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A Radical overhaul (another blog with pics)


Keyser

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Good Evening :wave:

 

 

So news from the Zed Shed, we started the wiring (maybe not such a good idea :lol: ) but before we get into that let me introduce Tim

 

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(on the right in case you were wondering :lol:)

 

As you can see Tim is a dab hand with a vacuum cleaner

 

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That was a bit unfair Tim has quite a wide skill set and is an all round nice guy, he also happens to be a complete petrol head which is rather good, we had been on a few go-carting events together and he has done a few driving day experiences including open wheel so last year I asked if he fancied a shot in the Radical, needless to say he was hooked first time out :) So after spending the rest of the season on as many track days as we could fit in it looks like we are going to make the Radical a joint venture, meaning

a bit more can be invested and we should both get even more fun :drive1 if we ever get the Radical rebuilt :lol:

 

Tim just happens to be an electrician as well so who better to start stripping the old wiring loom out?

 

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While Tim got on with striping the wiring so we can separate out the old ECU and engine management system I took the old broken boost cable

 

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some ally

 

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and made this

 

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You will see where that goes soon :)

 

 

Then more wires to come out as the old wiring is looking very messy after years of changes and repairs

 

Before

 

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After

 

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Then I turned round and Tim had this pile on the floor :scare:

 

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Not sure if he knows where it all goes back though :lol:

But the engine bay is looking better now

 

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This is what is under the nose cone in front of the dash

 

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The ideal place for the new ECU and wiring to go so I made a panel to mount it all on

 

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That's the base it will be lightened and powder coated when we get the layout sorted :thumbs:

 

 

More soon.

 

Keyser and the Zed Shed Crew

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Good progress my friend.

I know a cracking guy called Tim but there is know way I'd let him loose with Radical wiring!! Hang on to this guy. Lol

 

Funny you should say that as both the Tim's were involved in building the Zed Shed II ;):lol:

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Awesome work, at least you don't have this tim working for you . . . although he is a bloody nice chap :teeth:

 

2AD9FDDA00000578-0-image-m-11_1437902240856.jpg

 

a bit more can be invested and we should both get even more fun :drive1:

 

Does this mean more cylinders are coming? I will just leave this here for your consideration . . . :stir:

 

http://www.roushperformance.com/engines/50l-coyote-rsc.html

 

:lol: :lol: :lol:

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Thanks Doogy, no more cylinders think more boosted :thumbs:

 

 

So another weekend on the wiring - it's still a mess :lol:

 

20161119_162458_zpszr3gzad2.jpg

 

wires everywhere

 

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A few new parts

 

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Tim finished the loom for the rear end

 

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and installed the new lights -

 

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Found that the lights are extremely expensive from Radical :scare: but they are exactly the same size as the old land-rover lights ( 1 for 1 swap just need longer bolts) I found an LED upgrade kit for the land-rover to LED lights and bought the set, I also added one of those brake light flashers for fun and as for the never used fog lights -seems pointless keeping them as fog lights never used them and last time I was on a track day and we had fog they shut the track - so wired those into the brake circuit giving us 4 flashing rear brake lights :)

 

After much fun ( 4 hours ) working out how to get the flasher working given that it came with no wiring diagram and the brake light switch on a radical is at the back in the brake line, we put the back cover on to the chassis connected our newly installed bulk head fixing (last one was in a bad state) and tested the lights - surprisingly the all worked :thumbs:

 

Look good as well :)

 

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Next up front lights - slight delay in that as they sent the wrong part :wacko: and the dash re-design :thumbs:

 

 

Keyser and the Crew

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I took my photography lessons from you :lol:

 

Hey it's just my phone camera and my phone is 4 years old, I can never tell when I take the pics if they are any good as I don't have my glasses on so it's hit and miss anyway :)

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Before we can finish the wiring the dash needs sorting out to handle the new layout and additions we are making one being one of theses :cloud9:

 

motec-cdl3-slm-c-shiftlight_1_1_zpsojmaja6c.jpg

 

The current dash looks like this

 

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The problem with a direct replacement of the digital dash is the current one feeds the input/output wire over the top of the carbon fiber dash, the new one has it's connector in the center, but there are 2 bars (part of the safety frame) behind the dash which will block the new cable. I also want the dash to be easier to see for the driver. The current one has very small LCD screens (it is over 12 years old) and points straight back not towards the driver so it is actually quite hard to read.

 

Blue Peter time :yahoo:

 

Out with the scissors tape and cardboard I made this :lol:

 

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After a few more attempts I came up with the right shape - now I just have to make it - a bit of head scratching and coffee or two and a smoke break later I came up with this .............

 

 

Mark out the start line with tape

 

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Add

 

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it's a bit of insulation foam left over from the Zed Shed build, double sided sticky taped to the original dash and shaped to the new design.

 

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Cut recess for digital dash and cover with masking tape

 

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Add tin foil and bake for 30 mins

 

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cover with fiberglass

 

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allow to dry and repeat

 

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allow to dry again and turn over

 

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cut out the back

 

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remove insulation

 

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clean it up add a new layer

 

inside

 

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and out

 

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all dry

 

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quick sand and a test fit

 

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Getting there :thumbs:

 

Need the dash so I can finish the install also need to relocate some switches and controls so more soon :)

 

Keyser and the Zed Shed Crew

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  • 2 weeks later...

Not been keeping this up to date but things have been happening.

 

Started on the engine -

 

This is the engine spec as I bought it, However it has been completely rebuilt by Sean at BigCC in Wokingham with further mods and I have changed some parts to suit it's new home in the Radical. - I have noted them for you :)

 

SUZUKI HAYABUSA GEN 1 ENGINE

 

COMPLETE REBUILT, ALL NEW PARTS - Rebuilt again by BigCC

 

IT HAS A 1 INCH BILLET FLAT SUMP – Replaced with Radical Dry Sump

 

SWINGING OIL PICK UP AND ANTI SURGE BAFFLE - Replaced with Radical Dry Sump

 

BILLET UP RATED OIL PRESSURE RELIEF VALVE

 

UP RATED OIL PUMP DRIVE GEAR

 

BILLET OIL FILTER , WITH REMOVABLE INNER GAUZE

 

BRAND NEW GEN 2 1340 CRANK SHAFT WHICH IS LIGHTENED AND FULLY RACED BALANCED - Replaced with Gen 1 Balanced shaft

 

BALANCE GEAR REMOVED - Added in again

 

CARRILO CONRODS

 

J E TURBO PISTONS (9.5:1)

 

TOOL STEEL PINS

 

BRAND NEW GEN 2 BIG END AND MAIN BEARINGS - All new Gen 1 race parts fitted

 

HEAVY DUTY CYLINDER STUDS AND NUTS – Now uprated and drilled out to 14mm

 

HEAVY DUTY CRANKCASE STUDS AND NUTS

 

RUNNING A 26 TOOTH FLYWHEEL

 

APE HEAVY DUTY ROLLER CAM CHAIN CONVERSION WITH ADJUSTABLE CAM SPROCKETS

 

CRANE TURBO CAM SHAFTS

 

60LB UPRATED VALVE SPRINGS 1mm OVERSIZED STAINLESS STEEL INLET AND EXHAUST VALVES MANUAL CAM CHAIN TENSIONER – Replaced with OEM Item

 

CYCLINDER HEAD PORTED AND FLOWED

 

UPRATED 5TH AND 6TH GEARS

 

TOOL STEEL SHIFT SHAFTS

 

HEAVY DUTY SHIFT STAR DETENT

 

KOSMAN OUTRIGGER /BEARING SUPPORT – Removed to fit radical

 

POLISHED BILLET GENERATOR COVER

 

2 STAGE LOCK UP CLUTCH

 

BILLET LOCK UP CLUTCH COVER

 

BILLET STARTER GEAR COVER

 

HIGH FLOW BREATHER COVER - Replaced with Radical unit

 

EMTES OIL RECOVERY PUMP FOR DRAINING TURBO .

 

Sean also added a high performance output shaft and a billet clutch basket to increase strength :thumbs:

 

 

 

 

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Sump cleaned

 

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and fitted

 

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New cam chain tensioner

 

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fitted

 

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Then we had to drill a hole in the head :scare:

 

It is for the scavenger pipe that stops oil build up in the head on high G corners, I have spoken to Radical and they say I should keep it so we did.

 

Protect everything -

 

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engine on its side plus an industrial vacuum cleaner and an airline

 

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all done

 

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Engine all together - the drive cup was a nightmare - so much so I will post that up next

 

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Diff cleaned and ready

 

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Empty space

 

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filled

 

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:yahoo:

 

Some new bits have arrived to be added on

 

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20161217_153448_zpswnew5hmw.jpg

 

More Soon

 

 

Keyser and the Zed Shed Crew.

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So The next bit is one of those - I wish I hadn't done that / how to engineer yourself into a corner and then back out again :lol:

 

 

So this is the new High Performance (up-rated) output shaft from the new and improved engine

 

20161110_114804_zpsqbqlxq4r.jpg

 

That shaft has the same spline setup as a Honda Blackbird (and a load of other bikes) it is a lot bigger than the original Hayabusa output shaft but the OEM shaft has been known to snap when you turbo the engine, it was therefore logical to go for the upgrade.

 

Onto that shaft fits the drive coupler cup

 

20161110_114752_zpsd7hsagup.jpg

 

Now this had the splines for the Hayabusa output shaft, I contacted Quaife who make the diff for Radical and this was a known upgrade and they gave me the part number for the coupler that fits the larger output shaft but can't sell it to me as they are only made for Radical. I contact Radical who are aware of the part BUT only 2 cars were ever fitted with it from new as they then upgraded to the Gen 2 engine which has a larger output shaft, They have in fact only ever ordered 6 of them 2 went on the afore mentioned cars the other 4 have been sold over time to owners doing the same upgrade I have just done, They will order me one on the next order but that could be a while (still waiting for the phone call to confirm) and it takes 6-8 weeks from order to delivery :dry:

 

So not to be outdone I found out about a process known as "Spark Erosion" which should allow the new spline pattern to be cut into my existing coupler, I tracked down a local company that specialise in spar erosion and sure enough they could do it :thumbs:

 

Excellent I thought jobs a good un - BUT No

 

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Spot the deliberate mistake the splines line up perfectly the nut fits but you can't get a socket onto the nut to actually tighten it in place :doh:

 

So all my upgrades were at a bit of a standstill, To the junk box - I found this (on the left)

 

20161210_120518_zps8lptrgpi.jpg

 

It is a 32mm nut from a Citroen C1 Drive shaft that has a knackered thread (we did the clutch on my daughters car recently) the nut on the right is the 36mm one that actually fits the output shaft that went on the lathe

 

20161210_121224_zpssoaqqdrl.jpg

 

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it now fits over the shaft

 

I used the lathe to align the two nuts

 

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welded them together

 

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Then between the lathe and the mill I cleaned them up so they would be balanced, finished piece

 

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Fitted

 

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and there you have it 3 hours work to solve a problem I created myself by not checking the fitment before opting for the upgrade :wacko:

 

 

More Soon

 

 

Keyser and The Zed Shed Crew.

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