Monday, 17 March 2014

Build Day Twenty Two - Radiator, Dry Sump Tank and Cooling Pipework

Tonight was the start of what I'd been holding off for as long as possible - the radiator, oil and heating pipework.  I fitted the heater a while ago, so that was one part ticked off.  The reason I was holding off doing this is that the R500 doesn't have any build instructions for the routing of the pipework so its pretty much left to guess work, internet research and cross checking against what the manual suggests for the R400...  Luckily Nigel Pugh was kind enough to take some pics of his engine bay and sent them over to me, which certainly helped.

First I fitted the fan to the radiator cowl.
R500 radiator cowl fitted with fan.
R500 radiator cowl fitted with fan.
 The instructions then state to fit the clutch cable to the banjo bolt, so I done that.
Clutch cable fitted to banjo bolt and tie wrapped to battery housing.
Clutch cable fitted to banjo bolt and tie wrapped to battery housing.
Next was to start the dreaded cooling.  I started off by drilling and riveting the expansion bottle mount.
Expansion bottle mounted to chassis using rivets as suggested in the manual.
Expansion bottle mounted to chassis using rivets as suggested in the manual.
I slid the expansion bottle into place, and it appears I have the wrong expansion bottle.  There should be another larger hole which mounts using a pipe to dry sump tank.
Expansion tank fitted.
Expansion tank fitted.
I used some rubber P clamps to mount the bottom of the dry sump tank to the chassis and some bolts through the P clamps. Then found a suitable bolt in one of the fastener packs, used four washers and bolted the dry sump tank into place.
Dry Sump Tank Fitted.
Dry Sump Tank Fitted. 
The next part was the pipework, and the first pipe to be cut to size and fitted was the breather cover to  top of the dry sump tank.
Breather Cover to Dry Sump Tank pipe fitted.
Breather Cover to Dry Sump Tank pipe fitted.
Next was the bottom radiator hose.  Was a tight fit getting my hands in there to push the pipe into place.  Not sure I've been supplied the correct hose though, so will need to double check that.
Bottom radiator hose fitted to engine.
Bottom radiator hose fitted to engine.
 Then onto the race line oil pipes.  They have a big nut on them, and need a 32mm spanner to tighten!
Raceline oil pipe fitted to top of dry sump tank.
Raceline oil pipe fitted to top of dry sump tank.
Raceline oil pipes fitted to bottom of dry sump - very fiddly indeed..!
Got plenty more questions for Derek at CC to answer for me tomorrow. I'm not sure I have the correct bottom radiator hose, expansion bottle, and also would like some clarification on the heating pipework too.

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