Honda VTEC Conversion Diary


  My decision to go down the VTEC path in the pursuit of power was not one that was taken lightly. At first, I'd liked the idea of VTEC power, though I'd all but ruled it out due to the extensive bodywork mods that would be required to lengthen the front of the car by the 4" required by the various available subframes on the market. I also didn't like the idea of the increased track brought about by the use of the wider Rover 100 based subframe needed to house the VTEC engine. I'd pretty much set my mind on a 1293cc turbo engine when I heard about a new subframe that would allow me to use a VTEC engine in a standard length mini. Some research proved this to be true and after joining the 16v Mini Club forums and checking out the rumours, I bought a VTEC subframe made by Allspeed engineering. This is designed to take a Honda B16A2 engine which, as luck would have it, is probably the best 1600cc engine in the world! Next, I bought a 1993 Honda CRX VTi to use as a donor car, as it has the B16A2 engine. Having driven the Honda before removing the engine, I was pleased to discover that the engine is an absolute screamer! It produces 160bhp in standard form, which is enough to make a rapid car indeed of the CRX, so should be far more impressive when installed in the much lighter weight mini.

Having bought the main components; the subframe and the engine/gearbox, I set about removing the engine and gearbox from the Honda and transferring it to the mini. Below is a diary of my progress with this work, with the most recent updates appearing at the bottom of the page.
 


Nov 6th 2005 :: Getting the CRX Home
Having found a suitable donor car on eBay, I enlisted the help of Mark to help me get the car home. Although the car was drivable, it had no tax, so I couldn't drive it on public roads. I'd hoped to arrange a trailer to transport the car home, but my plan fell through at the last minute and we ended up having to use a solid towbar to tow the car home. This turned out to be a terrifying experience - it's really not natural driving that close behind another car - but it did the job and we got the car back to my house safe and sound. Big big thanks to Mark for helping me with this!


The Donor Car - Click for a larger image

A shot of the Honda CRX VTi that I'll be using as a donor car for the engine and gearbox.
Honda CRX VTi - Click for a larger image

Finally at home and ready to be pillaged of it's internals :-)
The Engine - Click for a larger image

Give it a few months and this'll be in its new home in the mini!
The Allspeed Subframe - Click for a larger image

Here's the Allspeed VTEC subframe and various other parts including the custom driveshafts, tie rods etc.



Nov 12/13th 2005 :: Honda Dismantling
I spent all day today preparing the CRX ready to remove the engine. It's taking a long time, as there's far more electrical connections, hoses etc to detach compared with the mini. I'm making good progress though and it's almost ready. I've so far removed the radiator, power steering pump, bonnet, strut brace, airbox and bonnet and removed at least a million electrical connections and a thousand hoses.


Making Progress - Click for a larger image

The parts bin is now getting full as I remove all sorts of parts to clear the path for the engine to come out.
A Bit More Spacious - Click for a larger image

There's far more room in the engine bay now :-)
Electrical Connectors - Click for a larger image

A few of the mass of electrical connections that need to be disconnected before removing the engine. I've been careful to take lots of photos of exactly where they all came from and I've labeled them too. I want to be sure I know what to connect them back up to when I put the engine in the mini.
Dead Rad - Click for a larger image

It's just as well I wasn't planning on using the Honda radiator, it certainly looks like it's seen better days!



Nov 15th 2005 :: More Honda Dismantling
I only got chance to to spend about an hour working on the car today, but I made quite good progress. I got the exhaust manifold disconnected, which was quite a feat given the way the bolts were rusted solid! I also disconnected the lambda sensor, which required some contortion to disconnect! I didn't make much progress with the roll pin for the gear change linkage, but I did measure it up for size so my Dad can make up a proper drift on the lathe, which should make it much easier to remove. I did manage to disconnect the stabiliser bar for the gear change linkage, which took some effort. All of the bolts underneath the car have been a real pain to get undone, which is understandable I suppose, given how exposed those parts are to the elements and to road salt.


