Major Organ Transplant Begins

[Sabbot]

After nearly a year of procrastination I finally got around to starting to swap the 1700cc crossflow to a 1640cc BDA.

 

I couldn't find a lot of information on the web regarding exactly how this should be done so will add some comments on some of the critical steps, such as modifying the bulkhead to accept the dry sump tank, remote filter positioning etc. At the very least if the whole operation goes horribly wrong and the “patient” dies this should serve as a guide on how not to do this.

 

Parts required:

1x slightly used, but otherwise sound BDA

2x 45DCOEWeber Carbs

1x 3"x 13" extra-wide oil cooler - from JEGS

Assortment of AN fittings and hoses and plugs (Note: titan pumps require 1/2"BSP to -10AN or -12AN fttings)

1x 12x24" flexible adhesive heat shield - from JEGS

1x BDA top radiator hose - from Sevens and Elans

1x BDA / dry sump right hand engine mount - from Sevens and Elans

1x electric 2-3psi electric fuel pump - from Summit Racing

1x 1.5 gallon dry sump tank (in hindsight I should have gone with a slightly smaller tank but with the bulkhead / footwell modifications it should fit) - from Dave Bean Engineering

4 into 1, 3 bolt head BDA exhaust primaries and collector - from Sevens and Elans

1x remote oil filter - from Dave Bean Engineering

1x 1 quart aluminum catch tank (with all the other shiny parts it seemed a shame to run the breather into a plastic soda bottle). - from JEGS

1 distributor and Aldon ignitor hall effect pick up - from Burton Power (UK)

 

Step 1

Securely suspend a 1 ton capacity chain hoist from the garage ceiling…..then swing on it a few times to check and see that it is really securely attached.

Drain the coolant, unbolt the engine from the gearbox and remove all ancillaries except the carbs.Thread lifting strap around the engine and gently lift……then gently lift again until you figure out which earth strap you forgot to undo that still holding the engine in the frame, disconnect and lift out.

 

Sit back have a beer and congratulate yourself on what a good idea it was to buy a chain hoist and removing the old lump in about an hour and a half without dropping it on the car or bringing down the garage roof.

Step 2

Measure about 6 times prior to cutting once to figure out how to modify the bulk head / foot well to give enough room to fit the dry sump tank. The bulkhead of the passenger foot well is inclined forward at about 25 degrees so to give an extra 4 inches of space I cut mine to be perpendicular to the floor. I scratched my head for a while on how to cut the old bulkhead so as not to have to patch metal into it after the cut. The finaI solution was to grind the heads or tails off all of the pop rivets that hold the front of the bulkhead to the side plates. Then I scored across the top of the foot well with a sharp Stanley knife a few times before using the knife to neatly cut the top sheet - I was going to use cut off saw but the knife works rather well - so much so that I used the same method to trim all of the other sheets. Make a few more bends and cuts and poprivet everything back together including some strengthening pieces to mount the tank to

Step 3

Drop the BDA into the hole that the crossflow came out of; not too much to tell on this one.. The new right hand engine mount from cleared the scavenger pickup on the dry sump oil pump and mated perfectly with the chassis pickup points. The top of the BDA clears the hood by ~1/8" so a a bit of fettling will be required to stop rattles abd rubs.

More to follow on alternator fitting, hoses, exhausts etc but that will have to wait until the garage warms to above 14oF.

 

[blubarisax]

Love the new motor. Can't wait to see it in person and on the track!

[S1Steve]

Looks like that BDA was born there.... Look forward to more photo's, and checking it

 

out this spring/ summer... Wish I lived closer, I'd love to help out...

 

Nice Work.. Steve

Edited January 26, 2013 by S1Steve

[Kitcat]

There is something menacing-looking abt those BDA engines.

 

Glad to see all of the progress, hope it makes its annual appearance at the se7ens track day at NJMP in June.

 

I know another X-flow owner (or 2) here are drooling!

[S1Steve]

Stuart, How's the transmission, driveshaft and rear ,going to handle the BDA. Is this a big jump in power . I ask because I see you left the transmission in the car..

[yellowss7]

Stuart, nice work! Looks like I'm going to be following you around the track this year. Can't wait to see and hear it. Hope all the rest goes smoothly. Good luck.

 

Tom

[Croc]

There is something about a BDA in a seven that looks just so right!

 

Make sure you stay warm in your garage.

[xcarguy]

Thumbs up!!!! Keep us up to date. :cheers: