Pre IVA Checks

Got back from the garage.  Had the emissions and alignment adjusted to help with self centering. 

Emissions are so close now, its just balancing between the CO and Lambda going over. Its fine for about 20 seconds then one or the other goes over the limit.  The chap at the garage said his machine was very sensitive so fingers crossed its more sensitive than the IVA centre.  

Rained again, got soaked and very muddy!  Can't wait to drive it not in the rain! 

Sound is better but my meter was reading less than IVA Centre..

DB Killer

DB Killer turned up today. Its well made and very strong, its not something thats going to just fall out or break so looks the real deal.

Excuse the very dirty car.. Not washing it until after i'm back from garage tomorrow ready for IVA on Monday. 

The killer fits in perfectly.

Bolts securely into place. 

Before fitted the car would idle at about 86 db..  Now with the DB killer is was 78 db at idle while warming up.

It was getting a little late so couldn't rev it much but at 4-5k it was alot lower. Fingers crossed at 9k its well under what it was.

My only concern is the internal edge on the DB killer and will it fail the external radius edge check.

Baffle DB Killer

I've ordered a Baffle DB Killer from ebay.. I should be able to fit this to the end of the exhaust and still get the IVA testers probe down the end of it.

The IVA tester thought most of the noise was from the engine but wanted to see if how much was made up from the exhaust.

I will ensure I get the emissions tested with this installed just incase it effects flow.

Another trip to the garage..

Today wasn't fun.... 

Wet and cold i've learnt today don't mix well with kit cars..  It results in wet bums, wet arms, pretty much wet everything. Still enjoyed the drive there apart from getting soaked. The rear end lights up really easy, took it steady. 

Drove to the garage to get the emissions, handbrake and to look at the self centering issue if it was one. 

Well straight away on the drive there the car still wasn't self centering at all. I thought this was to do with the stiff column but it must be setup but it can't be that as its now moving freely.  On the previous alignment check we set it up with 1 degree toe in and 1 degree negative camber on the front end.  

Dropped Marc a text to enquire what else could be done, apparently each wheel (Front and rear) should be 1mm Toe and 1.5 to 2 degrees negative camber.  To confirm thats each corner front and rear.  First time suspension was setup we did not do this.  

I am alot closer on the emissions, didn't get any readings as it was a real rush and their machine started to melt so they had to end the test early. At one point I had all green results so nearly there. 

Handbrake fine, 18-19%. So just strong enough. Brakes were super cold also. 

Noise.. lets not go there.. Its going to be a problem!  

I am booked in again this week, garage have allocated me a couple of hours. Should get it all done in time ready for retest on Monday. 

IVA List getting smaller..

Really cracked on this weekend and pretty much got the list sorted.

Sorry been crap at taking pictures recently, i've just been cracking on to get things complete so I can book my retest asap.

01 - NOISE 

RS5: The stationary noise must have a measured sound level not exceeding 99dbA.

Additional Information: OVER 103dBa RECORDED. 02B - METERED EMISSIONS

RS4: The emission limits must be met as prescribed in the flow charts in the IVA M1 Manual Section 02B for CAT1 or CAT 2 Additional Information: EMISSIONS LIMITS NOT MET.(see printout)

Well i've done the best I can. everything the exhaust side has deadening material on it. Any rattle or anything potentially going to rattle has foam or rubber on it. 

05 - STEERING EFFORT

RS8: When the vehicle is driven at speeds above 10mph, there must be a degree of steering “self centring” evident.

Additional Information: NO SELF CENTERING WHEN DRIVEN.

The steering was stiff, I think this might have something to do with the car not self centering. I've played around with the column and its now much easier to steer.. With the wheels off the ground I can move the wheel with one finger. 

09B - SERVICE BRAKE CONTROL / MECHANICAL COMPONENTS

RS26: It must not be possible to manually adjust braking rates between axles
Additional Information: BIAS BAR ADJUSTMENT MUST BE LOCKED WITH EITHER LOCKWIRE OR ROLL PINS.

Bias bar now locked out with split pins..  Not sure split pins are going to be suitable for IVA. mIght have to get some roll pins. 

09D - HYDRAULIC AND VACUUM SYSTEMS

RS10: A brake pipe or hose must have suitable joint fittings

Additional Information: NO PTFE TAPE TO BE USED ON HYDRAULIC BRAKE HOSE TO CALIPER FITTINGS. 

PTFE tape has been removed and adapters refitted. Still need to bleed the brakes. 

09E - BRAKE PERFORMANCE

RS16: The parking brake performance must be a minimum of 18% Additional Information: ONLY 10% ACHIEVED.

Handbrake removed and refitted.. I've taken all the slack out and now I get max performance on 3-4 clicks.  Fingers crossed this will be strong enough, going to get it check at the garage before IVA. 

12 - INTERIOR FITTINGS

RS1: Interior design features and fittings in the “specified zone” which are contactable with a 165mm sphere in a forward direction must have a radius of curvature of 2.5mm or greater, except where a projection from a panel is less than 3.2mm where the edges must be at least blunted

Additional Information: -BOLT HEADS ON NEARSIDE TUNNEL AND ABOVE BATTERY. -TOP EDGE OF GEARSHIFT MECHANISM BEHIND STEERING WHEEL.