Roll Pin - Click for a larger image

The roll pin that's been giving me so much grief! It's not a very good photo, but there's not a lot of room under the car and I can't get my head in a position where I can see the viewfinder, so it's mostly guess work!
Dangling Bits - Click for a larger image

The exhaust, lambda sensor and gear change linkage steady bar all disconnected.



Nov 16th 2005 :: Bodywork Stripping
Until Sunday, when my Dad will drop round the drift for the gear linkage roll pin that he's made for me, there's not a lot I can do with regards to getting the engine ready for removal. It's pretty much there now and only really needs the gear linkage disconnecting. Instead, I set about the interior, getting the gear transfer box ready to drop through the floor. That didn't take long, so I then started to remove some of the bodywork so I can put it up on eBay to recoup some of the cost of the donor car. Anything I don't manage to sell, I can use to practice my welding on :-) I made pretty good progress, managing to remove the offside wing and door, both headlights and indicators and the front bumper.


Body Work Removed - Click for a larger image

I managed to remove a fair bit of bodywork tonight :-)
Gear Lever Removal - Click for a larger image

I also started on the interior, removing part of the centre console to get access to the gear lever area, so I can drop it through the floor.



Nov 17th 2005 :: Interior Removal
My aim for today was to get the instruments removed from the car, as I'll need to use them in the mini to begin with, until I can make up a custom dash and fit Stack 8130 instruments. I managed to remove the entire dash, though it took quite a long time, mainly due to the mass of wiring that needed to be disconnected. As I was labelling and photographing all the connections as I disconnected them, it was quite a laborious task, though I'm sure the effort will prove its worth when it comes to putting it all back together again!


Ignition Key Socket Removal - Click for a larger image

As expected, the ignition key socket was fastened on using shear-off bolts, so I had to use a chisel to force the heads of the nuts to spin round.
Getting There! - Click for a larger image

Making progress! The heater controls were a bit of a pain, as was tracing the wiring of the aftermarket immobiliser.
Electrical Spaghetti - Click for a larger image

Labelling each electrical connection when disconnecting them from the fusebox was fairly time consuming, but neccessary. There was plenty to label!
Dash Gone! - Click for a larger image

Finally, the dash is removed!



Nov 21st 2005 :: Gear Linkage
Yesterday, my Dad brought round the drift that he'd made for me on his lathe, so I put it to work to drift out the roll pin for the gear change linkage. Thankfully, it worked an absolute treat and with a few good whacks with a "persuader" it soon came out. Thanks Dad :-)


Gear Linkage - Click for a larger image

The gear change linkage, finally removed!
The Drift - Click for a larger image

This is the drift that my Dad made for me. It fit the roll pin perfectly and made short work of removing it :-)
The Roll Pin - Click for a larger image

The roll pin itself! A real pain to remove without a proper drift, but a piece of cake with one :-)
The Seats - Click for a larger image

I also removed the seats. They'll be going on eBay soon, they're really comfy and look pretty cool too.



Nov 22nd 2005 :: Engine Crane
Not much progress to report on the car tonight as my engine crane arrived this morning, so I've spent tonight putting it together. It's taken me ages to put the thing together, mostly due to the total absence of any assembly instructions :-( Still, after a bit of trial and error it's together now, with just two side supports left to complete it that need a bit of modification, as they don't fit properly. I need to figure out a good way of strapping the engine to the crane to lift it, then I should have the engine out by the end of the week :-)


Lots of Bits - Click for a larger image

The bunch of bits that arrived in a very large and very heavy parcel this morning. Sorry postie ;-)
Almost There - Click for a larger image

The crane almost completely assembled.



