My mean green hornet

Thanks guys,
Sometimes you just gotta be brave/stupid to reach the result you're after right? :LOL:
You may well be right about both Paul, I'm sure it will evolve naturally but I have a clear idea of what I want to achieve- and plan on making it happen!

Today I got the 3.5 and bw35 out, in preparation for a trial fit of the 4.6.



Here's why it wasn't sitting square, 1 failed engine mount



Here's the 4.6 with the new carb resting in place, manifold and block will be detailed in burnt copper gold as soon as I'm happy with the fitment.
Alternator and PAS pump still need to be mounted lower..



Jim
 
Hi Jim,

With that edelbrok manifold, your 4.6 will certainly make some waves. I have said it before, the 4.6 will blow the doors off the 3.5.

With regards cutting the door frames off and removing the gutters, I'll reference Sir Humphrey when providing advice to the Minister. "That is the most courageous thing you have ever done"

Ron.
 
Sick of seeing the two ZF boxes I bought 9 months ago sitting untouched in my workshop, this afternoon I jumped in and began dismantling.
Interestingly the volvo 22 box coupled with range rover 24 bellhousing is very very close to the BW35 length.
From bellhousing to propshaft flange it measures roughly 28" or 71cm. The 35 is a few mm shorter.
Not really important for me as the prop will be lengthened for the jag diff installation anyway.





I've also recently re-made the centre piece for my grill, this is yet to be welded but I'm happier with the fit and should look just how I envisaged once smoothed and polished.



Jim
 
Thanks Chris,
There's a couple of guys locally I'm thinking of using, haven't made up my mind yet.
I would like to get the skill of TIG under my belt really, but that's not a priority right now and this is far from an easy first task!
Duncan has recommended this guy which will be my first point of call being so local http://neildunnewelding.co.uk/products/
Jim
 
I've just read this thread from start to finish - there's some great stuff going on here! I like your thinking - a lot of the improvements and alterations you're doing, or planning, are along the same lines as the plans I have for mine.
 
Long overdue update!
Thanks for the kind words in september Baron, shows how little I've done/been on here recently..

Today I've had the 4.6 in and out a few times trial fitting everything up.
The only fitment modification is a mocal remote oil filter, the rest is stock range rover (serpentine front cover, sump etc)
Starter motor is still to be decided (I'm thinking around ways to remount/adapt the range rover one as it's arguably so much better, and lighter)

To obtain reasonable fit where the remote filter take off is, I've massaged the cross member lip. This will either be bent over across it's length or seam welded flush, I am yet to decide.



Contrary to popular belief, I have no issues with sump clearance :D In fact there's plenty. So no messing around cutting and welding the sump, checking capacities and re routing the oil pickup pipe!




Once I had the engine fit how I wanted, I pulled it back out and joined my hybrid ZF box.
This is a volvo zf4hp22 attached to a range rover bellhousing and torque converter. It will be rebuilt with the stronger hp24 parts.
The range rover bellhousing is large, but again I had no fitment issues. The only thing I need to fiddle with is the volvo box dipstick as it's angle interferes with the throttle rod.



By the end of this week, I should have the mounts for the gearbox and Jag rear end done.
If all goes well I can make a start on the B&M shifter installation. I have opted for a sunken "tray" that the shifter will sit in, in the tunnel, facilitating a neat flush mount to the inside of the car.

Jim
 
Looks like a good fit so far Jim. What's that that in front of the cylinder head on the top right of the last picture, an aircon pump?
 
testrider said:
Looks like a good fit so far Jim. What's that that in front of the cylinder head on the top right of the last picture, an aircon pump?
Click to expand...
Hi Paul. It's the PAS pump, a nice little ZF unit. It won't be mounted like that ultimately, I'm just using the original lifting eye currently for ease which is attached..
Speaking of PAS, I've just bought a mustang cobra hydroboost and master cylinder. This uses the power steering pressure to boost braking, rather than vacuum.
I'm aiming to fit it where the stock master cylinder is mounted, but can be remotely mounted if space becomes an issue. ie where the servo is remotely situated.
Jim
 
Nice work Jim!
I have a LDV 4ZF for my Rover P5B. The filling tube of this box goes to the front of the engine so i bought a Range Rover filling tube which goes to the back of the engine. It fits nice. May be also an option for you. These should be plenty available in the UK.

