The Indycar is FINALLY Together! Painful but it almost fires up

It is time to reassemble the Indie car, the Champ car, the cart from the ground up. We have the fuel system out. I've made the fuel pump adapter, done all the measurements. Obviously, I've been 3D scanning it so that way I can fit everything together in CAD without the pieces actually touching cuz you can't measure as soon as everything's together. But we are going to get the whole fuel tank back in, which I think is going to be an absolute pain in the ass. And then that allows me to put the engine, which is the chassis, onto it. and then from there the transmission and so on. So, our goal is to have one long train. Now, that might not happen all in this video, but that's the progress that we're about to make. — All right. So, Princess doesn't like the sound of real work happening. — Oh, sure. Cutting a square. I'm going to tell you guys right now, this is the coolest square that's ever been cut out of aluminum. Single-handedly, this is the one piece that holds the entire Cossworth Indie Car engine drivetrain from all going together for a final time. It is the fuel pump and it goes inside of the fuel bladder. So, this is the one from Cossworth. This is an absolute beautiful find. But this four-bolt flange with an O-ring is not what bolts to the side of the damn bladder. It basically holds it against this flange here, this nut prevents it from rotating. Then you put the nut on this and so it holds it against the bladder. The O-ring goes inside of this side groove here and then it just simply bolts to this flange. And there's an O-ring here to protect the methanol from getting inside of the pump internals. So, I've basically recreated it. And those of you guys that are machinists watching me, guiding me, you'll notice one very big challenge to this. I can't cut that. I don't have a lathe. I can cut this side and side, but I can't cut inside. So, this is meant for cutting a keyway, but I'm going to use it very slowly and basically do this. If you notice, mine is a nut look shape on here where the real nut it's not it's nutting so hard where this one actually has threads on the top part. I'm not making this out of steel. I want the threads to be steel because that's what's holding this entire pump. I'm going to thread my piece. Put half of these threads into it. Cut the head off of this and then drill with this carbide drill bit. Drill the center of this out. If you think that's crazy, you're right. But it was actually already done by Cossworth. You can see it's slightly offc centered. It was done by hand. I didn't get Joel's attention until I was already halfway into this. So that is the little ninja star and it's already starting to cut the O-ring groove into that. That is looking pretty good. So what that should do is be smooth enough. A little bit of squish. I've never cut a nut on a CNC machine. That is very promising. I'm going to go ahead and tap this center hole. Look at how clean those threads came out. So, I'm going to tighten this all the way through. I made enough space on the bottom. So, this head of the bolt is going to actually bottom out. We're then going to drill through it, back it all the way out, put some Loctite on it, and hold it in the correct place. You'll see this kind of sticking out a little bit from the tank. And then this will go on and hold. Pretty happy with this. Now, if for any reason this is too short, I can always throw this in the machine and take it down the slightest bit and that'll actually pull the pump closer. It's actually driving right now. Very happy with this. We can put this in the tank right now and with the two O-rings in there, fill it up with methanol and it should not leak and it should when spun send fuel pressure. As some of you already know, long before I got into YouTube, I was an IT guy. And I thankfully retired from that life and chose one way more complicated and frustrating. But you know what's neat? Revisiting the world of creating websites and seeing how much easier it has gotten. I am not a very creative person. I can tell you when something looks bad, uh, but I can't create something new from scratch. GoDaddyy's Arrow has revolutionized the use of just the buzzword AI to something that is so useful for people like me. With GoDaddy Arrow, I was able to create a basic website and then go far deeper than I ever would on my own. The coolest part about it is the AI tools allow you to see things that you would have otherwise just been staring at blankly going, I have no idea how to make a logo. the page should be laid out. I'm going to have to learn HTML again. arrow takes care of all of that and gives you choices that even if it's something that isn't exactly what you would want, you now know, I wish the logo had this. And that is very powerful, especially when it comes to trying to be creative and starting your own little small business online. I wish all this existed many years ago because it's been a pain compared to how easy it