Dec 10th 2005 :: Engine Out
Although I've not updated the diary for a while, I haven't been completely idle! I've been struggling with engine crane difficulties, they sent some wrong bolts and no instructions, which made assembling the thing impossible. They still haven't sent the correct ones, but I've managed to get it together thanks to some help from my Dad and his wonderous array of tools and bolts :-) While I've been crane-less, I've been cracking on with removing various parts from the Honda, concentrating mainly on the wiring loom and parts that I can sell. The Honda's looking pretty bare now! This afternoon, I finally got the engine out of the Honda and tried it for size in the AllSpeed subframe. What I think are going to be the tricky bits are in the photos below. It's certainly going to be tricky fitting that lot into the mini, but I'm sure I'll get there sooner or later!


Frozen Mini - Click for a larger image

I need to finish stripping the Honda as soon as possible, so can I get rid of the shell and put the mini back in the garage and out of weather like this!
No Interior - Click for a larger image

The interior is looking pretty bare now!
Wiring Loom - Click for a larger image

The stripping of the interior has given me much better access to the wiring loom and it's pretty much removed now. Here's part of it.
Empty Engine Bay - Click for a larger image

The front of the Honda is also looking pretty bare now, as the engine and gearbox have at last been removed!
Engine in the Subframe - Click for a larger image

The first trial fit of the Honda B16A2 engine in the AllSpeed subframe.
Pulley Clearance - Click for a larger image

One of the tight areas getting the engine into the subframe is clearing the crank pulleys. This can be got around by tilting the gearbox end down and tucking it under the other side first.
Gearbox Clearance - Click for a larger image

Getting the gearbox in place is a bit tricky. The engine doesb't fit if you lower it straight down, you have to twist and tilt it about a bit to get it in place.
Inlet Manifold - Click for a larger image

Another tight spot is the bracket that supports the inlet manifold (to the right of the oil filter). I'll need to remove this bracket, as the engine won't go into place with the bracket there. The alternator also needs to be removed, as there's no room for it here!



Dec 16th 2005 :: More Honda Dismemberment
Now I've got the engine removed from the CRX, I've turned my attentions to stripping anything else off the Honda that might be useful or that I could sell on eBay, so that I can get rid of the shell and put the mini back in the garage. I've been working on the back of the car today, which hasn't been possible until now, as I've not been able to get access to the rear of the car, due to me being unable to open the garage door! The problem was that the boot lid on the Honda raises to the same level as the roof as part of the electric roof mechanism and I'd raised it up so I could get into the boot. Trouble is, with it being electric, once I'd removed the battery I couldn't drop the boot lid back down again! The boot lid caused the garage door to catch on it when I tried to open it, so the door's been closed for the last few weeks and I've had to get in through the back door. Today, I removed the boot lid from its electric stilt mechanism so that I could get the garage door open. This was much harder than it sounds! Now I can get the garage door open, I've stripped down the back end of the Honda too. All that remains now is the middle bit, mainly the electric roof mechanism and the fuel tank. Once I've stripped those out, I can get rid of the shell :-)


The Bootlid - Click for a larger image

Removing this took some effort! It raises vertically upwards on stilts and forks come out the front of it to pick up the roof panel. It was secured to those stilts pretty securely and the wires and connections were pretty well tucked away too!
Roof Mechanism - Click for a larger image

This is the roof mechanism that raises the boot lid. It's fairly sturdy kit to cope with the weight of the boot and roof panel. Once I've removed all this lot, the car will be almost ready to go to the scrappers :-)
The Stripped Back End - Click for a larger image

The back end soon started to dissapear once I'd got the garage door open!



Dec 21st 2005 :: Honda Gone!
I finally finished stripping the Honda of any parts that I need for the conversion, or that I could sell, so it was time to say goodbye to the shell. Someone came round to collect it yesterday, so I've spent today clearing all the remaining crap out of my garage and made a trip to the tip so that I could get the mini back in the garage. There's a LOT more room in the garage with the mini in there as opposed to the much larger Honda, so I've at least got more room to work now :-) Next up is to remove the engine, then the subframe from the mini.


