulkhead and newly printed mountings

printed some supports to hold the original relay panel and the new fuse box

and finally with the fuse box mounted ontop ready to be bolted down in the dashboard module

 

[ChaosMS]

Once I got this lot sorted and finally finished the laser cutting design I got it submitted and then this lot came back from the laser cutters

so this lot includes the end plates for the front lower arms so i can weld in the threaded inserts (12mm and 16mm) the front lower arm shock mounts, the rear upper shock mount adaptor plates, and the wheel arch mounting plates which bolt onto the hub uprights, first job is to build up the front lower shock mounts and get them welded onto the lower arms, and weld up the ends with the inserts

and build both front arms up and complete them

I've added some threaded inserts to the upper face of each arm so I can mount a 3d printed clamp to hold the brake line Ive done the same on the rear arms

And here they are fitted to the chassis

Next job was to finish the guard plate that seperates the expansion bottle from the rear of the drivers head

Then it was time to strip the whole lot down ready for paint, which in the end I decided was going to be a proper pain so I opted for powder coating at a new very local to me location - good guys and have done a cracking job - here is the chassis in partial strip down, engine out (and on it s stand ready for service parts and a clean up)

notice the whiteboard in the garage with the final list of jobs on it!! 36 in total!!

Here are most of the parts stripped off the buggy

and the stack of parts ready to go to powder coating

and then a few days later I picked up the powder coated subframe suspension arms etc looking very smart in RAL3028 Red!!!!

So Ive now finished stripping the entire chassis down and made a couple of mods to it first one being a additional brace for the steering rack and additional brace for the column - it is now ready to be picked up by the powder coating company and get its final finish also in RAL3028 Red

As soon as it gets picked up Ill post some more pics of the chassis - and of the final assembly!!

Rich

 

[ChaosMS]

So the buggy chassis went on its holidays yesterday!! - Shaun the Owner of Northcoat picked her up in style!!

As this is what she looked like before her hols - will post the in progress shots next...

Ill take some shots of the chassis once its out of the oven tomorrow

Rich