Right then chaps I managed to find enough time. Tested and ready for Cornwall.
Holes enlarged and temporarily edged.
I tried the Dremel to enlarge the holes, but it was no quicker than a hand file and harder to control.
If you need to file the edges of a hole, use a pile of masking tape rolls as a stand and all the filings drop down the middle.
Test fitted and found to be OK. i.e. dipstick pulls out, and oil filler cap pulls out. The oil filler cap on the GDI is a tight fit and a fiddle to remove at the best of times.
I've fitted a collar to the oil cap. This is rubber sheeting. The inner edge is chamfered so that the cap will secure properly.
Next a light dusting of etch primer and satin black.
Then remove the protective film......
....and test fit. At this point I'd planned to edge the whole thing with the same profile as the two access holes, but I've decided it looks OK as it is..................
This is the air gap..........
So we'll see how it performs.
Just an update on the throttle return neoprene block -
This is a 2cm cube of high density neoprene. It actually came as packing in a curtain pole from John Lewis. Double sided tape on one side to fit on top of the throttle lever, which moves towards the bulkhead when pressed. Garage tested but not road tested yet.
What this really needs is a conical coil spring which will compress into one coil width, of the same spring rate as the neoprene block, which compresses but not fully.
If it works I'll see if Cain has access to or can produce such a coil spring, because it might make a cost effective and simple mod to the super sensitive throttle we have at present. I only have one conical coil spring on the shelf and it's the right size but way too soft.
