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Ollie's 4Age Ke70 Wagon


ollienewc

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  • 2 weeks later...

Finally got around to getting the fuel lines in, decided I'll use the vent line (1) for fuel going up to the motor, and the stock fuel line (3) for my return as these are the two with the biggest diameter, and they also work reasonably well with where the fuel pump is mounted. The lines will get bent so sit behind/underneath the manifold, this allows me to hide basically everything out of sight.

 

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I dropped the tank out to sort out the lines between that and the surge tank. I found a small hole in the lift pump assembly, so I'm thinking I'll modify my stock one in the same way, but extend the hard lines to run over the top of the tank to the rear of the car, where fuel hose will then connect to the surge tank. Either that, or make some spacers to drop the whole main tank down 15mm, allowing normal fuel hose to squeeze through. I'd prefer the hard lines, but we'll see.

 

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  • 2 weeks later...

So I've been playing with the fuel system for longer than I should have, didn't end up going down the above route, but I'm happy with how it's turned out. All well and good except that I forgot about the need for fuel filters :bash: I'll need to squeeze one in somewhere, not in the bay though. What are peoples thoughts on pre filters,, worth it or not?

 

I actually made two lift pump setups as I wasn't happy with the way the first was going to work. Basically, I blocked off the return and only kept the one outlet coming from the lift pump, planning to use one of the other three inlet/outlets at the rear of the tank for the return. But I realised that the returning fuel would be squirting out and into the tank, aerating it and possibly creating a dripping noise. Not sure if this would have in fact been an issue, but I wasn't happy with it.

Using the assembly from the 4age sedan tank, I cut and drilled out the tube with the crack in it, and was able to bend up the remaining tube and used cold weld to epoxy it back in place. Would have preferred to braze it, but I don't have the equipment. Painted it, reinstalled the pump and even extended the wires before deciding to redo the lot. This was the first one completed..

 

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So I got my stock wagon assembly and drilled the vent tube out, went and grabbed some more fuel line, bent it to shape and epoxied it in. Drilled a hole for the wires, passed them through and extended them to make wiring easier later on. The stock fuel pick up/feed is now used as the return from the surge tank, returning the fuel to the bottom of the main tank. Also hoping it might 'blow' and debris away from the lift pump. The final setup

 

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I realised I can squeeze the lines down the side of the tank, basically along the chassis rail without the need for spacing down it down at all. The rounded corner of the tank creates a gap that allows the fuel lines to poke through too, perfect :rock:

 

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I've also cut and bent the lines in the engine bay to fit, but I'm going to need to flare the hard lines as the rubber fuel hose will just want to slide off. After that's all sorted including the filter/s, it's onto wiring, and hopefully making some noises after that.

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  • 4 weeks later...

Got around to cleaning, painting and installing the steering column and surround, finally have control of the front wheels and get an idea what the ratio is like. Getting 3 turns lock to lock on the outermost hole in the T3 steering arms. Tried installing the surround on the firewall first, who knows why, but I made an absolute mess of the new paint so I might try go back and touch it up later.

 

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Haven't had the best run with the surge tank lately.. in trying to squeeze the new filter right after the pump, I had to bend the bottom outlet upwards slightly, which of course ended in a crack which turned into a clean snap. I used cold weld to fix it up, fair bit of wishful thinking was involved here, and of course it let go as I was installing the tank after rethinking filter location :notimp: I was keen to get this in the car once and for all so I grabbed a fitting off the old surge tank, drilled out the mess that remained on the new one and self tapped it in. Backed it out, applied sealant and snugged it all up. Hopefully she'll hold..

 

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I decided I'd put the filter in the rear drivers quarter, there was way more room making it heaps easier to get in there and change. In doing this I had to swap what was the feed to the return and vice versa. I'll be using the stock lines for now, I've heard they're fine so it'll do, eventually want something much nicer though. I quickly knocked up a filter mount out of some alu strap and piece of rubber and bolted it up.

 

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The tank is installed and plumbed up, I ended up using all the stock vent lines as I wanted to make sure there was going to be no fuel coming out anywhere. So I'm just waiting on a reg and I can finally tick the fuel system off the never ending list.

Ollie.

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Drove mine home today, and thought somewhere along the 550Km.." the surge tank is just fine, a Subaru fuel filter that I gutted and welded a couple of outlets onto. Why do you need a litre or more?"

 

So you do only need 100ml or so, up and down hills and around corners..

 

The only piece of high-pressure line in mine is 30mm between the main pump and the filter, under the inlet manifold. From the filter it goes into the stock flexible hose, and before the main pump everything is low pressure.

 

I'm just waiting for the posts labelled "wiring..."

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So you do only need 100ml or so, up and down hills and around corners..

:notimp: :notimp: :notimp:

I'm just waiting for the posts labelled "wiring..."

 

Not really sure what you're after there Altezza.. A pat on the back? Someone else to stroke your ego?

No wonder this forum is turning to shit. Think I'll just stick to photos from now on, if that.

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Not at all- I'm confident these small surge tanks hold enough fuel for general driving, while no surge tank makes them undriveable with less than half a tank. There's no reason to use the common pots that hold over a litre, but they are the only tanks that ever get considered.

 

The forum is quietly dying like all of them, its just the change in social media.

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  • 1 month later...

So after spending basically all of today chasing down a grounding issue with it ending up being a faulty relay, it now finally turns over and starts. Only let it go for a few seconds, but shit I am so stoked. It's been four bloody years since I first got the car.

I've been pretty slack with taking photos lately, but the wiring is basically done and just in need of tidying, fuel reg went in on the drivers strut tower as usual. I'll try get a video and some pictures of it tomorrow, need to get some radiator hoses before running it for too long, and a windows laptop so see how everything is going. Hopefully I can be a bit more on the ball with pictures and updates too

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  • 3 weeks later...

As I said I haven't been taking many shots as I've been doing things, but here's a few photos of the wiring as it stands. Main relay and fuse panel is in the passenger foot well behind the blower system, and other one is in the rear in the tool compartment. I'll have to make sure the rear window is well sealed, but it should be fine. The stock relay and fuse box that sits in the engine bay has been moved into the front left wheel well. I'm planning to make some form of shield to protect it from stones and excessive water too. I also notched out the coil pack plate for the wires too.

 

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Moving things about was a bit of a headache, especially tracing all the necessary wires from the key barrel to the various locations, but it was good fun learning how it all works and making all my own cables. I made a few mistakes and had to redo some wires/connections, but pretty stoked that it started up first pop without any electrical issues after doing this myself and learning from scratch. Big thanks to a good mate Tom who pointed me in the right direction :y: Tried to make it as neat as possible in the engine bay with new wiring for the alt and starter, with a circuit breaker in between, as well as new trigger and signal wires covered in sheathing.

 

Also received the fuel reg, I modified the bracket and bolted it onto the brake line splitter thing.

 

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I took apart the blower system, cleaned it all out and replaced all the foam I could access, including that around the heater core. Probably a bit of overkill, but I'm trying to get as much of the musty old car smell outta there, and maybe even make it blow a bit harder :thumbsup:

 

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wow that wiring job is awesome, id love to learn how to do that kind of stuff..

 

Cheers Gage :y: I'm not sure if if it's all technically correct, and I'm sure there are probably things that are a bit dodgy that I'm not even aware of, but it starts and runs so there's that at least. And man all you've gotta do is start! I had no clue about wiring before I started this, I didn't know what a relay was or how it worked for example. Just have a google, read up and jump on youtube and you'd be well on your way.

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  • 1 month later...

Been a while between updates but I've been getting a few things done.

Finally painted my accelerator pulley and got that installed so I can measure the cable length and get that made this week. I also made up a little bracket for the cable that bolts to the engine mount too.

 

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Painted the sway bar in dupli-colour metalcast red (groundcoat then red), wasn't sure how it was going to turn out, but was stoked with the end result. I chipped the shit out of it when installing it which sucks, so I might get it powder coated down the track, but it's staying for now.

 

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After getting screwed around on ebay, I finally got my radiator overflow tank and installed that right next to the rad. A bracket is riveted to the body, and the tank bolts to that.

 

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Last weekend I ripped the dash to pieces so I could spray it satin black. I've been debating on colour for too long so just went with the safe option. I removed the blower controls, vents and all the little clips, then sprayed it down it with degreaser, hit it with the karcher, rubbed it with scotchbrite, blew it down with air then wiped down with wax and grease remever. I used septone plastic primer then acrylic black and it seemed to come up alright. Time will tell though. Same goes for the gearbox cover too. There's a whole heap of interior pieces left to paint though :(

 

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I've got my braided brake lines getting made up locally, costing around $240 for the two one-piece fronts and the one from the diff to the body. I'll get the accelerator cable made at the same place too.

Tailshaft has finally gone in, as has the blower system, but I'm thinking of pulling it out to get some further sound deadening foam on the firewall, but not too sure about that just yet. Anyone had any experience with foam on top of dynamat and if its even worth it?

Ollie.

Edited by ollienewc
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  • 1 month later...

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