Bare Shell - Click for a larger image

By the time I got rid of the Honda shell, it was looking pretty bare!
Wiring Loom - Click for a larger image

For those of you wondering why it's taken me so long to remove the wiring loom, this is why! I've had to carefully disconnect and label and photograph every one of those connections!
The Mini - Back in the Warm & Dry :-) - Click for a larger image

Loads of room in the garage now the mini's back in there :-)



Dec 24th 2005 :: Mini Christmas!
I've been a bit too busy lately to do too much to the mini, but I managed to squeeze in a bit of work this morning :-) I've now removed the radiator from the mini, along with the carb and inlet manifold. I've also drained the fuel tank and disconnected the gear linkage. This is usually a real pain, but luckily, the drift that my Dad made for me to use on the Honda gear linkage was a near enough perfect fit the mini roll-pin too :-) Everything is now disconnected to allow the engine to come out, except the clutch, which is turning out to be a bit of a pain. Once I've got that sorted, all I need to do is unbolt the engine mounts and lift the engine and gearbox out. Easy peasy compared to the Honda! I'll be away for most of the Christmas break so not much progress will be made now until the new year, Merry Christmas everyone!


Carb Removed - Click for a larger image

The inlet manifold and the carburettor have now been removed and the exhaust manifold is also free.
No Rad - Click for a larger image

I've removed the radiator and that's the carb sitting in front of the car :-)
Gear Linkage - Click for a larger image

The gear linkage is now disconnected too!
Clutch Arm - Click for a larger image

The clutch is being a bit of a pain. Both of the pins that link the throw arm of the slave cylinder to the clutch are stuck fast and I can't get either of them out :-( More brute force is probably the only way they're going to come out.



Jan 3rd 2006 :: Mini Engine Gone!
I removed the engine from the mini this evening. It's kind of sad to see the end of the MG Metro engine that's seen me through France, Belgium, Luxembourg, Germany, Austria, Italy, Spain and Andorra (see IMM2003 & 2005 pics for more on that), but I'm hoping that the Honda conversion will be done in time to get me to the IMM2006 in Poland at the end of May this year :-)


Engine Ready - Click for a larger image

Everything ready for the engine to be removed now! Only the speedo cable left to disconnect.
Speedo Gear - Click for a larger image

The speedo gear connection is a bit tricky to get to with the engine in-situ, so I raised the engine on the crane a bit to improve access.
Engine Out - Click for a larger image

With the engine now out, the subframe is next on the hitlist!
The Twins! - Click for a larger image

The two engines in the corner of the garage. As you can see, the Honda lump is significantly larger than the Mini engine!



Jan 21st 2006 :: Subframe Removal Prep
I've been away from home for most of the last few weeks, so I've not been able to get much done on the mini :-( I managed to get a few hours in today though :-) I spent my time today preparing the subframe for removal, mainly removing suspension components. All that's left to do now before removing the subby is to undo the floorpan mounts, which I'll hopefully get chance to do soon, then I can trial fit the new subframe and get an idea what bodywork mods will need to be made to the bulkhead in order to squeeze the VTEC in. Watch this space!


Suspension Cones - Click for a larger image

Front suspension still attached to the subframe.
Liberated Suspension - Click for a larger image

Here's the top arms, rubber dohnuts and Hi-Lo cones after removal. The cone compression tool's also lurking at the back there.
Gear Selector - Click for a larger image

The gear selector removed from the mini.