is with GoDaddy Arrow. If you're somebody that's looking to do something with their website idea, this is the perfect opportunity. Go to the link in the description and get started with GoDaddy Arrow today. This is my dream come true thanks to Shining 3D. What you can see from this side is actually ass of the carbon monok. My very first thing that I'm excited to do is throw the actual correct tank for the oil in there. It's got space underneath. It's got space above. Just really exactly where it would be. One of the reasons I need this is these are the two oil in and out here. And as soon as you add the motor, you don't have much room to get oil out from there. Now I know exactly what we need to make. The wild part is I took my engine mounts and they're going to look really clean because they're the CAD models. So I line them with the body. The holes on my engine mounts lined up exactly to the holes on the body. So I'll turn off the body. You can't even tell where the sketch holes are when I turn this off. There's the sketch holes, but I didn't get lucky with was I was slightly off. And then same thing on this side, but even less. So, just machining that hole just the slightest oval. The last piece now that we've got all those together, the fuel pump adapter that we just made. So, you can see that hex is lined up to the center of this. the thing that's not lined up. And you can see the wobbliness here, a little offset hole. The actual fuel bladder has moved over time. There were no bolts in it. So, you have to get the bladder in the right spot, bolt it in, and then we can put the pump in. And we now can bolt the damn thing all together. Here's the real world actual version of everything I've been looking at on the computer. There's like a marionette of cables and hoses all right here. This area is very small. So that's the surge tank. These two fit onto these two pulling from the other areas of the bladder and just peeing it constantly into the surge tank. Then you have your traditional lift and pump. Hopefully 1997 rubber is a still usable but b can be formed back into the right spot. I might look at taking the chassis apart to fix this. I am going to be taking off the safety wire. It's kind of a fascinating way to do it. These hold this in. And this is holding back this plate. — Oh, I felt the whole chassis kind of bump. — Take the nut off the clutch line, which then lets us pass this piece through. and just give it a little bit of a Look at that. You don't take these off. They're part of the chassis. This is the moment. Wa! Oh, it's bigger than I thought. — How many times you say that around? That trap door is definitely a another section of this whole tank. So, we should probably pull this whole tank out and just inspect it. But if we were just trying to rush, that's all we needed was to get to this. Figure out the bolt sizes these are. These things just must be violent cars. Like shaking everything if you have to safety wire things like this. There we go. I feel like Indiana Jones. This should Yeah, that's pretty cool. So, we have this one off. We just took have been trying our hardest to not screw this car up. And we've been stopped at this damn piece. It's a fascia. These holes have bolts underneath them that are bigger than the holes. We've tried all different sizes. And then we figured it's got to either pry out, which we gently did and it didn't work, or it's got to rotate out. And so, I just held this thing on my penis. And you can hear it. Yeah, the years have not been kind to this car. There we go. Joel wants me to go reach in deep and hit it from the back. — Yeah, it's working. — Is it working? — Yeah. — Okay. I doubted you. I'm sorry. We didn't have to remove those other bolts. So now with all of that gone, I kind of want to see if this tank is capable of being pulled.

Oh yeah, you're getting there. There we go. That is never getting back in there. Oh my god, — that's a big baby. — That is about 10 lbs. — Looks like it belongs on like a submarine. — Yeah, that is cool. That is a lot bigger than I was guessing. Jesus Christ. We're never getting this back in there. But look at how empty it is. We can actually put these together in the way that they weren't for the last 20ome years. And that is lining this up with the bolt holes. And you can see it still has to be massaged just the slightest bit to get this to line up. Obviously, the bolts have to be the correct length or they will pierce the fuel bladder. So, that was also another pain in the ass trying to guess. I bought a couple different sets. But, this gets the fuel pump closer to the engine with this being on. Now, with that in the correct spot, see how these fittings are now not sitting in their respective holes? The whole thing underneath here is all r like raw rubber and has a memory of sitting neglected. There's actually a bolt hole for that one, too. This might make the installation easier. There's a plate that's supposed to be over this. It looks all fancy. And uh it bolts actually to the tank. These fittings were holding them in these holes. So, it didn't need this bolt. Well, now that I put that bolt in, this wants to misalign badly. So, I have to play the back and forth game. These all dusted off, cleaned off, ready to go. Uh, cleaned out the inside and then of the cavity. Couple things that we have to watch out for are the fire suppression lines. They're actually metal lined. And then we've got the clutch lines right here. Throttles here. We're going to hope that bolting that on made this a lot easier. It already doesn't want to fit. This is going to be a long night. A very long We knew it would be an easy part at some point. We did it. It took all of our hip, brain, and all all hands on deck situation. It was pretty rough. All of that has now led us to the very beginning of the end, and that is the entire fuel system. Now, you can see there are two hoses, one from uh feed and return, and the return line really