MNR Build Diary

noreply@blogger.com (Steve R) — Fri, 13 Nov 2009 20:52:00 +0000

Bit of cleaning, thinners, cillit bang, wire brush etc... then some paint....

New ali bellhousing as well, not sure whether to paint or polish atm..

noreply@blogger.com (Steve R) — Tue, 10 Nov 2009 20:49:00 +0000

Today I've spent all day in the garage, never even noticed how cold it was till I've just come out to see the lawn covered in frost! Brrrrr... I've lifted the motor out this morning after disconnecting everything, trailer has gone so I have tons more room to move about, with the car directly under the winch out it came.

Not wanting to remove the clutch as I want to see how the ali bellhousing fits I attached the engine right hand stand to the side of the block. trying the bell housing on I could see it was touching the starter ring on the flywheel so out came the carbide grinder and a little bit of fettling later, nothing touching.

Cleaned the left hand side of the engine which is quite corroded for a 2002 motor. It was the front in the Focus so someone may have had a modified body kit that let a lot of crap into the bay. It certainly is a lot worse condition than the 1.8 I had before. Cleaned it with a circular wire brush in the drill ready for a coat of engine enamel.. sprayed the sump with some HT matt black I had lying around to tidy it up.

I've also remade the idler mount at the front which previously used the pas pump bracket which was very bulky and a bit over the top. With the hacksaw and welder the bracket is now much slimmer! I've put the front engine mount cover back on to keep any nasty stones off the cam belt and used that to mount the idler bracket. Just needs a bit paint.

With the motor up on the stand I can see where the oil is coming from, there is a big leak at the back that will be OK to brass back over and although I though the plug was leaking it doesn't appear to be, maybe when its hot? Anyway, new plug and seal should sort that.

noreply@blogger.com (Steve R) — Tue, 20 Oct 2009 18:53:00 +0000

While I've enjoyed driving the car this year to various meets and shows and I've been slowly upgrading the brakes and transmission etc time has come for a bigger step. Changing from carbs to EFI.

One All Ford show to attend this Sunday then the engine is coming out for a tart up. With it out I'm going to be painting the block and sorting the oil leak from the sump. Hopefully its the drain plug as I checked it after welding by filling with oil and leaving overnight....

Installation of the aluminum bellhousing at the same time as I've figured out how to modify the type 9 clutch arm and pushrod system to replace the clutch cable.

Heres some pics of my new EFI setup. I've spent weeks whittling this from a lump of steel and have faithfully recreated the port injection position from the original ST manifold and the front set of injectors are from the ST170 engine.

The TB's are off a CBr1000RR which had an 8 injector setup. The bodies have 4 on them.

ATM I intend to use the ST injectors as they came with the engine so should suit it across the rev range, if not, I can configure the extra 4 on the TB's to give more when needed...

noreply@blogger.com (Steve R) — Tue, 13 Oct 2009 21:30:00 +0000

New brake master cylinders fitted tonight. Gone is the remote reservoir and hopefully thats the end of the fluid leaks I've had since starting the build! New front brake pipe to the front union so I can put the brake light switch on the side and maybe it'll work.

I've trimmed the pushrods on the cylinders to get the pedal back in line with the clutch. The brake pedal has always 'hung' forward to far for my liking.
New LSD in, lobro's on with a bit of machining to the spindles to get rid of the ABS teeth and my brand new set of massive 10" drums under the back wheels.Brakes need fluid and bleeding and maybe some bias adjusting. If it keeps dry I'll go find a road somewhere for some brake testing!

noreply@blogger.com (Steve R) — Mon, 12 Oct 2009 17:21:00 +0000

After the recent event where the bonnet flew off I'm going through a few upgrades.

First up got an lsd diff out of a 92 dohc Sierra and have fitted that in place of the open 3.62. The lsd is 3.92 so some recalibration of the speedo will be required, nothing major as its simply inputting a different factor. New diff is bolt on lobro's as opposed to the push in items I had on before.

