Cooling system - maintenance

On the way back from Norway the car decided to chuck out all its coolant and peg the temp gauge at best part of 130ºC. After letting it cool and topping up the coolant everything was fine - but it was a particularly cold night coming back - so possibly just got away with it due to forward motion?

Today I let the car run at idle, part of its static monthly exercise, running up to full water temp and letting the oil circulate.... the coolant gauge again jumped up over max temp and on switch off blew the bulk of its coolant out of the overflow onto the garage floor.

Something then is still not right.

I wasn't really watching it so not sure if the radiator fan cut in when the engine was running.

Tests so far

Confirmed the ECU is seeing a temp reading - check

Used the ECU software to check the ECU could turn the radiator fan on - check

Swapped the fan relay with the aux panel one to confirm identical behaviour - check

Removed the thermostat and checked it opened around nominal 91ºC - check

Next up, monitor the ECU temp reading and see if its seeing the coolant temp rising and see if the fan relay keeps flipping - not sure if that is because the battery is low due to the car not running?

...

Update - sensor replaced issue fixed.

Heater upgrade - 2

Air box for the new fan progressing...

Taken from the paper template then adjusted for even gaps top/bottom to accept rubber trim.

While everyting is in bits, the tunnel heater vents are changing too - rectangular peg into a round hole - but will mean I can reach them when buckled into the seatbelts.

The small cover panel will be at least blacked out and possibly carpeted so shouldn't notice once complete.

That should do the trick.

New ducts, the new vents need 55mm rather than the existing 50mm.

The important bit - just reachable from the seated/belted position.

Heater upgrade - 1

Finally got around to some car work. 

Upgrading the existing heater fan to a squirrel cage from the original axial fan. The axial fan moves air - but can't generate significant pressure - I'm hoping the new fan will improve on that without tipping me over my current budget.

The space I have to work with. The heater radiator hoses will stay outside the air box.

Mocked up the new bracket and airbox to draw fresh air in from above, through the bonnet vents with offset more space on the drivers side where the fan intake will be.

Starting with the fan bracket, 1mm aluminium but seems sturdy enough once the panel has flanges added.

Offered up - looks ok so far.

Some challenges with fouling the pedal box lid bolts - might be as simple as a shortened bolt in the back position.

It's a 3 speed fan - I'm intending just to have one setting - On or Off - no point in finesse of air speed in an open top Zero + avoids any changes to the dashboard controls.

Air box surrounding the lot to follow.