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Old 02-07-2021, 09:43 PM   #276
lookforjoe
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More paint





Removed the Rad/Fans/AC condenser to replace the damaged condenser





I'd like to have added a Volvo fan - but just no room to make it work



Cut slots to add side vents like a Volvo setup (took the flaps from my old V70 fan shroud)







New condenser attached



Adding a VW two-temp fan switch



Need to add a another fuse/relay panel up front to run the headlights, fans, etc.,

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Old 02-16-2021, 10:52 PM   #277
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Been working on the rad/ AC cold. install - I decided to revise the layout after I found a posting from another X1/9 where they tipped the rad backwards to alleviate the fans pointing uphill into the back of the tub. I can't go as extreme as in my case the AC condensor & 3" rad core prevent the same degree of offset.

Normally the rad leans forward - following the nose rake - now I have it about 6" back. Added an angle bracket at the top to locate it whilst I rework the rad support







Started cleaning up all the wiring - going to use a Volvo 900/850/x70 fan relay





chopped up some 700 ancillary adjuster arms & used the sleeves & 1378153 bushings to isolate & mount the support at the required angle





in place



welded some 3/8 stock to the rad base & threaded about an inch



bushing to isolate rad some more





Rad didn't want to align with evenly spaced brackets - determined the rad was tweaked in the accident - so I bolted a couple 6' angle iron to it & tweaked it back



test fit - had to cut the lower hose due to the increased distance



fans now sit at half below the floor line & point downward compared to original layout



made seal attachments to close off gap above & below rad





riveted seal support brackets once I got the precise location figured out





then paint







just have to finish up the fan shroud mods to compensate for the revised offset


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Old 02-26-2021, 10:12 PM   #278
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Did some cleanup on the shroud, and also I added a locating tab - since I removed the lower frame section of the shroud the bottom edge is no longer rigid.



Started on the wiring for the fan circuit - I'm leaving all the stock wiring intact unused, except for the AC-on trigger. The Volvo relay will go under the molded AC hose/wiring cover. I'm moving the headlamp relay mod under that cover also.



although I have the big ugly fuse breaker & Honda ELD, I really don't want extra wires running over by the battery or over to the wiper relays, so I ran new wires crimped with the fusebox supply cable, in through the bulkhead & back out into the trunk following the stock harness. I used heavier (than the Fiat) gauge Volvo wires - to make sure I don't have load issues. These will be the fused 30 supplies to the headlamp relays, wiper relays, cooling fan relay, and something else I've probably forgotten at the moment



Tidied up the new wiring (constant feeds) to the fuse box, wired the two headlamp relays & the cooling fan supply relay, and added 2 switched feeds .

Plenty of spare fused circuits should I need them. So far, every time I thought I was done, I needed more circuits.



Added 2 M6 rivnuts for relays, cooling fan/sensor grounds - one for power (fan) grounds the other for sensor/relay coil



Fuse panel will go under here, eventually. I have to fix the inner fender / strut reinforcement behind it first - I was going to leave that until next year



Weather-proof connectors finally came so I got the body-side fan connections in place
Yazaki 58 series





VW fan switch connector & boot in place



For the larger ground connections I had to buy yet another tool - I have a hydraulic crimp tool, but that is only for closed barrel type, not 'open barrel'



Cut holes for tub vents / brake ducts - I'm keeping it non-structural, so no cutting of the frame rail. Using readily available ducting. 3x4 rectangle fits between the frame.