Lobro's and shafts have been derusted, treated to zinc primer and black top coat. Drive flanges and bearing carriers have had new bearings and seals installed and I've used the opportunity to fit the 10" drums I've had lying around for a while. Local motor factor had all the bits new for the drums so was fairly painless. Had to space out the handbrake cable clamp as the entry into the back plate was a good distance further out than the 7" ones I took off.

Next step is new brake master cylinders. I have some integral units to replace the remote reservoir as they still leak and chuck fluid onto the chassis. Not good. As the backs need bleeding down now anyway it should be a straight forward task. if a little messy, but hopefully no more fluid leaks!

While I have the tunnel off fitting the diff I'm going to be running a new fuel pipe as I need a return after deciding I'm defiantly going the EFI route. I have nearly finished fabricating a new inlet manifold to accept the 43mm Honda TB's I have and have welded in bosses at the port head to use the original ST170 fuel rail and injectors. Management will be Megasquirt as I fancy learning the system thoroughly....

I have a new bonnet sitting upstairs as well and will have all the work done for the last Ford show on the 25th October.

noreply@blogger.com (Steve R) — Mon, 31 Aug 2009 16:22:00 +0000

Been a while now, not much happening apart from driving. Had a couple of incidents, very minor but managed to start it up from outside the car with it in gear. CRUNCH!
Then couple nights ago was messing with the carb jetting ahead of a power dyno run and forgetting to fasten the bonnet back down... WHOOSH 80mph and off into orbit. All in, two small bits of damage, not too bad....

Saturday 29th saw me a nd another couple 7 owners at McDonald Racing for a dyno run. Making 167bhp at 6200rpm, I'm quite chuffed with that as after removing Fords variable tract injection system for home tuned bike carbs there is only 1bhp different from Fords claim for the Focus. Still undecided whether TB's will be an advantage or not.

Here's the run...

noreply@blogger.com (Steve R) — Sun, 21 Jun 2009 19:23:00 +0000

Ho ho, been to Newark this weekend, what a hoot! After a little rain during Friday night Saturday was cloudy and windy but today has been glorious. Got home safe, warm and dry!
Big thanks to all the Locostbuilder peeps I bumped into and it was a lot better than Stoneleigh (and free!) I was mightly impressed with R1pete's turbo motor on th rolling road, put the TVR to shame!
I tried to take a lot more pics this time so click HERE for my pictures.

noreply@blogger.com (Steve R) — Sat, 16 May 2009 18:22:00 +0000

I still have some thoughts about improving the MNR but atm its all about driving. I may leave some to the winter when its off the road.

In the meantime I'm starting a new kit car project, all be it more of a conversion. I've always fancied a Jago after lusting after WWII jeeps and now I'm on the road to getting one. It has to be 4x4 for me so I've got a Suzuki SJ413 off ebay that will be stripped down to the chassis and built up with a Jago body to replicated the Willy's.

This is the starting point.....

Ive started a new blog, HERE, just need to see how much work I get done on it the rest of this year.

noreply@blogger.com (Steve R) — Thu, 14 May 2009 13:47:00 +0000

I've been busy driving! Been down to Stoneleigh for the car show, camping 2 nights. Nice 450 mile round trip, wet coming back. No drama's to report, car behaved perfectly, was comfortable and despite the downpour and truck spray I managed to stay dry!

Wilwoods are starting to feel better than the OEM Sierra brakes but the pads squeal very loud at low speed. Need to see if that improves with bedding in.

Pics from the Stoneleigh show can be found HERE! I only really took pics of things that caught my eye and stood out like the beautiful SS100 rep. And the V8 engines... yum yum. There was just too much to look at on the 2 days.

Got some tips lining the bodywork up and some ideas to make a new column shroud. More car building to come!

So, bodywork to do, steering cowl to make, switches to move and 10" drums to install.

I will have tons of time on my hands soon...

noreply@blogger.com (Steve R) — Thu, 30 Apr 2009 21:09:00 +0000

Sorted the lights, they didn't have a wiring diagram and I wired them up wrong. Sorted that out and all is good again.