Jan 28th 2006 :: Subframe Removed
I managed to spend a fair old while in the garage today and I got a fair bit done :-) I've now removed the subframe from the mini, which means that I can now trial fit the new VTEC subframe and then I can offer up the Honda engine to see just how much of the bulkhead I'll need to cut out to get it to fit! I also removed the carpet and sound deadening from the interior so that hopfully nothing will catch fire when I start angle grinding and welding the bulkhead :-)


Carpet Removed - Click for a larger image

The dash and heater have been removed and here you see the sound deadening material.
Sound Deadening Removed - Click for a larger image

And here's the same area with the sound deadening removed. It should be safe(ish) to start cutting the bulkhead now.
Old Subframe - Click for a larger image

The old subframe almost ready to be removed, just need to remove the hubs first.
Hubs Removed - Click for a larger image

The hubs, bottom arms, tie rods and drive shafts. Now the subframe's ready to come off :-)
Old Subframe Gone! - Click for a larger image

Hoorah! The subframe's gone :-)
Old & New - Click for a larger image

Here's the old subframe next to the new AllSpeed subframe. Quite a difference!
Half a Mini - Click for a larger image

PJ's looking a bit naked with no front end!



Feb 25th 2006 :: Honda Gearbox Removal
I've barely touched the mini for the last month as I just haven't had the time, but I've been feeling a bit guilty about it, so I made sure this weekend was kept free for me get cracking at it again. First on the agenda was to remove the gearbox from the Honda engine, so I could remove the crown wheel & pinion and replace them with my shiny new ones with a taller final drive ratio. First up, I had to drain the gearbox oil. While I was at it, I also drained the engine oil. Next up, I removed the gearbox from the engine and removed the half-shaft. The clutch and the flywheel seem to be in good condition, which is good news, so the next job is to open up the gearbox. I've never touched a Honda gearbox before now, so stay tuned, things could get interesting!


Oil Draining - Click for a larger image

Draining the gearbox oil is dead easy with an engine crane and a load leveler, just tilt the gearbox end down to make sure all the oil comes out :-)
Gearbox Separation - Click for a larger image

Here's the gearbox freshly separated from the engine block.
Gearbox - Click for a larger image

Nothing much to see here in the clutch housing. The fun starts when I get the gearbox apart :-)



Feb 26th 2006 :: Gearbox Fun
Thanks to some advice from the ever helpfull 16v mini club, I got the gearbox apart today. There was a circlip hidden away behind a bolt that needed un-clipping before the shaft it was attached to would drop down and allow me to open the gearbox. Once that was done, the gearbox came open fairly easily and I can now try to figure out how I'm going to disassemble the gearbox in order to remove the crown wheel & pinion. I also worked on the mini for a bit too, mainly removing the wiring loom so I've got a clear canvas for cutting away the bulkhead when I trial fit the Honda engine.


Circlip - Click for a larger image

This is the circlip that was stopping me from opening the gearbox. It was a bit tricky to keep it open while lifting the gearbox case off, but persistance won in the end :-)
Lots of Cogs - Click for a larger image

With the gearbox now open, you can see it in all it's glory!
Honda Crownwheel - Click for a larger image

The original Honda crown wheel.
New Crownwheel - Click for a larger image

...And the new custom crown wheel.
Honda Pinion - Click for a larger image

The left most of those two towers of gears is the pinion. I need to remove all of those gears and mount them on the new one.
New Pinion - Click for a larger image

Here's the new custom pinion to match the new crownwheel. It'll be quite a job fitting it by the looks of things.
Bare Interior - Click for a larger image

I've been stripping all the wiring out of the mini too, the interior's looking rather bare now!
Bare Outside Too - Click for a larger image

The outside's looking pretty bare too, all that's left is the brake servo. I'm not sure yet whether I'll need to remove this.



Mar 6th 2006 :: More Gearbox Fun
I didn't have a lot of time tonight to work on the gearbox, but I managed to get done what I'd aimed to. I've now removed the gear selector mechanism, the reverse idler gear & shaft, all the selector forks and the countershaft and mainshaft. I still need to remove the crownwheel & diff, but it's a good start.


