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 BF Powered XF Race Car

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Joshy351
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PostSubject: Re: BF Powered XF Race Car   Tue Jan 31, 2017 8:13 am

Another quick update!

I bought some stuff this week.

Bonnet Pins to hold the bonnet down when racing.



An Engine mount I thought I was getting 2 but I only got one.  Another is on the way.



All our paint and some sand paper







Thinners to wash out the guns!



A new clutch



The roll cage is going to look so cool in this thing!



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PostSubject: Re: BF Powered XF Race Car   Tue Jan 31, 2017 8:20 am

I undercoated the bare metal in the engine bay while its at the panel beaters.



So I got the beast to the Panel Beaters here in Rockhampton.  Peter Smith Panel Beaters!

Ready to load!





Got some good mates to push it on for me!





Dropped my mates off before heading to the panel beaters.



And unloaded it myself at the panel beaters.  I just used the hand brake and slowly let it roll of the trailer.

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PostSubject: Re: BF Powered XF Race Car   Thu Feb 02, 2017 6:40 am

I can't believe it! The rust is all done and she's back at home already!! i will post up some pics when I get a chance! Its like this car is falling together. It just wants to go lol! With progress like this we will easily make the deadline.
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PostSubject: Re: BF Powered XF Race Car   Mon Feb 06, 2017 3:35 am

Ok so I have a few huge updates for you guys.

So shes back from the panel beaters 3 days later and now no rust or dents.  These guys done such a great job they even fixed dents and rust that I didnt even know was there!  Just so happy.

















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PostSubject: Re: BF Powered XF Race Car   Mon Feb 06, 2017 4:06 am

Got our rollcage foam.



Thinking about buying this so I can plug the laptop in.



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PostSubject: Re: BF Powered XF Race Car   Mon Feb 06, 2017 4:33 am

So we got all our undercoat the other day. Mel spent most of Saturday sanding (4/2/2017) while I was at work then when I got home we both spent a good portion of the night have a couple of drinks and sanding.



Finally the next day we got all that red and yellow paint gone and back to the orginal gold. Man I love that color. Any whay so we prep washed and got undercoating.







And a couple of photos this morning.



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PostSubject: Re: BF Powered XF Race Car   Fri Feb 10, 2017 4:40 am

Ok so I got the engine bay painted.  Some parts of it came out a bit ruff but when we fit in all the engine components it should hide most of it.  I thought I would buy Nason in silver thinking that should be an easy color and paint to spray but how wrong was I lol. I sprayed some of the chassis black in the wheel arches and underneath and that came out awesome!















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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 8:03 am

Ok here are some massive update for you guys!  got heaps done over the weekend so here are all the pics.


I let the paint bake in the sun hoping the finish may come up a bit better!










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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 8:07 am

So now the bay is all painted its time to get that Barra engine in! I had to do a few things before fitting it in:

I had to cut away the sump for the clutch cable to pass through









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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 8:13 am

Now to install the spigot bearing, sandwich plate, flywheel, and clutch kit.


Spigot bearing installed



Getting the clutch ready to install



Flywheel bolted on.  75 nm on the torque wrench







35 nm on the clutch kit bolts and tighten them down evenly



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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 8:26 am

I couldn't believe it!  I bloody broke the taps on the throwout bearing that holds it to the clutch arm.  Dame what to do! So after Mel calmed me down and got me thinking about how to modify it, I had the thought to get the throwout bearing from the old XF t5 and removed the retaining ring.  I then cut grooves into the new bearing retainer and presto clipped in the ring.  Better than standard now and easier to install lol







I cleaned and painted the powersteering box to be installed before the engine goes in.  



After all the crying (about the throwout bearing) we called it a night and when I slid the motor back to its storage spot I broke the Head Temp Sensor!  GOD DAME time for a beer and swim then sleep.  The next day I bolted down to PickaPart and got another sensor for 10 bucks thank goodness. (no pics)


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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 8:33 am

Ok so the next day (saturday 11/02/17) we were ready to slap a Barra into the ol XF.  After I installed the new sensor and bolted up the AU T5 Gearbox.





Mel decided it would be a good Idea to remove the shifter completely so it didn't scratch our paint as it went in





Up Up and away!  Got a nice angle there straight away!



I went one more step and sticky taped an old car wash sponge to the back of the gearbox to further protect our freshly painted bay. It works a treat!

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PostSubject: Re: BF Powered XF Race Car   Wed Feb 15, 2017 9:23 am

We didn't get many shots of the engine going in as it was all hand on deck!



Mel getting selfies while I'm going hard lol













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PostSubject: Re: BF Powered XF Race Car   Thu Feb 16, 2017 1:41 am

So I quickly made up some brackets to mount the gearbox in.  They maybe just tempry for the moment till I sort out a better way of doing it.  I have seen a couple of pics on Facebook that have given me better ideas but this will do for the moment.





