Roxanne - budget milano/75 track car - Page 58

**AR4me** · #**856** (**permalink**) 03-24-2007, 12:37 AM

Yeah, unfortunately that is often how it goes with custom stuff...

Ok, made some progress. Attached are some pics of the engine bay. You'll see the mounting of the 164 air-box, the plenum mounted (and the throttle body mount cut off), the coolant bottle mounted for mock-up to measure the cutting and fitting of the 180* aluminum bend for the plenum, all Motronic wiring complete (had to extend the crank angle sensor harness tail - a bit of a pain with shielded cable, made a custom coil to distributor wire). Also, you'll notice that I remounted the two Motronic relays, the starter junction box, and the made power point for the car. All three are no longer mounted on the stock bracket, but instead mounted directly to the firewall further back. This was to allow better clearance for the 180* aluminum bend for the plenum.

What you don't see in the pics is completion of installation of drive-shaft and associated items.

Jes

**AR4me** · #**857** (**permalink**) 03-25-2007, 12:33 AM

Worked most of the day on the car. I put together the coolant system - I thought that would be a 5 min job

Nothing is ever that simple

The fitting on the back (towards the firewall) is a different size than the Milano. In retrospect I actually knew this. Anyway, it meant running around to auto parts stores trying to collect the necessary pieces... It all went in - see pics. I also put together a throttle body (mixing parts from the two - the Milano and 164S). We mocked up the plenum again, cut the aluminum 180* bend a bit, and trimmed it to fit on the plenum. Colin took off to start the TIG welding of the aluminum pieces...
Jes

**AR4me** · #**858** (**permalink**) 03-25-2007, 12:38 AM

The battery was re-relocated from the trunk to the interior - mostly due to the custom fuel pump and filter occupying the trunk area. This also meant relocating the kill switch from the rear of the car to further front, since it would be kind of wasteful to run power cables all the way to the trunk and then back up front. It took some time, but I got it done.

So, what's left:
1. Finish welding plenum
2. Fab custom Alternator bracket
3. Fab Exhaust
4. Mount fuel pressure gauge & fuel level gauge
5. Mount fire ext., harness, and seat.

Jes

**AR4me** · #**859** (**permalink**) 03-25-2007, 03:28 PM

The 180* aluminum bend is welded 99% onto the plenum - Colin ran out of gas

You may see the miscoloring and splatter on the aluminum. The throttle body mount is cut and trimmed and ready to be welded onto the other end of the 180* bend. Note the odd angle of the throttle body - necessary for the throttle cable to reach. I expect to use a 3" silicone connector between the throttle body and air-box. This morning I also wired up the new fuel level gauge as the FuelSafe sender isn't compatible with the Milano gauge. Still need to fab a plate for the mounting.
Jes

bobsiopener · #**860** (**permalink**) 03-25-2007, 03:56 PM

Hi Jes,
Whats the function of the gatoraid bottle?

**nizam** · #**861** (**permalink**) 03-25-2007, 07:35 PM

Quote:

Originally Posted by bobsiopener

Hi Jes,
Whats the function of the gatoraid bottle?

bobsiopener · #**862** (**permalink**) 03-25-2007, 07:44 PM

in the stock car doesn't the reservoir act as the over flow as well or is there no over flow in the stock set up? if it does is there a rule that they must be separate?

**AR4me** · #**863** (**permalink**) 03-25-2007, 08:23 PM

Bob,
The stock cap will release pressure through the cap at around 10 psi, or so. This may eventually include coolant - as I have experienced a couple of times

In that case you want a coolant catch tank to collect it. BTW, the 164 cap (or some of them) conveniently has a nipple from where you can collect overflow

That's what I'm using - it fits on the Milano coolant bottle

Jes

**AR4me** · #**864** (**permalink**) 03-25-2007, 10:08 PM

...and some pictures of the new fuel related gauges mounted and wired up - fuel pressure to the left and fuel level to the right. Mounted in a carbon fiber board in the location of the stock center vents.
Jes