Selector Mechanism - Click for a larger image

The selector mechanism removed, so I can now remove the selector forks and shafts.
Selector Bits - Click for a larger image

From left to right: Reverse idler gear & shaft, reverse change holder and the selctor mechanism
Gear Shafts - Click for a larger image

From left to right: Selector forks, countershaft and mainshaft.
New Pinion vs Old - Click for a larger image

At the front is the new custom pinion and at the back the standard Honda one. Now it's time to transfer all the gears & synchro's onto the new one.
Empty Gearbox - Click for a larger image

This is what the gearbox looks like now, with no gears :-) Only the crownwheel & diff left.



Mar 15th 2006 :: Empty Gearbox
I took my gearbox round to my Dad's today to borrow his vice and his help. I could never have got the nut off the countershaft without holding the pinion in a vice and I certainly wouldn't have got very far with the diff bolts! We managed to remove all the gears & synchro's from the original countershaft and fit them to the new one. We also removed the diff from the crownwheel, ready for fitting to the new one.


Gear Removal - Click for a larger image

Most of the gears removed, just the synchro hub and first gear to go!
Getting There... - Click for a larger image

Some of the removed gears, synchros and bearings.
Done! - Click for a larger image

All done! Here's the remainder of the gears.
New Pinion vs Old - Click for a larger image

The old countershaft at the top and the new one below it.
Assembled Countershaft - Click for a larger image

The new countershaft with all the gears fitted.
Empty Gearbox - Click for a larger image

This is what a gearbox looks like with no gears in it :-)
Diff/Crownwheel Separation - Click for a larger image

The diff bolts were pretty tough to get undone. A large breaker bar and a good grip in the vice were required...
Diff Separated - Click for a larger image

...but they came apart in the end :-)



Mar 22nd 2006 :: Gearbox Reassembly
Having taken the gearbox to bits to change the crown wheel & pinion, the time now comes to put it all back together again! Reassembly is always more difficult than just taking it all apart, especially for a gearbox beginner like myself. Anyhow, I had a go and surprisingly it all went fairly smoothly. There are some bits where an extra pair of hands would make life much easier, but it is possible to do it on your own - just expect a few cuts and scrapes!


Empty Box - Click for a larger image

The gearbox recipie begins with one empty gearbox casing...
Add Some Gears - Click for a larger image

...To which you add some gears, seasoned with synchromesh...
The Diff - Click for a larger image

...Add a differential and crownwheel to taste....
Crown Wheel & Pinion Installed - Click for a larger image

...Add them to the pot and stir over a low heat...
Fitting the Mainshaft - Click for a larger image

Now comes the fun part, juggling the gears on the countershaft and mainshaft to get them to mesh!
Adding the Selector Forks - Click for a larger image

Then add the three selector forks while trying to lift the countershaft and mainshaft at the same time!
Gear Selector - Click for a larger image

This is the mechanism that transfers the movement of the gearstick into movement of the selector forks.
Assembled Gearbox! - Click for a larger image

The completed gearbox, you can see the diff, crownwheel, countershaft, mainshaft, selector forks and reverse idler.



April 17th 2006 :: Engine Mounting
Since putting the gearbox back together, I'd been a bit stuck, as the next few jobs involved a lot of heavy lifting and maneuvering, for which I really needed an extra pair of hands. On the Bank Holiday Monday, Chris came round to give me a hand and we got a fair bit of work done :-) First up was to mount the gearbox back on the engine. I couldn't do this on my own, as it needs to be maneuvered into place fairly accurately and it was too heavy for me to lift it and move it accurately enough. Between the two of us, we made short work of it though. Next up was to trial fit the AllSpeed subframe against the mini to check that everything locates properly, which it did. We then removed the brake servo and other bits and pieces from the mini's bulkhead that might get in the way. Once we'd got that done, we mounted the engine and gearbox in the new subframe, which took quite a long time, mainly due to us having to modify the cam belt side engine mount slightly.