just sits in there. It does. It actually doesn't bolt to anything. And then one from this corner of the tank and then the other tank. And so the two corners bolt into these two. You have a filter bolt into this. And then this guy right here bolts in and feeds the motor. I just want to show you guys this. He's shy. — Oh, we got three more weeks of winter. Oh, then now it's gonna hit the O-ring. That's what O-ring's on. And look at that. I gave that little lip. — Wow. — So, we have to even take this nut even has to be flatter because it's going to the engine's going to hit this. That is — the missing piece. — That is That's it. So, now with the oil tank and the fuel pump all in place, we can bolt the whole thing back together and put the engine, at least the core of the engine, onto the car. It is time to put this engine into the chassis. Now, a couple years ago, I did that, but it was just a test fit to see if it would work. This is actually the time the engine goes into and becomes part of the Indie car. So, we're going to throw it in there, and then we're going to set the oil tank onto it. And I even have all of the injectors. So, we're going to build the engine back up mostly to prevent [ __ ] from going into the block, but also to get everything in its correct place. So, these guys promised that they can lift the engine without me. So, — I didn't promise anything. — So, I'm just gonna sit here and play with my belly button and watch. — Okay. All right. The monumental moment is all right here. There's the fuel pump. The fuel doors on. The pump is ready to spin and receive its blessing and seed from the engine. This should slide right in.

And then we've got plenty of other things to do, but this is uh really a huge moment at the same time. Oh, that's gratifying from up here. I let him go more. Yep. Okay, now he goes again. There we go. Okay, that is it. This works. Everything's in tight. There is no room for error here. Obviously, we can now put all the injectors on and all that. Really, we probably should have done that before we place in here. But we'll learn. We'll learn what order you can and can't service this car. But let's grab one of the headers. Now, with this being part of a chassis, I finally get to do the next step. This is rare. It's a 5in clutch. It is meant specifically for the XD. 5. 5 is what everybody else has. I have been wanting to put this on for the longest time. Now, the interesting thing is I'm not sure exactly which way the lines and it's got the timing marks on there, so that does matter. But for what we're doing right now, I don't really care about the timing marks. The engine in place, we can finally make all the changes and measurements necessary to have this thing activate the clutch. This is a random part that I got from the garage sale guy. And it looks so similar to the real part, but they are slightly different. You probably barely can see that on camera. This is the correct bearing that goes onto there. We'll have to swap the bearing over. And I think out of all the things that are so impressive about this car, this is one of the most janky. It blows my mind that this is how it was done. So, this piece goes inside of here. And then you put two screws with the threads gone on the end of them into here like this. And you just got this thing dangling around. You put this onto here. And then this whole assembly bolts in and pressing the clutch pedal pulls that cable over there. And that will have a little him joint on it. And that'll pull on this lever right here. And then that will push onto the clutch. I've been hoarding parts for this. As you can tell, I've got some of the random wrong parts, but with the clutch being able to engage and disengage, the transmission bottom part is what you hook into to start it. So, basically, I needed the whole clutch assembly to then hook the transmission on. And we can actually turn the engine over with the transmission. That's the only way these things work. You literally start it through the clutch, not on the flywheel. With all these pieces in play, now I need to get some hardware to bolt all the weird [ __ ] inside of here. We'll pop this bearing in or out, put it into here. Ultimately start getting that clutch line figured out. So, I sadly had to cut this piece up a little bit, but I retained it. It's for a 94, so I doubt I'll ever need it. Here's the bearing. I wrote the number down cuz I'll probably need that again. That goes into this guy right here. Wa, that fit too. Nice. — Yeah, that actually fits really, really nice. — Aren't you supposed to press this? — Yeah. You see this? — No. — It's like 1,000 lbs of pressing force. That's all in. Okay. So, with this almost completely to the engine, you can see, look at it. It hits the clutch right there. So, if I go to push on it, it pushes the whole thing back. If this was actually bolted to it, that would uh engage the clutch. So, I think we've got the main parts of that and it's right in that middle of that throw. So, that makes me feel even better. But, it certainly means something off with this. So, one of the first things I realized is that this cable wasn't even connected to the pedal. And so, when I press the pedal, it didn't do anything. So, now the cable gets to the correct length. And then they've run these little extension cord things to get to there. But I've got the clutch bolts. Now allows us to put all this on. Now with my nuts in place, that's the clutch engaging and disengaging. That is so cool. I've put the ninth throttle body on with one bolt. And then I've put the scuba nose on top of that with one bolt. That leads us to whatever attaches to right here. Well, it's crazy to think that this is just turbo zone. This is one of the turbos that were used in that era. And this is just an incredible piece. It's not a Garrett, uh, but they ran Garretts. And so this one I was kind of surprised to see. But one of the thing you'll notice almost immediately is look at how thin the casting is on this. It's probably Incanel. And it is super light. So you can't deny that. It'd be nice to reuse this on one of our Garretts. But this is what I'm going to have to figure out. There is the oil

