Oil Catch Tank

I'd been meaning to fit an oil catch for a while.  Then a new OBP one came up on eBay locally and the price was absolute bargain.  A guy had bought it for his Lancia Statos build, but had changed his mind; he no longer wanted a 1 litre tank and was going to use a 2 litre tank instead.

Mounting the tank was relatively straight forward, but before the pipe from the crankcase could be connected, the internals needed to be removed from the Positive Crankcase Ventilation (PCV) valve.

The valve itself just pulls out of the rubber bung in the crankcase.  To get the internal of the valve out I ran the angle grinder around the end using a very thin metal cutting disk, 0.8mm I think.

The internals were then discarded and the valve reinserted into the rubber bung in the crankcase.

Here is the catch tank with the crankcase and camshafter cover pipes plumbed in.

Then finally an air filter was added to the top side exit.

Throttle Pedal

The throttle linkage assembly is mounted underneath the throttle bodies. This is much easier to attach before mounting the bodies on the engine.   Lucky then that I read ahead in the installation manual to the next chapter to where that is mentioned

The throttle cables are attached to the throttle pedal using the fitting kit provided. Before this could be done the angle grinder and cutting disc had to be used to remove the flat plate that was welded to the top of the throttle pedal.  I assume this is used for a standard installation.  With the Webcon throttle bodies this is not needed, only the round shaft is needed.

The cables had to be shortened significantly.  I tried to solder the ends to prevent fraying of the cut inner cables, but the solder would not take.  Probably some kind of coating on the inner cables. In the end I used some epoxy resin.  As Tiger warned me the throttle pedal is too stiff with both return springs fitted so I have removed one.

Thermostat Modification

As I have blocked off the two coolant bypass pipes I needed to remove the thermostat.  The thermostat housing is taken apart via just three screws and then the thermostat assembly can be removed.  With the angle grinder two cuts were made to remove the mechanism and just leave the outer ring.

A new rubber seal was used when replacing the modified thermostat in the housing.  The orientation was kept the same, with the air bleed valve at the top.  Not that it serves any purpose now.

Rear Suspension Upright Modification

The Sierra donor brake back plates do not fit flush with the Tiger provided rear suspension uprights. The extremeties of the flat angled plate foul with the curved bulges on the back face of the brake back plates.

A small amount of metal has to be removed from two places on the rear uprights. The areas to be removed can be marked out with a permanent marker pen with the back plate pressed against the upright. Then an angle grinder with a thick metal cutting disc can be used to remove the offending portion of metal. Removing small amounts at a time and repeatedly trial fitting ensured that only the minimum of metal was cut away. Thereby ensuring minimal reduction in the structural integrity of the upright.

Here is a view of one of the uprights after surgery. The bear metal surfaces will be painted with smooth black hammerite prior to fitting of the brake back plate.