Wilwoods are on and the brakes feel a little better, not sure if I have all the air out as I didn't have the correct size spanner for the bleed nipples 1/4" AF, American calipers you see. I'll be having another bleed before I go away this weekend.

I'm now in the possession of some new drums as well, 10" jobs off an XR4i. They look simply massive! No time to get them fitted before Stoneleigh kit car show tho, they will have to wait.

Finally decided to make a new gearknob after loking at my aweful broken Ford one for nearly a year! Saw some nice ones in Burtons catalogue and decided to have a bash meself.

Anyway an hour on the lathe and I'm well pleased!

noreply@blogger.com (Steve R) — Sat, 18 Apr 2009 18:13:00 +0000

New brakes arrived yesterday from Rally Design while I was out picking up my new Dominator headlights in carbon fibre effect. The lights are much smaller, 4", and are more of a 'torpedo' style than the rounded bowls of the 5 3/4" jobs.
Fitted them today and they do look smart, however I seem to have created a fault in the wiring, the main beam indicator on the dash is lit up all the time now. Little bit of investigation has found it not to be the lights or new wiring so I'm a bit stumped.
Great day out at Specialist Cars last Sunday, hundreds of cars and people, more Porches than you could shake a stick at. Excellent turn out from the 7's as well and we had a nice steady blast over the moors afterwards. Apart from the heavy frost on the morning it was thoroughly enjoyable.I have put all my pictures from the day in a folder inside my picture galley, just click the link on the right to see them. click the 'my pictures' in the gallery then select 'Yorkshire Breakfast 2009'

Ford RS meet tomorrow, and then I'll be cracking on installing the Wilwood 4 pots and bigger discs...

noreply@blogger.com (Steve R) — Sun, 12 Apr 2009 16:46:00 +0000

Got the carbs pretty close and the motor revs past the 8K ceiling on my tacho, need to keep that in check!

Had a run over to Specialist Cars in Malton today for an open day in aid of the Yorkshire Air Ambulance. Met up with fellow 7ers on the way down. Hundreds of people and some very exotic motors lying around.

I took plenty of pics, just click here to go straight to it: Yorkshire Breakfast 2009

Set of Wilwoods next I reckon...

noreply@blogger.com (Steve R) — Wed, 18 Mar 2009 20:33:00 +0000

Got the Lambda and AFR gauge working now. Haven't really done anything yet apart from see how it idles. With the new exhaust I noticed it hunts and drops down when idling, the Innovate lambda's telling me its very weak at tick over. I'll be having a look at tuning the carbs this weekend, even if its just near enough to get back down to Blogg Brothers for a proper set up.
Still need to complete the new inlet manifold tho!

Any, here's some pics of the exhaust I got from AAS in Newcastle. Sounds great, ticking over quite quite but once the revs build and the VVT kicks in it howls... nice!!I've constructed a copper heat shield for the sensor out of 28mm copper pipe as advised inthe Innovate manual.

noreply@blogger.com (Steve R) — Sat, 14 Mar 2009 11:00:00 +0000

Some pics of the sump chop on my ST170. Rear section of the sump boxed in to create extra capacity. I left the original part of the rear section, you can see the profile where the weld is and drilled holes through it to create a baffle.

Needs to come off soon as its leaking, making a mess on the garage floor!

noreply@blogger.com (Steve R) — Tue, 10 Mar 2009 20:42:00 +0000

New exhaust on last Wednesday, had a run down to MNR Saturday. I've connected the VVT to the aux output on the Mj and set it to switch a relay at 4K. This allows high cruising speeds without the cam kicking in and buggering the mpg up.

SO, couple of nice empty straight roads and 4K in third gear... whoosh! off she goes and pulls like train!
Carbs are not set up properly yet as there is a fluffy moment between 2.5~4K where I think it is running a bit weak. I need to get the LC1 connected so I can see the AFR and have a go at tuning myself....