Peter
 
It's interesting that the 4.6 will go straight in without any alteration, except for around the oil filter area. Everything I've read about this conversion so far suggests that it's an awful lot of work to get it to fit. What are you doing about the water pump, or does that fit without any alteration as well?
 
Martin, the front cover including waterpump is shallower than the earlier p6 type so no problem there.
I'll be putting an alloy rad with twin fans in and there should be plenty of space still.
Peter thanks for that, I'll look into it. The volvo one just has brackets welded to it which are the main obstruction currently so I might get away with cutting/rewelding..

The mustang hydroboost does fit but would be very tight, and close to exhaust headers. I'd need to make a custom bracket, buy fittings and lines, plus adapt the brake pedal/fit mustang pedal etc.
So for now I've decided to put that off until a later date.
However the front brakes are still getting upgraded.

I've had some slotted vented discs re-drilled to the rover hub pcd, centre bore enlarged by 1mm and radiused (discs won on ebay for 99p :D )




I've also just received some used Outlaw 4 pot billet calipers from the states. These are going to get a rebuild, polish (or perhaps black re-anodising), and its stainless pistons re-polished. They only weigh 1.8kg each, feeling even lighter in the flesh.




Jim
 
Thanks Jim - do you know if it's a Thor or GEMS type, please? Presumably you'll be using megajolt, or similar, for the ignition as IIRC the 4.6 doesn't have provision for a distributor?

All advice appreciated as I'm slowly acquiring the knowledge, etc, to do my own conversion.
 
Martin, I'm using an Edelbrock 500 carb and Performer manifold with my 4.6. For ignition, ford coilpacks and NODIZ (megajolt ignition only style ecu) triggered by the stock bellhousing sensor.
My engine was originally a GEMS, I have sold off much of the top end but have intake manifold and injectors left to sell.
If you want to use a GEMS engine complete, you'll either need it's original ECU or Megasquirt etc to map fuel and spark.
Jim
 
Trial fitted the new brake setup yesterday. The other caliper has been dismantled and I've re-polished its stainless pistons.
New seals, pad shims and pads to order. Still haven't made my mind up about re-anodising or polishing the calipers.
Next I will refurb the hubs and while I'm here I'll paint the suspension components.



For sale soon,
My original front calipers and discs;
My V8 diff;
V8 auto Propshaft;
BW35 in need of rebuild (rear band, rear servo housing cracked) + torque converter;
BW35 shifter, oil cooler lines;
Polished aluminium BW35 sump pan;
Polished BW35 rear mounting with good bushing;
3.5 short engine (block and heads, water pump);
Polished SU manifold with rebuilt hif6 polished and black painted carbs;
Polished carb elbows and adaptors;
Satin Black and polished P6 valve covers (once I source replacement offenhauser ones)
Stainless rear exhaust can;
Set of polished NADA style hub caps;
Polished 4.6 valve covers;
4.6 GEMS inlet manifold + injectors;
I also have a 4 pot valve cover and oil cap I can polish if anyone shows an interest..

Jim
 
Sure let me know James.
Annoyingly, whilst dismantling the other caliper I'd noticed the pistons seemed rather smaller than the 1.63" they were advertised at.
I don't know how I missed it earlier, but they've turned out to be 1.36". A typo according to the US seller.
Long story short, I've negotiated a partial refund and can keep the calipers.
So these will probably be for sale soon too, I have found an alternative pair with the 1.75" pistons I was originally looking for.
These 1.36" calipers have smaller total piston area than P6 V8 calipers (5.81" vs Rover 6.67") but substantially lighter ( less than 2kg each).
I don't know about the 4 cylinder caliper piston area? They do allow a bigger pad and vented disc of course..
They could be an upgrade for someone?
They will need new seals (wilwood) and pipe fittings. I was planning on getting new pistons, but have polished the old (stainless) and they appear to be serviceable..
If no interest on here, i'll ebay them.

With the larger piston replacement calipers and the jag rear end I should have a front to rear bias of 65/35
Jim
 
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