return area right there. That actually is how this is mounted to the car. There's a pedestal I'm gonna have to make in CAD. O-ring. That's where the oil gets sucked in through here, goes over here, and then goes through a hole in the front of the motor. But these two bolt in, and then you bolt in the other two onto the top of it. So, it's going to look This is a first for me. No space wasted. — That's sick. — That is cool. This is Cossworth XD. So, we know that this heat shield, brand new, was a super rare find and it's meant for this exact situation. We now have more of a clear understanding of where the exhaust has to go. But if we kind of tilt this back up like that, you can see it like just lining up. I'm going to assume when you do it all right, this whole thing kind of sits symmetrical with the engine and all of that. But this is a absolute first for me. I've never seen any of this like that. Now, this isn't the correct one cuz you can see there's a kink in there. We almost 100% have to remake this, but kind of fits. The one that we have has to kind of come down more. You can see that there's a kind of a height discrepancy. These might not be for this car. So, this is ultimately the wrong one, but it's the right one for this. And that shows you that's wastegate prioritization on both sides. And then the rest goes directly into the turbo. That is right there. Oh, the first time I've ever seen this that close to complete. So, I am super excited to let you guys know that our resident expert on Indie Car and all things Cossworth is here, guys. That's not the truth, but he uh is here to help. And he's actually going to be working on getting injectors on this thing for the first time. Right now, I'm going to go ahead and start putting the suspension back on. Starting right here. This is what holds up the car. So, the weight of the vehicle is pushed through the pedal, goes into this, goes into the rocker, and then pushes on these for the shocks. So, 100% of the weight and force of the downforce is being transmitted to this thing right here. So, we're going to get these rebuilt, put those on. I think we're going to build this side of the suspension first. Two really neat things we found some of their rebuilding equipment. It's look at O-ring, clicks in, protects the engine. That's the coolest thing ever. instead of having to make that. And then something as simple as this extension piece right here. So this piece was in one of the boxes. And all it does is extends the throttle cable to the correct length. Now, if the intake manifold's sitting right here, that's actually where the actuator is. I knew we were going to have to make one of these. Well, no more. It's making me realize how much this car was Cossworth. The whole wiring harness is all Cossworth. The ECU is Cossworth. The turbo is managed by Cossworth. the exhaust system, the wastegates, all of these adapters connecting it to the fuel system. It was all Cossworth. And that blows my mind because we're very lucky that we now have all these Cossworth parts. We're going to see what Christian actually did. I We heard the drill going for a while. Oh, that does look good. Okay, so I remember the very first thing that will go back on is this. And we're not greasing them up yet. Uh we're just putting it all together. There we go. So, the only thing we don't have is the push rod, which I'm not even going to mess with. I'm going to take that back off to get that part going. Let me just for the moment put this bolt on. Yeah. So, now the There's our camber gain or almost lack of it. Now, with the suspension mostly on, we're going to put all these ball bearings and thrust bearings and all that on. And we'll put the shocks actually on cuz we've never done that either. I haven't had the chance to fully clean these. So, it's got bearings on here. It's got bearings in here. Uh then bearings on this top as well. This whole assembly is one of my favorite things. Thrust washer for the bottom. So, then that goes on there. It's a thrust washer plate. Thrust washer. Okay. So, that's in. It's missing parts. So, see how the rollers are right there? They're going to roll onto uneven surfaces. So, that's bad. But, if I put this on there, which is what should be on there, and then put this on now, it's going to roll on whatever's above it. We will solve that later. Um, the one thing that we also have to solve is we'll have to cut into the block. I don't believe we can weld magnesium easily, but either way, we need to straighten that out and then make another thing to hold this. So Joel, for the price of three slushies, thinks that I'm not going to fit this on the floor right there. I think I as my expert jacking. — Oh, no. — What were you saying? — Hang on. — You're expert at jacking what? — No.

