GTV-S2000 (warning not for the Alfa purist)

[Keven]

Been working on sorting out the wiring. I cut out all the parts of the
harness that I would not use, electric steering, ABS, etc. The stock
S2000 harness is not a thing of beauty, its really a rats nest! I tried
re-routing and bundeling as best as I could. I had to add length to
some parts of it, and traced every wire and labeled every connector

I then got rid of all the cheesy twisted wire and elctrical tape connections
and soldered them and used shrink wrap tubing. All separate runs of the
harness were then wrapped with electrical tape, and when possible I
sheathed them with nylon friction wrap. The runs that had large connectors
and I could not cover in nylon wrap, I twisted plastic harness wrap to
protect them from any harness chaffing.

Both fuse boxes are inside the car, and are attached with custom made
brackets. The actual wiring is held in place with riveted tie wrap bases
and tie wrapped down. Wheww what a job....

[Keven]

Oh, forgot, I also welded gound nuts, as the Honda hasness has about
100 grounding points! The wires near the header in the engine
compartment will be sheathed in a thermal cover and tied down.

[cowfy]

its obvious Job was your ancester.

[Subtle]

Subscribe...++++

[Keven]

It's operation Roll Cage! I bought a hydraulic bender from T&J Dielsel
Performance. I have my cut off say from Horrible Frieght and
my drill press with a tube notcher. I got some 1-5/8 DOM steel tube
0.065" to practice with. Bought 40ft of it, and used most of it to
make 1/4 of the roll bar It's a lot trickier than I imagined,
which is why I am making a template first out of the cheap steel.
The actual roll cage will be 0.095" 1-5/8 chrome molly. The bender
uses a mandrel which is not suppose to kink the steel, but it
does not work very good with the thin walled tubeing 0.065",
so I tried it with some 0.120" stuff I had laying around, and it
bent is very smoothly. I am waiting for the chrome molly to be
shipped, so will make the template, and try to replicate it in chrome molly.

[raff_gta]

wow! nice! hows the car coming along?

[Keven]

Raff,

Thanks! Go back a few pages, and check out the u-tube
test drive and exhaust sound

[Keven]

A good friend offered to dyno my car, so we trailered her up and
headed to his partner's shop. First run showed 168hp to the wheels.
A fan was placed in front of the car, and that run to 8K rpm showed
180hp to the wheels! My buddy told me that if I had a Hondata
computer, he could tune it up to 200hp to the wheels with no problem!

Here's a link to the video:

YouTube - alfa_tomato_dyno.AVI

[p_lo]

So were the results what you expected? Were you pleasantly surprised? How many torques?
Great work BTW. The problem is, however, once its done...you'll want another project.

[raff_gta]

far out 200hp at the treads! thatd go like an animal!

[Keven]

Here's the plot of the dyno.

[Grant]

Here's the F20c in an ae86, a car that weighs about 50lbs more than your car once it is put back together. Are you excited for this kind of speed or what??

YouTube - F20C AE86 vs the best from Germany

These corollas have a solid axle like the 105's, but have a pan-hard from the factory. I'm hoping your diff will be OK too. The corollas need their's changed out when using the Honda engine.

[GTV-GR]

Holy **** -it ATE THE PORCHE.
Well if Keven races this thing , too many of you back in the USA are in for a serious SPANKING

[Keven]

Ok, holidays are finally over, and can get back to working on the Alfa
Tomato I started assembling all the tools needed for making a roll
cage, and actually tried bending one up using some cheap this steel
1-5/8 tube. I quickly realized that I had no idea what I was doing
and needed some educating as to how to make the roll cage without
wasting a LOT of chrome moly tube I did some research online,
and found this really nice write up:

Pirate4x4.Com

This a brilliant and easy way to accurately bend the tubing for the
roll cage. So I have a plan to guide me, I just need to find a source
for some 1-5/8 4130 chrome molly tube 0.095" thick in LA, I tried
M&K Metals in Gardena, but they do not have any. ANyone have
a source here in LA? I would prefer to buy it locally as shipping
a 12ft piece for the main loop would be very pricey!

Here are a few pics of the layout and my bent tube template...

[Keven]

I plan on having the cage be removable, so that I can have it
powder coated, and then bolt it back in after painting the car.

While, the goal is not to make the cage FIA compliant, as to do
this the rear sea would be unusable. It will be a street cage
to add stiffness, and a bit of extra safety in the unlikely event
of a crash or roll over. That said it will be bolted thru the frame
with 3/16" steel plates, and the three pieces : 1) Main Loop,
2) Front arms & 3) Rear arms will be bolted together using solid
3/4 inch rod ends, and two 3/16" tabs. The rod ends will be
pinned thru the tabs. The rod ends will connect to the 4130
tubes via chrome moly rod ends welded into the tubes. This
is some very hefty hardware, and almost negates any weight
savings by using 4130 tubing versusu mild steen DOM tube!
But I think it will be bulletproof, and look really cool once installed.
Thoughts, concerns or comments welcome

Here a few pics of the rod end assembly...