Well, Ive made the bracket with many thanks to Maik for the drawings! cheers..
First off I had to find some material. I looked everywhere at work but couldnt find any thin alluminium plate, just some 3mm stuff that would shear if bent that sharp. So...I raped one of the machines for a nice sheet of 2mm stainless steel! 63..
MmmWahahah, they'll never notice! lol.
Anyway, after a lot of marking out, cutting, drilling and filling, I started to wish I had some softer ally, but hey, it was a quiet night shift and its not like It was on my own time
And before you start about my lovely blue gloves you can feck off! moon.. I can get quite bad hand excema so try to keep my hands clean. I guess my carrer choice as an engineer wasnt such a good idea on reflection but i love it!
Unfortunatly as Johnny surgested and I feared, the distance between the intake duct and the ECU plug was too tight for the Astra and Vectra. There looks like a big enough gap in the picture bellow but the plug that sits on the ECU is 45mm tall and wouldnt fit. That and if you look at the 2.4l TB casting, the butterfly spindal housing that sticks out the side was pushing on the ecu and not ideal.
So, having sat there and contemplated my next move I reluctantly chopped off half the plate. This allows it to sit 10mm lower on the front edge, and removes the problem of the TB fouling the ECU. I was concerned about the rigidity of the bracket having only three mounting points left, but they're spaced in a triangle and fasten the mounting plate solid as a rock and TBH I think it helped being stainless steel and not aluminium. Also, it means you dont have to start messing about with two TB gaskets!
As you can see this gives you the lowest possible mounting hight giving me the best chance of the plugs fitting. I looked at moving the ecu further round but thats not posible in the engine bay, it will just hit the rad and the plug wires are pretty short, Its best to keep it where it is.
Now the gap looked a little bigger but still a little snug so I tried a plug on with my fingers and toes crossed.....
And it fits!!! ohyeah.gif Its tight and its hard to see as I took the picture in the pitch black with one hand and rather tired at 5am, but there is about 4mm clearance between the plug top and the bttom dead center of the silicon hose.
Just need some longer 6mm stainless screws now to bolt the ECU onto the plate. A 6mm nylock nut and a thin washer gives you the pefect spacer hight btw to get a 1mm gap between the ecu and mounting plate. Hope this long winded report helps out those who have a Vec or astra! dunno..
