More progress - everything is starting to come back together. The chassis is painted, the sheet metal is done (well except for a hood), and pretty much everything except for the throttle cable is sitting on the shelf.
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The fuel tank is in and I'm working on plumbing. Nothing really got changed back there aside from another fitting for a return line. I am much happier with this trunk design though - its much lighter (you can see the horizontal support z-angles in this picture).
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After I got the car running, I started kicking myself for putting the battery at the end of the passenger footwell. Not only did I always have to worry about someone getting caught up on a cable and stranding us but it was a pain to remove and install. I like the new location much more and the mounts are not made from 1/8" thick angle iron (add lightness right?)
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I was also not happy with gluing vinyl fabric to the dash. It looked great as first but after it sat in the sun some areas started to separate from the metal. You could push it back down but 20 minutes later it would bubble up again. I gave truck bedliner spray a shot - so far it seems much better. I'm probably going to do the trunk in the same stuff.
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I had some friends from work over the other night to help bleed brakes. The front circuit went fine but the rear refused to send any fluid to the calipers. After a few minutes of head scratching we found out that the master cylinder had jammed. I unjammed the piston and it jammed again - new master cylinder time.
I was having trouble reading the diameter from the side of the cylinder so I checked my spreadsheet. I noticed that it said the rear was supposed to be 5/8" and the front was supposed to be either 0.7" or 3/4"....then I had an "oh [PooPoo]" moment...yes I swapped them when I assembled the brakes over two years ago. I guess this explains why the front brakes were always really strong and the bias bar seemed to do almost nothing. Either way everything is back together now and hopefully will perform better (the plumbing also got simplified).
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Last but not least are the ITBs. I picked up a set of GSXR750 ones about a year ago. The bore spacing is close to the Duratec's but not quite there. Luckily I was able to borrow a buddy's lathe to turn some bushings. I'll have to weld little tabs onto the lever that connects each throttle body but overall it hasn't been too difficult to tackle.
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How have you guys balanced ITBs? I'm planning on getting a vacuum gauge and setting each cylinder to pull identical vacuum at idle. Any other ideas?