The lower rad connection was always meant to be the problem when connecting a Series rad to a Disco 200tdi. But using a couple of new hose sections and a right angled stainless section it all went together quite easily.
Next hurdle was the fuel filter location and means of mounting it. Some weeks ago I knocked up a simple plate to allow the fuel filter to be mounted on the blind box section part of the bulkhead. So all that was required was for sheet nuts/clinch nuts to be fitted and it would be good to fit? Well that didn't go to plan and the four mounting points are now limited to two as the nuts were screwed by the knackered tool (stripped threads) that I was lent. Not happy but the mounting is at least secure.
By the end of play Saturday it looked like this.
Well Stu 'Twizzle' dropped over Sunday and we had a game plan. Get the 109 started!
Stu tackled the fuel line routing from each tank while I connected the power and earthing then finished the injection pump pipework ....and in a bit of a rush before we lost the light we managed it. See link below. (Note no turbo pipework/or exhaust and a lot of loose stuff rattling).
In Hi res, but a 120MB file so a bit slower to download---> http://www.youtube.com/watch?v=ukBEbDrphBA
Well as can be seen in the video there was a lot of air in the pipework and after an hour or two of fiddling we located the source. Originally the intention was to feed the return supply from the injection pump back into the fuel filter. This had a two fold benefit. First we wouldn't need to feed back to the selected fuel tank (there are two so the manual fuel tank selector only has to deal with the supply) and secondly if the fuel is heated, either by an FPHE or from the body of the IP, this would assist the temp (and therefore the viscosity) of the fuel as I plan to use veg oil in some concentration, which is the main reason for retaining a two tank system.
But, the source of the air was found to be the IP return. So what to do? Either find a way to use the IP return supply without air being included or we/I have to feed the return back to the tank - but then there is the problem with having dual tanks and only a three port fuel selector? Worse case scenario is the passenger tank will be a spare which can be pumped to fill the main tank via an electric pump, but then veg oil concentration would then never be able to go past, say, 50-60% as there would be no 'pure' dino to start from. Basically it would then be a 'single tank' system.
Also, before we packed up for the night we ran the gearbox through. Props are currently off anyway and everything seemed to be running as it should :)
THROTTLE
Stu had located his 'spare' Disco throttle cable so when I get a moment that will fit straight on with only minor tweaks here and there (drill the bulkhead to suit).
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