In the meantime I've been kicking on with the log burner, bit late for this winter but will get rid of tons of rubbish in the garden and its there for next year. I got an empty 19kg bottle a while ago and left the valve open for a week, turning it upside down after 3 days. With tons of old engine oil I drilled a hole in the top of the bottle next to the valve and filled it with water. I then cut the valve off and left it full of water in the garden for 3 months!

I got a length of 4 1/2" 3.5mm pipe the other day so I've been cracking on....

Doors marked out a partially cut. Thought original marking out was too high.

Doors fully cut out.

Hole cut in the top for steel chimney pipe. Next step, hinges and welding up.
Its tight in the garage when all the toys are in!

noreply@blogger.com (Steve R) — Sat, 21 Feb 2009 15:31:00 +0000

Been for a drive out today, nothing more than a mile eating session, sitting in traffic, testing the new coolant pipe setup. Couple of burst in first and second some speedy motorway driving. All went well with no incidents and I took some pictures.

Its going in for a new performance exhaust next week, bigger primery's and beefy silencer to extract as much power as possible out of the motor.

noreply@blogger.com (Steve R) — Sat, 31 Jan 2009 11:36:00 +0000

Some pictures of my ST engine install....

Thermostat/header connections.

Exhaust on, straight off the 1.8.
Soon to be replaced for a bigger one!

Engine on the stand showing the sump chop.
I cut it level with the bottom of the bellhousing.

New nearside engine mount with custom alternator mount
using the original aircon pump bracket.

noreply@blogger.com (Steve R) — Sun, 25 Jan 2009 16:48:00 +0000

Yesterday I had my first run out with the new engine. Nothing spectacular as the roads were damp in places and it was very cold. Went down to see a fellow MNR builder who is getting ready for SVA.

I've bought an Innovate LC 1 lambda kit so I can have a go at tuning the carbs for their new application. So, I need the lambda boss welding into the exhaust..... paid a visit to AAS Exhausts in Newcastle to see about getting that welded in and a couple of other tidy ups on the exhaust, welding two joints, nice hanger etc... Anyway to cut a long story short, and explaining I wanted 200bhp from the motor I've booked the car in for whole new exhaust system with much bigger pipes throughout. I hadn't planned this atm but knew it needed doing so I'm in for it just need a hefty cash injection....

Got back home in the dark with no drama's apart from a concern with the coolant. I'm not convinced I'm getting the correct reading from the temp gauge, and its chucking coolant out when its cold. I suspect this is due to the header tank connection being very close to the bypass output of the thermostat housing. I'm going to move the header tank connection down to the bottom hose close to the radiator to try and smooth out any surges that may be the cause of the coolant being expelled.

Immediate plans are to cure once and for all the brake fluid leak that's been a constant problem with new master cylinders with integral reservoirs, move the header tank connection and get the exhaust done. Then I can think about cams to get up to 200bhp. And I still need to make a new inlet manifold.

Roll on the warm weather!

noreply@blogger.com (Steve R) — Sun, 18 Jan 2009 20:10:00 +0000

Got my hands on some 5mm steel plate. I've decided to make a new inlet manifold. Seeing as I made the original one I can save a bit of cash making this one too. I've got the Ford Plastic one to use as a template and it should be easier this time as the ports on the head are larger. I wont have to reduce the tubes to make them fit!

I've swapped the thermostat housing for the one of the 1.8. This is because the newer ST one has temp senders that are push in and held with sliding clips, where as the 1.8 one has threaded sensor holes. This has enabled me to fit the Acewell sensor to the bottom of the unit. I started the engine again for another warm up/leak test and while the fan came on as it does at 86 degrees the dash was only registering 55... This may be due to the sensor sitting on the bottom of the thermostat. The problem is I've blocked the rear outlet that would have gone to the heater so there's not much flow over it. However this may or may not be problem during normal driving when the water is going round a lot faster. Time will tell. I have a mechanical Racetech water temp gauge I may attempt to plumb into the top sensor.

