Coopz
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 posted on 2/9/11 at 04:34 PM |
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Re-Test Fail
After a busy couple weeks ticking things off the list thinking I'm there! Went for my retest today and unfortunately came away with another Fail
and most definitely loosing the will, although driving her to the test centre makes me feel a bit happier 
Run through of previous fails and solutions for people to refer to.
Noise- Previous of 106.7 db had the exhaust packed and baffled ran 99.5db and said seriously 0.5 you wouldn't hear a pin drop and he was happy
to retest it resulting in a 98db PASS
Indirect Vision- Passenger side mirror was obstructed by the roll cage, solution fitted a Longacre 14" and trimmed the edge for radiuses PASS
Brake performance- Hand brake efficiency was awful running the willwood handbrake calipers so the solution was after speaking to andy B and adrian on
here to fit a pivot lever and definitely the way forward! unfortunately with time running out and really couldn't work out how to get one
mounted in the tunnel with very limited space. I tightened her up so she was just binding, and they went flying through PASS
Protective Steering- After explaining the column had two collapsible features in it and as long as it acted in the same way with my set up this would
be ok. trimmed the radiuses on the centre of the wheel PASS
Statutory Plates- Was unhappy with a stamped Vin plate spot welded, so got the dremel out and engraved into chassis PASS
Installation of lights- Reverse lamp was dim the feed was from the starter, solution was to swap the power straight to the battery and is run through
the savage switch PASS
Retro Reflectors- Were too low albeit mighty close, easy solution raised them up a couple of mm PASS
Directional Indicator- As the hazards were wired in turn with the digi-dash unless the digi-dash is turned on there is no warning light. Solution fit
a small flashing relay above steering wheel take a feed from the switch PASS
Rear fog lamp- Easiest fix wrong markings, replaced with a like for like with correct markings from SVC PASS
General construction- My bodgy Indicator extensions were too wobbly for the testers liking.... too be fair I think he was right! so did them right
second time round, Replaced with 15mm copper walloped 8mm nuts in each end covered with black conduit! drilled 4mm hole through bolt to pass cable
through PASS ( When I pass quite happy to send these to a good home)
Wiring- Needed to P-Clip wire brake reservoir wiring back to bulkhead as was close to steering sorted PASS
To my failures!
Emissions- The big one for me had the car on a rolling road to get her mapped correctly and learn the power commander software properly! new cat put
in the exhaust, and also reinstated the AIS system in the engine to help!
Im really Pissed off about this as so close but so far!
After running way to rich on first test he said we could have another play on the laptop if time at the end of the retest.
Results
Fast Idle Test
C0- Under 0.20- 0.01 PASS
HC- Under 200- 286 PASS
Lambda- 0.97-1.03- 1.108 FAIL
Natural Idle test
C0- Under 0.30- 0.02 PASS
Interior fittings- There were some bolts and rivets on show from under the dash securing items, the tester said to me should put a panel in hide all
of that! Cut in the finest Fake carbon I could find fixed it all under. Tester said that looks great shame you didnt sort the radius of the panel!
Exterior Projections- Doesn't like self algamating tape on the To balljoint Adjuster Nut Heat shrink needed.
The Rear roll cage mount radius and the panel gap on a MK Rear Panel to side panel where pointy meets smooth! How have people resolved this issue I
lined it with self adhesive foam tester ripped it off said thats not a solution if it gets wet it comes off! Really stuck on this one advice needed!
Fail
Cheers Coopz
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shindha
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| posted on 2/9/11 at 05:08 PM |
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Keep at it seems like it's not too far away now.
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Yorkie
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| posted on 2/9/11 at 05:23 PM |
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You're nearly there, keep at it mate.
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Coopz
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| posted on 2/9/11 at 05:31 PM |
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Cheer Yorkie, I was delighted to get the wilwoods through! I went to the test knowing they might be a fail they actually hold really well.
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norfolkluego
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| posted on 2/9/11 at 05:59 PM |
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quote:
Originally posted by Coopz
The Rear roll cage mount radius and the panel gap on a MK Rear Panel to side panel where pointy meets smooth! How have people resolved this issue I
lined it with self adhesive foam tester ripped it off said thats not a solution if it gets wet it comes off! Really stuck on this one advice needed!
Fail
Cheers Coopz
I can't quite understand that one, any chance of piccies?
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RichardK
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| posted on 2/9/11 at 06:45 PM |
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Nearly there, keep it together! Just look at how many items you've knocked off the first fail sheet, well done mate, others are easy just need
the emisions sorted, did you say its been on a rr?
I'd be asking them what can be done next??
Cheers
Rich
Gallery updated 11/01/2011
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Coopz
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| posted on 2/9/11 at 07:01 PM |
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I'm a persistent little bugger, I just cant wait to get her on the road definitely closer shall take a day out of the garage then get back in
there and work out how to sort these final few bits and pieces! Then hopefully get her back in, in a week or two! Will upload some pics of the rear
panel join and edges.
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jack_t
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| posted on 3/9/11 at 07:36 AM |
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put new oil in the engine and fill the tank with shell v power and it will sort the emissions
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matt_gsxr
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| posted on 3/9/11 at 10:07 AM |
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You are so nearly there.
Emissions are interesting.
You are too lean rather than too rich, which is why everything else is fine (assuming they don't measure NOx).
Could you have an air leak? (i.e. extra air in the exhaust). Or perhaps the AIS system isn't receiving the correct inputs.
If you have a friendly localish garage, then you are now allowed to drive over there (book appointment of course). Most/all will have a 4 gas
analyser that they can let you use which should allow you to sort it out.
Good luck,
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fazerruss
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| posted on 3/9/11 at 11:55 AM |
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I'd be interested to see any pics or diagrams of the pivot lever for the rear wilwoods. I too have the same calipers and will soon need to make
them work better.
I assume it will just increase the mechanical advantage at the handbrake lever but that will probably increase the stress on the cable by at least
five times?
"if assholes could fly this place would be an airport"
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Coopz
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| posted on 3/9/11 at 06:23 PM |
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Matt-I was adjusting the fuel to around -10 on the power commander and then back up if there was a -8.5 we would have cracked it! Shouldn't be
any air leaks', I will double check all the system. I was running the AIS through a little crankcase breather as not running the original air
box i'm wondering if that was too restrictive?
Jack is an Oil change likely to help, it's easy enough to do if needed the oil was change recently, I filled the tank to the brim with the posh
bp fuel as its the station opposite the test centre.
I am running a new ceramic cat fitted in the exhaust system, the tester reckoned it may not have been hot enough to work, is this likely?
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Coopz
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| posted on 3/9/11 at 06:28 PM |
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fazerruss- I didn't actually get the pivot/lever system fitted but definitely is the best solution have a search adithorp has loaded some pics
up somewhere of his set up. I was very limited on space in the tunnel and couldn't fit one in time. I failed first time round with the willwoods
they were pathetic I could put the hand brake on and push the car around. For the retest I adjusted the slack on the cable and tightened them so much
they were just binding but will bed in and loosen up and they flew through, does make the handbrake a bit stiff though!
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