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Old 03-07-2021, 10:55 PM   #279
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Cut out the right side ducts





ducts bonded in place



wiring to fan sensor done



sidetracked with some rust repair - I was going to leave this for another year or so, but I need to do it now



cut out driver's side rot



removed & cleaned up the rot off the brake line brackets



templates & cut repair sections



test fit





left side mostly done



right side tacked



Once these are finished, I have to add reinforcement plates from the strut housing back down the lower frame rail - chopped up a S40 bumper bar to use for that



Once this is done, I can get back to finishing the wiring, get the rad back in, then get the HVAC & dash back in....
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Old 03-13-2021, 11:34 PM   #280
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Got the repair panels all welded after this



and added the reinforcements cut from the S40 parts car bumper





primed, caulked & painted ready for stone chip & undercoat





stil have to do cleanup on the inside





figured out the brake line brackets



made a bracket to mount the relay/fuse panel - cut up a V70 AWD fuel filter bracket





tub area done



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Old 03-19-2021, 07:40 PM   #281
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Got sidetracked with replacing the DP flex coupler on my C30 last week - royal PITA with the AWD conversion



After that, got the stone chip & undercoat done in the wheel wells



Brake line retainers installed - put rivnuts in the skin & used torx machine screws



struts & brakes back in





Reworked the #8 hose to the condenser, required a #8 FOR 90ยบ elbow due to the rad/cond re-alignment. I'll work on the #6 hose to the evaporator soon



ran the hose along the rail instead of along the water pipes - since the dogleg end of the stock hose is gone



The other end, I had to cut & splice a new section where the original was sliced in the accident



#8 straight MIOR was needed here to attach to hose running to compressor.



#6 line with orifice tube figured out. Then removed & crimped line fittings.

Fuse panel installed.







made a bracket to retain the fan relay to the inner fender



Check everything fits. I'll have to rework the carpeting for the frunk around all this

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Old 04-07-2021, 09:59 PM   #282
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Put the HVAC back in, finished the floor stone chip & undercoat





Added a Volvo chime relay to use for 'lights left on' warning





Had to repair another rust hole in the d/s cowl - probably what caused the floor rot









Then dash back in











Finished the brake ducts





fan shroud & hoses back in.



Speakers from the S40 mounted in the kick panels





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Old 05-13-2021, 08:59 PM   #283
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Cleaned the X1/9 ready for Carlisle Import Show tomorrow morning









Hopefully I'll get the final touch on this year -



The 'factory" rear spoiler used on the original Dallara



EDIT - also swapped out the fans for 12" FFD 1600cfm versions


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Old 06-05-2021, 09:00 AM   #284
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Drive to Carlisle - only me & one Volvo this year -



Fiat got moved away from adjacent to the Volvo section this year :(

The other red X1/9 is what mine looked like originally





I did get this



Did the exhaust note trials - just for fun - noticed I'm getting some oil smoke :(



Finally got the car Dyno-tuned on Thursday. 195WHP, 165WTQ












https://youtu.be/YRUDMYGVwCY

https://youtu.be/gkhGNtn2R6c
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Old 10-24-2021, 09:20 PM   #285
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Drove the car to Colombus, Ohio & back this summer. Fiat gathering out there. Car ran very well, but.... the header I made leaks at the flange, and it is a significant restriction in terms of performance.



I found a PLM header for the K24 - so I'm in the process of making that fit





bought 2" SS mandrel bends to fix it



had to cut out the cross support to do this - I'll make a new section when it's all done



runners rerouted for the Fiat chassis



Slip joint sections cut from original header & reinstalled



reworked 2-1 collectors to fit





mostly welded




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Old 10-24-2021, 10:36 PM   #286
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Cool seeing your progress on the X1/9. Definitely one of the better-executed custom ones out there, considering how many things you've modified.

I'm using the same two-speed VW fan switch on my wagon, and may someday adapt one for my X1/9 as well. Where did you get the plug/pigtail for it? I looked for it online for ages and couldn't find it available anywhere.
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Old 10-25-2021, 11:48 AM   #287
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Quote:
Originally Posted by al_ngl View Post
Cool seeing your progress on the X1/9. Definitely one of the better-executed custom ones out there, considering how many things you've modified.

I'm using the same two-speed VW fan switch on my wagon, and may someday adapt one for my X1/9 as well. Where did you get the plug/pigtail for it? I looked for it online for ages and couldn't find it available anywhere.
Thank you.