Well, you know, I don't know what would happen. Oh, — I saw that. I saw that. That is the first time where the back of this car has ever You can see how much movement the little movement is. Those shocks are really valved for minute movements. That's so crazy. There's a lot of science behind that. We're gonna have to work with some setup sheets that worked back then because I'm not going to be able to uh relearn all that very quickly. But there is the whole chassis all together. And this allows us to really put the whole car together with all the major pieces, 3D scan the tunnels and get the correct rest of the radiators and oil coolers and make this car fire up. With only eight bolts, the car has radically transformed so much so that I can just step on this. You can see — the only thing holding it on is just these eight tension rods and nothing else. There actually are bolts underneath it to kind of help with shearing. But none of those are on. It's actually not really a lot of car. It just looks like We got this from Pit Lane Spares in England two years ago. This is the side pipe. The telltale sign that this is meant for this car is these two holes right here. Both of these rods go through it. Joel was asking the same thing I was wondering is like, "Oh man, those things are in the way of the air flow. Does that affect it? " But for the lightness and the minimal air turbines doesn't create, it's really elegant solution. This little radiator and oil cooler is meant for this car. Same shape. You can see it's sitting in an indent here. So, what I'm wanting to do is take these two off, which are kind of a pain in the ass. Set it in there and then ultimately scan that because we don't have this on the other side. And so, we need to model it the same because I just tested this radiator is the same size as the one on that side. Same footprint. Other really fascinating thing about this is that these are actually mounts for all of the electronics. So, the battery mounts into a little bucket right here. The ECU mounts right here. The alternator control mounts right there. I always wonder why these studded looking herpes things over there and they're actually to be mounted into. — I wonder if this was like damaged over here and they just overlaid it with carbon and never cared to — Yeah, you're right. cut it out cuz that's why the hole's only halfway through maybe. — Yeah. Cuz it's definitely got like a recarboned like patch look to it. But on the inside doesn't look damaged. So assuming we find all the dimensions we need and we make our own radiator. This is ultimately how this thing goes together. And it's almost depressing how much it hides. As soon as I put the top cap on, makes you want to cry. That's the turbo inlet right there. And I never understood how the thing got air. So the blowoff popoff valve that they were hiding here would be sticking out like R2-D2. Interestingly enough, this was another piece of cloth. I didn't know what it was for. That's the air inlet for the turbo. — So this is the turbo screen. This is a little baby air uh inlet for cooling like the alternator on the other side and whatnot. And then there's going to be a carbon duct that we have to make that goes from right here into the turbo. — What's that other one up there? — Oh yeah, a little nacaduct doesn't have a channel. Maybe that's for passive cooling. I'm sure there they wouldn't do that unless they have a reason. And so you can see now with absolute certainty that okay that is clearly meant to evacuate the not only the half of the radiator but the other half is a transmission cooler. Very effective for not modern CAD. I mean this is raw year after year results improvements but kind of want to put something here to make the R2-D2 shape look cool. Uh cuz there's nothing there's no blowoff valve nor did there need to be a blowoff valve. That's the fascinating thing about this car is that was a pop off valve. POV, meaning that you went too high a boost, it popped like a turkey timer type of thing. It almost looks like how when we first went parking lot to go pick this thing up, it looks almost exactly the same minus some dents and dings from us moving around. But that is hilarious and sad that it's all hidden underneath all the body