I used the AU crossmember for the moment





I had to wedge a block of wood because it the gearbox wasn't central







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PostSubject: Re: BF Powered XF Race Car   Thu Feb 16, 2017 1:56 am

So I cut the tunnel out a bit to clear the shifter.  Lucky I'm running with an AU Falcon T5 because the BA/BF Boxes are even longer and you have to cut back to that strengthening crossmember you can see running across the floor.







The old Aricon holes in the fire wall are great to run the new wiring loom threw.



And got a new power steering line made using the BF pump end and the XG steering box end.  Cost a bit but hey its done right and if I even wanna use the sensor its there ready to hook up.

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PostSubject: Re: BF Powered XF Race Car   Fri Feb 24, 2017 6:07 am

Just another couple of posts to keep you all in the know of what I'm up too.

I bought a double flare kit to do fuel and brake lines!



So I double flared the ends of the fuel in and out lines so I can run rubber section of fuel line to the stock steel fuel lines.





I ran the wiring harness though the fire wall and mounted the computer!





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PostSubject: Re: BF Powered XF Race Car   Fri Feb 24, 2017 6:10 am

Doing some wiring!











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PostSubject: Re: BF Powered XF Race Car   Fri Feb 24, 2017 6:19 am

Dummy fitted the radiator and reservoir tank.  Not a straight in fit like I hoped but just a little notch a couple of holes to drill and some welding and should be sweet.  This is where I need to buy a welder!







Painted the steering column and pedal box.







Mounted them in.  Starting to kinda look like a race car lol.

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PostSubject: Re: BF Powered XF Race Car   Wed Mar 15, 2017 4:25 pm

Ok guys time for a massive update.  A couple of weeks ago my brother in-law was up visiting and he brought his new toy with him.  A 2017 KTM EXC 6Days.  What an awesome machine.  So we both got stuck into working on our machines.  While he was bolting on some custom parts to his bike I continued work on the XF getting the radiator mounted properly and customising the airbox to fit.  I also cleaned up the brake booster from my bros old XF and got it mounted in too.













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PostSubject: Re: BF Powered XF Race Car   Wed Mar 15, 2017 4:35 pm

I also put the bonnet back on so I can make the cuts to clear the Barra engine!





I also installed the bonnet pins!







Me and Mel also decided to go with the bonnet scoop to allow lots of air in to cool the future turbo.

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PostSubject: Re: BF Powered XF Race Car   Wed Mar 15, 2017 4:50 pm

I had to extend the pipe work for the airbox so I went to the wreckers and found some pipe from a commodore lol  It worked well.



I almost completely cut the arse out of the airbox to get it to fit in.  Just enough room for the radiator pipe.   I'm going to make a new section for the airbox to go in behind the headlight and also run a nice K&N filter.



Just clears the engine too.





Some notching for the radiator mounts.  when I get my welder I will put a few tacks around them for  extra strength.  Its a bit rough atm but hey,, Race Car!!











I had to make a plastic spacer to go between the rad and the mount.





I have to lower this side a little yet!

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PostSubject: Re: BF Powered XF Race Car   Wed Mar 15, 2017 5:01 pm

So I realised I couldn't run the BF thermo fan because there is no room between the engine and radiator!  So I was off to the wreckers again for some EF/EL ones which suited the radiator better anyway.  Also JB Automotive Electrical done the wiring for twin fans anyway so worked out good.



And finally almost time to fire her up but not till i get fresh oil in first!



My bluetooth ELM arrived just in time!  Lit up so we have power!



I also got the whole inside of the car sanded and painted as well.





Boot done as well.







So we got her to fire up so I will post a video of it tomorrow for you guys!
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PostSubject: Re: BF Powered XF Race Car   Thu Mar 16, 2017 4:21 am

Ok So we finally got to kick the Barra in the guts. She fired up beautiful except the power steering pump is noisy. I filled it with fluid but as soon as it started it pumped it all around and was low again. I will grab some more fluid for it today when I'm in town so I can hear her fire up one more time and hopefully the noise in the pump will go.

She's Alive

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PostSubject: Re: BF Powered XF Race Car   Sat Apr 29, 2017 3:50 pm

Ok guys some massive updates coming your way.  I have been so busy since our holiday I haven't had a chance to to put anything up on the thread.  Making it back home from holidays by just one day before cyclone Debbie hit then the Rockhampton floods, Then easter we have been flat chat at work especially Mel,  so between all that we focused on the build.  Both me and Mel Feel like another holiday already lol.  So here is updates dating back about 4-5 weeks ago.  Hope you Enjoy.


Time to start the rear end!



Changing center to  LTD lsd



The perfect ratio to flog around in 2nd gear!



Ring gear bolted onto spare center.



All painted and installed

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PostSubject: Re: BF Powered XF Race Car   Sat Apr 29, 2017 3:59 pm

Playing around with the interior and wiring.




Dummy fit rear spoiler.





Parts arriving



Installing cables to run battery in the boot.



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