I got them from the local Audi dealer - VW dealer should also work:

connector 893906231 boot 867972525B, and 6mm Faston (female spade) terminals

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Old 11-20-2021, 09:44 AM   #288
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Made a new access cover to clear the headers







covering for access panel



foam, then carpet on the trunk side



Upper cross bracing figured out













exhaust layout Solo Performance STL25 muffler, Vibrant 1792 resonator, Red Hat performance tip









figuring out modified trunk floor











SS panel to cover it all

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Old 05-26-2022, 10:03 PM   #289
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New rear tires mounted so I can start driving the X1/9 once more. Have an alignment scheduled for next Wednesday, so before I wear them out again


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Old 05-29-2022, 10:08 PM   #290
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Worked on the trunk lid and spoiler over the past couple days



wet sanded 1-7k, compound, polish



closed cell foam on the standoffs



then today I put the lid and wing together, added the vinyl to the foils, and then the tape stripe across the trunk & uprights.

Steel lid required shorter offset bump stops







template for vinyl for foils





closed cell foam between spoiler & foils









going to take some getting used to - I already smacked my head a couple times closing the lid due to the rear overhang



added tape stripe to continue from sides, had to stagger the inner stripe since these uprights aren't flush with the rear edge as with the original design



will require reworking the inset strip where it meets the standoff







added two reinforcements for the plastic engine cover mesh, where the header heat had started to make it sag



wing doesn't impede rearward vision, I hadn't even thought about that





Volvo C30 car cover actually fits now



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Old 08-14-2022, 11:32 PM   #291
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Timing chain broke back in July. Wasn't an OEM chain, lasted 5K miles. Being used to generally equal quality with non-blue box Volvo parts for timing belts, etc., it did not occur to me that companies might actually make critical components that are ****e. Obviously I'm replacing everything with Honda-packaged items



if you look closely you can see fractures in many links



drivetrain coming out







gods must have been smiling - the valves did not hit the pistons, and this was with high(er) compression pistons



short block being reassembled



.... adding Cruise control from an '05 RSX while I have the access with the drivetrain out











chopped & reconfigured mount bracket to suit









head came back, confirmed zero damage





all Honda **** this time around



ready to reinstall









heater return hose is a 740 turbo rad-to-expansion tank hose cut to fit







almost there. Hopefully up & running tomorrow or Tuesday.

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Old 08-16-2022, 05:04 PM   #292
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Is it too late to suggest 4P chain guides?
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I hate the car and also cannot be free of it. I dream of having a different project but cannot separate myself emotionally from this one and so remain bonded to it like Sisyphus to his great stone.
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Old 08-17-2022, 08:06 AM   #293
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Quote:
Originally Posted by Harlard View Post
Is it too late to suggest 4P chain guides?
- The setup is basically stock output (around 220 max), just between a little higher rev limit & cam iVTEC cam advance. Other Honda ppl have used stock parts for much more, so they reckoned I just needed to make sure the critical parts are OEM.
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Old 08-17-2022, 12:48 PM   #294
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Quote:
Originally Posted by lookforjoe View Post
- The setup is basically stock output (around 220 max), just between a little higher rev limit & cam iVTEC cam advance. Other Honda ppl have used stock parts for much more, so they reckoned I just needed to make sure the critical parts are OEM.

I only said that because the engine was already back in the car
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Old 08-17-2022, 04:28 PM   #295
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Quote:
Originally Posted by Harlard View Post
I only said that because the engine was already back in the car
trying to be a wise-guy, huh?
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Old 08-17-2022, 04:41 PM   #296
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this thread has delightfully gone full plaid. That's awesome.
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Now with in-house Dyno tuning!

Megasquirt Tuning!
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Old 09-14-2022, 10:10 PM   #297
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Got the rest of the car back together. couple hundred miles so far, no oil consumption, running well.





EMS back in








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