The mini's bulkhead had a bit of rust on it, from where the manifold had scorched the paint off and left it vulnerable to the elements, so we cleaned that up a bit with a wire brush drill attachment and the trusty angle grinder. Lastly, we moved the engine/subframe assembly in front of the mini so we could get a rough idea of what bulkhead mods would be needed. You can see in the pics below that the inlet manifold will require quite extensive bulkhead mods for it to fit. It looks like about half of the upper bulkhead will need to be cut out and recessed to make room for the inlet manifold. That'll be next on the list then!

Thanks to Chris for coming over to give me a hand. We got far more done than I could have done on my own!


Gearbox Mounted - Click for a larger image

The gearbox mounted back on the engine.
Subframe Test Mount - Click for a larger image

The new subframe mounted to the mini.
Another Subframe Shot - Click for a larger image

Another shot of the subframe mounted on the mini.
Tidied Bulkhead - Click for a larger image

The bulkhead with the brake master cylinder & servo removed. You can see some rust here, where the exhaust manifold had burnt the paint. We tidied that up a bit later on.
Engine Mounted in the Frame - Click for a larger image

I had to modify this engine mount slightly, as a lip on the bottom of it was in the way of a bolt head. A quick bit of grinding soon sorted it out though.
Engine Positioning - Click for a larger image

The engine/subframe assembly up against the mini's bulkhead.
Another Engine/Subby Shot - Click for a larger image

Another shot of the engine/subframe mounted up against the bulkhead. The car needs to be raised a bit for it to fit properly, but you can see that the inlet manifold is going to need more space!



June 3rd 2006 :: Inlet Mods & Trial Fit
I've not had chance to really touch the mini for about six weeks or so now, so I was really keen to get cracking with it today as I've got a lot of catching up to do now! With the engine now fitted into the subframe, it was clear that the inlet manifold was going to cause problems with clearance against the bulkhead. There's quite a few bits on the inlet that I thought I could loose in order to gain precious millimetres of clearance. There was a few brackets and things bolted on that I removed, but the main thing was a large extrusion on the underside, where the stabiliser bracket bolts on. As I'm not going to be using this bracket, I got out the trusty angle grinder and hacksaw and set about removing it :-)
I tried mounting the subframe & engine against the car with the inlet manifold removed and I was impressed with how it fitted. Once I'd modified the inlet manifold, I tried it for size to see how much bulkhead I'll need to cut out. I was pleasantly surprised at how little of the inlet actually fouls the bulkhead! Another couple of inches of room and I reckon I could fit it with no mods at all. Unfortunately a couple of extra inches of room is something I don't have. Also, the engine's position in the subframe is currently adjusted towards the front. I'll need to move the engine back in frame by one or two cm in order for the front end bodywork to clear the cam cover.


Inlet Still Attached - Click for a larger image

You can see here that the inlet manifold takes up a fair bit of room at the back of the engine bay.
Inlet Manifold Removed - Click for a larger image

You can see how much room removing the inlet manifold has created, compared to the pic to the left.
The Inlet Manifold - Click for a larger image

The inlet manifold. You can see the injectors and engine wiring loom still attached in this pic.
Engine & Subby Fitted - Click for a larger image

With the engine and subframe fitted, there's actually more room than I expected between the engine and the bulkhead.
Unmodified Inlet Manifold - Click for a larger image

You can see the steady mount on the left of the manifold in this pic. This takes up far too much space, so it's going to have to go!
Modified Inlet Manifold - Click for a larger image

A bit of hacksawing and angle grinding later and the inlet manifold now has a much lower profile.
Inlet Trial Fit - Click for a larger image

The inlet manifold actually very nearly fits! I can't quite get it over the studs, as the back just about fouls the bulkhead.
Inlet Trial Fit - Click for a larger image

And a pic from the other side too. Bearing in mind the engine still needs to come back a bit, I'll definitely need to modify the bulkhead.
The Whole Thing Trial Fitted - Click for a larger image

A shot of the whole lot trial fitted against the car.



All Words and Images copyright Neil Brown 2005.