Hello new shoes. Hello air

[SMOKEY53]

What a massive effort - well done, mate.

I like how you mounted the compressor externally to keep the noise out of the cabin. That would have really ruined the luxury of the car to hear a compressor whirring away in the back.

Looking forward to seeing the end result.

[X5SND]

Progress Update:

I know I'm still WAY behind on this project....but we're gettin there! (The ol' motivation level was running on E after last weekends' detail session on the Rover)

Right now this is what remains:

- Install bag pressure supply bulkheads
- Install synflex bag pressure lines
- Assemble & install tank supply lines from air dryer
- Install Air filter & dryer
- Install pressure sensors
- Test for leaks

I should be able to knock this out over the next couple days..the only potential hold up is on a couple swivel 90* PTC fittings I'm waiting on.


The wiring harness I had to make from scratch more or less. The VU4 manifold comes with its own pigtail harness for Accuairs' own ECU, but as I'm using my existing dakota digital to actuate the valves it need to be modified. On top of that, I needed to add leads for 5 pressure sensors (4 bags + 1 tank) as well as my compressor on/off pressure switch....its a total of 21 wires (I think?) which I shrank down to 19 or so with the use of some common grounds. The harness from inside the box all runs through a delphi style bulkhead connector...making the disconnect process quick and clean!

Wires, wires everywhere! Wire ends with connector seals on (the green things)



Branching & loom process:


Initial fitment (The leads running up & out of the box will eventually terminate behind those covers...at their respective sensor terminal)


...It just wiring, so naturally it's not very exciting but was stupidly time consuming.


Moving onto the lines....my braided line assembly goes something like this:

1) Take a piece of SS braided line, tape up the end tightly and stick it into a chop saw to obtain a nice straight cut....like so:



The tape compresses the braids and prevents what would otherwise be a very very frayed end (which makes the next step impossible)

2) Twist on the collar potion of the fitting, paying close attention not to stray any of the SS wire strands along the way:



3) Stick the thing in a vice (OCD dictates using a rag to prevent marking of the fittings), and lube up the nipple end before threading it down. You get something like this:



As you tighten them down it bites into the hose and seals the end. It was a bloody slow process as every end had to be done with rags over the ends to ensure there were no tool marks left on the fitting end when completed.



Repeat this process time and time again with a few breaks for cold ones over the day and you end up with something to this effect:




After a few holes were put into the ol' digit tips from the occasional stray razor sharp SS wire and blood was spilt building this thing (literally).....you get to the point of this thread everyone comes here for.....Complete-ish Teasers!





(with some of the synflex line installed)


All you will see once its in the truck and buttoned up:




Last but not least; normally I try to refrain from aftermarket logos or branding but seeing as I had this kicking around and needed SOMETHING to fill the big bare space on the the aluminum lid figured I may as well stick the Accuair vinyl on. If I get really bored at some point, Ill anodize the lid and laser etch the X5 logo or something....but for now, its just this:



After all is said and done Im hoping to get everything up and running this week so I can get the X all detailed up next weekend to enjoy once again for summer!

[SMOKEY53]

Nnnnice. You nailed the symmetry - which for someone like me who is OCD would have been a massive achievement.

Do the valves dump inside the car or out?

[X5SND]

Thanks! Yeah I really wanted to get everything to look symmetrical...Took quite a bit of day dreaming, I mean errr... "mental construction sessions" to figure out how I was going to route everything.

As for the dumping, I haven't decided yet. The setup i have right now dumps through a single 1/4" line routed into the battery box with a silencer on the end (so technically its still inside the car, but can't be heard). I may just plug silencers into the PTC exhaust ports and see how that rolls as it would save me from having to put any additional bulkheads into the box. Theres no way in hell I'd allow it to be the stereotypical unmuffled "pshhhhhhht" sound....not a chance! lol. Refinement is the name of the game with this setup!

[X5SND]

Just wanted to report that after spending this weekend knock'n this project off....it's up and running!! Full update & pics to follow tomorrow sometime!

[SlickGT1]

It is tomorrow sometime.

[Ricky Bobby]

X5SND is literally a machine, I would never have the discipline to dedicate my whole weekend to this massive and meticulous of a project! Amazing to say the least,

[admranger]

Ummmm, yeah, that yellow line ruins it all. Toss it in the rubbish bin.

If you want a professional look next time, hog the box and tanks out of a single piece of aluminum. 6061-T6 preferably. :banana:

I always admire people who can do this sort of detailed project. Original thought needed on layout and execution. This isn't a skill set I possess.

Nice work!

However (comma) they make these things call soft jaws for vises. They come in brass, aluminum, plastic, etc. Aeroquip even has their own version for sale (at a BMW premium like price!). OCD my ass.

[X5SND]

Originally Posted by admranger

Ummmm, yeah, that yellow line ruins it all. Toss it in the rubbish bin.

If you want a professional look next time, hog the box and tanks out of a single piece of aluminum. 6061-T6 preferably. :banana:

I always admire people who can do this sort of detailed project. Original thought needed on layout and execution. This isn't a skill set I possess.

Nice work!

However (comma) they make these things call soft jaws for vises. They come in brass, aluminum, plastic, etc. Aeroquip even has their own version for sale (at a BMW premium like price!). OCD my ass.

Lol. Actually truth be told I did have a set of nylon soft jaws for the vise for exactly that....but as is with everything else you very rarely use; on the day you need it, naturally, you can't find it!


As for the tanks, I opted to go with these for a couple reasons. First, they carry the necessary DOT/SAE markings (as does all my PTC fittings & valves) required in my area. Secondly, I really didn't like the way it was going to look with that much aluminum. The black tanks, titanium/black hose ends and nickel plated fittings kept my overall theme more consistent IMO.

[ModBargains]

Ready to see that thing on the floor