Project EXI

The building of a Marlin 5EXi kit car, using a Seat Leon 1.8T 20v Donor

Jul 22 2010

Intercooler connections silicon hoses

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I've collected the pipework i need to finish off the intercooler connections.
I have 2 90 degree bends, one 45 degree bend and a length of pipe, all in 57mm diameter to fit the existing intercooler pipes.
Just need to order the silicon hose connectors for these and the coolant hose connecters from Viper performance.
Placed an order with Viper performance for the remaining silicone hoses and hose clips to complete the intercooler and coolant pipework. Currently a 20% discount on all phone orders so that saved me 40 pounds or so :)


Posted by Steve | Permanent link

Jul 20 2010

Intercooler connections over the gearbox

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I've been in contact with a local exhaust manufacturer who are able to help me with fabricating the last of the intercooler pipes I need.
I will need 2 90 degree bends, and one 45 degree bend out of stainless steel pipe, to complete the metal work and then a few more 57mm straight hose connectors.
This should let me route from the turbo output to to passenger side intercooler pipe. This should then complete this cirucit and move on to checking electrics and connecting the radiator.
The countdown to firing it up begins !!!!

I've completed the first wiring loom for Marlin, and it is ready to be shipped directly to the customer.
8 hours of work have gone into making the loom, I hope the next loom I can make in a shorter time :)


Posted by Steve | Permanent link

Jul 10 2010

Fuse plate labelling - connecting main loom wires

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I've labelled up the replacement fuse board, and have fitted it to the front bulkhead. The improvement over the first design is huge. This new design certainly works better.
I have started the integration of the fuse board into the wiring loom. I am now connecting the wires from the steering column and the center console to the fuse board. This should be completed on Monday 12th.
Updated photos to follow on soon :)


Posted by Steve | Permanent link | File under: electrical

Jun 26 2010

Fuse plate wire crimping

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Completed the first pass wiring of the fuse plate. Next to solder all the crimp terminals and the bind the wire together.
The increased size of the fuse plate makes for a less cramped area.
I have also found a plastic cover that can be used to fit over the fuse plate on the front bulkhead. This will keep all wiring away from the passengers feet and finish the look off very nicely.
I've been investigating the instrument options a little further and have now decided on clocks. Im after a road/track car and not a track/race car. So for this reason I have ruled out the ETB DDR2 dash.
In the first case I can brand new clocks for about the £300, then upgrade or add new clocks as when the need arises, (Turbo pressure/ oil pressure)
Measuring the size of the dashboard hole, 80mm clocks will fit perfectly, 100mm clocks are too big. The difference in price also makes the 80mm option slighty cheaper.
Also located a local company who may be able to assist with the creation of a custom intercooler pipe, to connect the turbo to the intercooler side pipes, using some T304 Stainless steel. I need to create a drawing for the pipe, then visit them to get a price.


Posted by Steve | Permanent link | File under: electrical

Jun 19 2010

Intercooler connections

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I've finally been able to fit the silicone hoses to connect to the intercooler. Starting at the throttle housing I had to cut and shut the supplied pipe to connect the hoses.
Most of the connections are now in place, but the problem area to solve next is the section around the Air intake and turbo output. I need to try and source some 57mm pipe and some different hoses.
I now also have my radiator, for which I wil also need to spec out the hose requirements for this and figure out how to fix it in place against the rear of the intercooler.


Posted by Steve | Permanent link | File under: heating and cooling

Jun 18 2010

Where have I been.....

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Its been a while since I have been able to do anything on the Car. I've recently got married so that has taken up alot of my time :)
I've decided my current fuse plate could be better, so I've increased the size and have started to rework it. Im creating more space between the components on it, so routing wires will be easier. Im also fitting some terminal blocks in the bottom right hand corner and the top left hand corner, to ease with removing and re-installing the board should the need arise.
Other updates, my silicon hoses have finally arrived from viper-performance, having taken 6 weeks, twice as long as initially discussed with the salesman.
I also have the radiator to fit.
So I have some free time, its time to get moving on the build again.


Posted by Steve | Permanent link

May 17 2010

Connecting to the VAG loom

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I've started to connect the wiring loom into the VAG donor, I have decided to remove any plugs/connectors from the donor, and twist and solder each wire into the Marlin loom, once soldered cover the connection with a small piece of heatshrink tube.
I dont have too many connections left to do and once completed I can see enable each circuit one by one, by fitting the appropriate fuse and bring each circuit up.


Posted by Steve | Permanent link | File under: electrical

May 15 2010

Rear Calipers wont take handbrake cable

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The handbrake system on the new rear calipers isn't right as when fitting the handbrake cable it will come into conflict with the drive shaft, the donor rear handbrake system will solve this problem. So I have set about refurbishing them. Next door neighbour kindly put them into his shot blaster, thank you !!. Once prepped I dipped them into VHT enamel paint have left them to dry.
I also had to lower the holes for the coolant pipes as the front was not lower enough to allow them pass under the fuel tank, moving the holes down so they are about 5mm from the front box section give sufficient clearance for the fuel tank.


Posted by Steve | Permanent link | File under: braking

May 09 2010

Stainless Coolant pipes received

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Now I have collected the stainless coolant pipes, it was a great time to fit them, so I made 2 35mm holes in the front bulkhead so the pipes can run through the tunnel.
I also fitted the nearside gear linkage cable, this fitted well although I did have to 8mm of thread of each end to fit and alignment the ball socket joint to allow enough room to select all the gears. That worked fine and it is now possible to select ALL 6 gears + reverse.


Posted by Steve | Permanent link

May 08 2010

Visited Marlin to collect some parts

Went to visit the Marlin factory today and picked up some more parts.
Mark had, headlights, coolant pipes, gear linkage cable, steering rack extensions, and replacement track rod ends as my first ones the rubber had perished and fractured. Brake cables are still causing a problem so I don't have them yet.
Was a good day, and meeting Mark again was great, we had detailed conversations over a number of areas, which answered all the questions I had at the time
I have left one rear brake caliper with Mark so he can investigate the best way to connect it up, as the hydraulic banjo bolt hole will interfere with the rear drive shafts on a VAG setup.


Posted by Steve | Permanent link
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