Caps on the bolts in the passenger footwall and covered the top of the paddleshift with some edging. 

14 - PROTECTIVE STEERING

RS3: The steering control and column assembly must provide adequate protection to the driver by absorbing energy from a driver- steering wheel impact. This is the case if the steering control has an approval (evidence may be markings or documents), or is similar to an approved steering control.

Additional Information: NO DRIVER/ WHEEL ENERGY ABSORBING DEVICE FITTED.

Still waiting for my collapsible boss to turn up, Been told tomorrow so hopefully investigate getting this fitted tomorrow.  

16 - EXTERIOR PROJECTIONS

RS2: All ‘hard’ parts contactable with a 100mm sphere, which form an external surface or protrude 5mm or more from the external surface must have a radius of curvature of at least 2.5mm

Additional Information: HEADLAMP BRACKET EDGES.

Used amalgamating tape, as suggested by the IVA tester.

RS29: An exhaust tailpipe must not project beyond the floor line lying directly above it by more than 10mm, unless it terminates in a radius of curvature of at least 2.5mm and in all cases project no more than 150mm. In the case of side mounted exhausts the tailpipe must terminate no more than 50mm from the extreme outer edge of the vehicle.

Additional Information: EXHAUST TAILPIPE CANNOT PROJECT MORE THAN 50MM PAST REAR WHEEL ARCH WIDEST POINT.

I extended the original MNR exhaust hanger with some steel.. After messing around with the exhaust I managed to just drill another hole in the silencer hanger which pulled the exhaust in so I was well within the 50mm limit. 

18 - STATUTORY PLATES

RS1: The vehicle must be fitted with a manufacturer’s plate, in a conspicuous and readily accessible position.

Additional Information: MANUFACTURERS PLATE MISSING. AS A MINIMUM IT MUST HAVE,

MANUFACTURERS NAME VIN NUMBER

I emailed the IVA tester to confirm that they would accept the following and they would. I stamped the rest of the VIN on and riveted this to the top bulk head panel. 

23 - DIRECTION INDICATORS

RS6b: Directional indicators must be positioned to meet the angles of visibility requirements as detailed in the table in Section 23 of the IVA M1 inspection Manual

Additional Information: SIDE REPEATERS NOT POSITIONED TO MEET REARWARD 5 DEGREE ANGLE OF VISABILITY. NOTE, SIDE REPEATERS MUST BE FITTED WITHIN 2600MM OF THE VERY FRONT EDGE OF THE VEHICLE.

The side indicators are fitted and working.  Can be clearly seen from the rear. 

25 - HEADLAMPS

RS11: For European type headlamps with centres not more than 850mm from the ground, the beam image horizontal cut-off must be between the horizontal 0.5% and 2% lines, i.e. the red tolerance band.

Additional Information: UNABLE TO ASSESS, AS BOTH HEADLAMPS HAVE NO BEAM PATTERN. 

Don't know what I had done to the lights. After some investigation I had just wired the dipped and high beam the wrong way round.

The below picture shows the right headlight now correct. Showing dripped headlight.

Right showing high beam.

Both headlights now showing a good dripped pattern.

Good high bream.. The right headlight looks a little high.

28 - REAR FOG LAMPS

RS4: The rear fog lamp(s) must only illuminate when dipped beam, main beam or front fog lamps are lit
Additional Information: REAR FOG LAMP MUST ONLY WORK WITH DIP AND MAIN BEAM. NOT SIDE LAMPS

The standard loom I received allows you to turn on fogs from side lights. I just rewired this at the fuse and it sorted the problem. 

33 - IDENTIFICATION OF CONTROLS

RS1: Where provided, identification of controls must be clear so not to cause confusion

Additional Information: DIP AND MAIN BEAM SWITCH PICTOGRAMMES ARE AROUND WRONG WAY.

Should have seen this was wrong.. The digidash symbol shows the high beam, which I should have copied but didn't.  Now correct.

Will try and get an appointment at my local garage to get the emissions, handbrake, and steering tested.

One picture... Of the mess I am working in!!   The weather has been terrible. I need to move the car out so I can tidy the garage. 

First day fixing IVA issues..

Been a busy week so first chance i've had to get to the car and start sorting some of the IVA fails.

First job - It needed a clean!

Some trim on the top of the of the gear change mechanism require. Sorted this but forgot to take an after picture.

Next up..  Sound proofing.  I purchased some Dynamat on Marc's recommendation. Its £40 a box so not cheap stuff.  I started off with the underside of the bonnet. Its sticky stuff and goes on well. 

Next was to try and and do the side passenger side of the body, its an interesting one as the engine is so close it leaves no room to get down there.

On first inspection I noticed one of the header nuts had come undone and dropped into the chassis. really lucky I haven't lost this.

The deadening was easy to add in small sections down this side. Was hard work and my hands/arms were marked badly.

 Also covered the scuttle and bulk head to try and cut down on the vibration.

I think I am getting lots of induction noise so next was the airbox.

Its not made a massive difference. I think I need to add a floor plan under the engine to conceal some of the sound.