First "First Start" Attempt - Fail

Today was my first "first start" attempt. I was pretty convinced it wouldn't start first time, but was hoping to be wrong. In the morning bought 2 litres of super 95 to put on the tank.

First task was connecting the Digidash looms to the car's main loom. It was quite easy, although I haven't connected the lights related ones (but then, I don't have lights yet). Then I connected the battery and tried to turn the key from off to on. The Digidash sprung to life and the fuel pump started to pump (quite loudly, actually). I turned it all off immediately and went to get the wife, that wanted to film the attempt.

Back with the wife, the kid and a friend, I poured the 2 litres on the tank, jacked up the rear wheels (brakes still don't work) and we attempted the first start. It failed. Eventually the wife and kid went back outside for him to ride his bike, the friend stayed with me trying to figure it out.

* The battery reads on the multimeter 12,48v either standing or with the Digidash and pump working;
* The pump makes loads of noise but there is no fuel going on the carbs. We disconnected the pipe that goes from pump to carbs and it was blowing (not sucking) air, but no fuel was coming out. My friend believes I need to put more petrol on the tank, that the circuit is full of air and not able to prime itself;
* When we turn the key to start the engine, there is a "click" coming from somewhere near the engine (ignition module? rectifier?) and then everything turns off. Like if a fuse had blown. And only after waiting some minutes we can attempt turning it on again. We don't hear the starter engine trying to fire the car up.

My friend had to go away, I stayed behind cleaning and packing up and came back home.

And as I was writing the above, it struck me!!! I can't start a bike engine if it is in gear without the clutch down. Could it be from that? I believe the car is in some gear since I tried to put it in gear when I was bolting down the diff. And I've tried to take it out of gear but unsuccessfully, it seems. Next time, with more fuel, I'll try it again.

Next tasks... Disconnect the pump and take some time to configure the Digidash with the tank empty so that it learns what an empty tank is. Confirm what dials and buttons I'll have on my dash, make up my mind as how to place them and then cut the dash. Fit the magnets on the prop shaft and craft a support for the speed sensor. Trim, drill and rivet the rear firewall so that I can then put in the seats and belts. Prime the brake system. Oh! And try to start the engine again... Lots to choose from!

Trying to start the car, but it just "click"'s

From HappyBlade

The Digidash powers up and acts like a Xmas tree!

From HappyBlade

Differential Oil

Yesterday I finished crimping all the terminals on the Digidash cables. Did the crimping while watching two episodes of "Wheeler's Dealers". With this, I can now connect the Digidash to the loom and, after powering up the car, check some readings (namely if the car is in neutral or not).

Today went for an hour and a half on the car (from 23h00 to 00h30). Spent it all using a 5cl syringe to push 1 litre of oil inside the diff (see previous post, can't open the correct plug so pushing the oil through the breather hole). While doing this boring task, my head was occupied for a bit with calculations. 100cl... 5cl syringe... 200 "shots"... I now have blisters in two fingers. But job is done! No pictures, who would want to see this?

Next? Getting some gas and try to fire up the engine? Maybe...

More Electrics

Got one hour and a half on the car. I had been planing this bit and had all lined up to make it worth. Or so I thought. Rushed to open the diff bolt and pour the oil inside. Unfortunately, I don't have the strength for it and the alan key I used ate a bit of the plug inside. One member of the locostbuilders.co.uk forum said that, due to his lack of access to the plug, filled his diff with a syringe, through the breather hole. So I decided not to loose any more time with the plug and do that too! I have a 5cl syringe at home, it will take a while but it's just once...

Fitted the battery in the car (but didn't plug it to the loom). The bracket I fabricated is a nice fit to prevent it from moving sideways. But on acceleration/braking, it will move a bit. I need to come up with some additional restraining, probably will use some straps for that. But will have to think it over, I want it to look nice and be safe.

Next work was done on the dash wiring again. Plugged the hazards and lights relays on the loom. Then also crimped terminals and plugged the ignition key thing on the loom. It's nice that the key has some additional terminals to connect cables for other feeds. I might use it for a lighter, to connect the phone charger or GPS to.

Last task, completed later at home, was to crimp terminals on digidash's cables to connect them to the car's loom. I need to buy more terminals but crimped all those not related to lights (since I'm not installing those right now).

Next time on the car will probably seem me filling the diff with a syringe, syphoning gas from the tin top (I'm cheap, don't want to shell out 10€ for a 5L jerrycan) into it, jacking up the rear axle and trying to start the car. The start might be delayed to a weekend, the wife want's to be filming...

Battery, Fluids and More Electrics

Had some time away to prepare for an event. I got that off my back this morning. Since I took the whole day as vacation, spent some time after lunch on the car (how I missed it!).

On the locostbuilders forum, there were two "Engine started for the 1st time!" threads last weekend. That made me want even more to start mine. So I'm really considering some change of plans: try to start the car within 2 weeks, even without a dash nor bled brakes (will jack up the rear axle). Just for the kicks of hearing it rev. Then I'll get it moving.

With this in mind, first task was to assemble the battery. Spent loads of time careful reading all instructions and mustering courage to deal with the sulphuric acid (all those warning are scary!). Properly protected (eyeware and gloves), Followed instructions to open the battery, pour the acid inside, prepare securely the acid bottle and funnel to be disposed and finally seal the battery. Had to use the rubber mallet to convince the acid bottles to open on the funnel and also to make the sealing cap fit.

It was odd to hear the acid fizzling inside, even after sealing the battery. Left the battery there, will charge it at home, so that I can monitor it. Should buy a voltmeter first, to be able to control charge.

Then, I looked into putting cooling liquid and diff oil in. Went around looking where to pour diff oil through. It wasn't obvious so I left that for later and took a picture to ask. Quickly got the answer.
Filled the expansion tank with cooling liquid but only some of it went away through the pipes. Will have to ask about this later on, don't know if I need to have the engine (and water pump) running for the liquid to move around and allow me to pour the remaining quantity.

The last work was on the dash wiring. Spent again loads of time looking at the Digidash cables, the look section that connects to the digidash loom, the schematics, ... Procrastinating... Finally inserted the 3 fuses on the fuse box and placed connectors on all car loom wires. Later will put the connectors on the Digidash loom.

Lets see if I can start the car soon, I bet it would make me feel quite happy!