Congratulations to Vinny, Bill & Basset for getting their cars started today. You can check their blogs out with the links on the right..

noreply@blogger.com (Steve R) — Mon, 29 Dec 2008 20:33:00 +0000

Quick update. I've used the inlet manifold just to get it running. Everything connected now I've had it outside toady with the engine running up to temperature. Revving it up its spitting a fuel mist out of the carb trumpets. Not sure if this is due to the manifold not lining up with the head so I reckon a call to Blogg Brothers again to make me a new inlet and set the carbs up for this engine.

Before I do that I'm going to try and get the Megajolt work the VVT, opening the oil pressure switch at 4k rpm.

Tidying the garage out atm to try and get my Rover in over the winter. Can't stand the windows being frozen up on a work morning!

noreply@blogger.com (Steve R) — Sun, 21 Dec 2008 10:41:00 +0000

Got some silicone hoses in the post yesterday and set to making all the water connections. This time I've run the bottom hose down the outside of the chassis in the gap between it and the body. I've run the hose through a tight gap between rad mount and chassis and am hooping it won't cause a problem. Its all solidly mounted and shouldn't be moving around.

Hoses going round outside of chassis.

Bottom hose going through tight gap in chassis.

Top rail is now secure thanks to some correct size reducing hoses and the tube is fastened to the engine with a home made ali P clip. Heater outlet on the back of the thermostat housing to block and it should be ready for some antifreeze. Next step is the oil filter housing to make oil tight and get some new oil in.

noreply@blogger.com (Steve R) — Tue, 16 Dec 2008 22:44:00 +0000

Took the ST inlet off and tried my homemade carb inlet off the 1.8 on it. Looks like the inlet will be staying with the 1.8. The ST inlet ports are about 10mm further up and nearly twice as big! Too far away to adjust the other one. So a new inlet manifold is required for the carbs.

On the opposite side the exhaust is on, no real difference in the exhaust ports so on it went without any fettling. I've made a top hose pipe out of B&Q aerial aluminium pipe and bent it to drop under the exhaust. Some slight crimps on the folds but nothing to worry about. I'm going to block the top vent on the radiator and use the vent from the termostat housing. This is higher up and makes for a neater installation. In order to connect the bottom hose I need a 180 degree hose to get the water pump outlet pointing forward. 180 is probably a bit too much but seeing as I can't get a 155 one it will have to do. Its not far way now, apart from the inlet, so will be trying to get it finished over the holidays. Merry Xmas all!

noreply@blogger.com (Steve R) — Wed, 10 Dec 2008 20:50:00 +0000

With my new camera in hand and after much tinkering over the last few days with engine mounts, remote oil filter housing and like took the plunge, hoisted it up and dropped it in. Clutch splines lined up no problem and the engine dropped onto the box. I've popped a 10mm piece of steel under the offside engine mount. With that in place it lifts the engine slightly and leaves the sump hanging down about an inch all round and gives it a bit of a run off towards the drain plug.

After mucho head scratching and different release arms off ebay I have abandoned the ali bellhousing as an expensive mistake. With it having the option of starter on either side it was a bit too wide. I ground a lump off the clutch arm side so I'm not really able to sell it on. What a bummer...In the picture above you can see how much further back the filter housing is. Theres no chance of the steering arm catching now!
Its just a matter of connecting everything up now and I started with my new alternator mount which has worked out quite well. Alternator is now slightly higher and further away from any chassis rails and is really much more compact. With the belt on and tightened up its ready to go.

Duratec (zetec) ST170 engine will initially get its chance on the carbs off the 1.8. 4 X 40mm should be enough... A trip to Bogg Brothers may be needed but at this time I need to be convinced injection is needed. I'll be wiring the VVT up to the shift light function of the Megajolt so it will open at 4K rpm. Should make it sing.

One thing about the ST engine is the port sizes. The standard zetec ones are heart shaped but these are just plain round holes in and out. BIG plain round holes. The exhaust manifold will be having soome metal removed from the flange and depending on the inlet shape once I take the ST inlet manifold off I may fettle the carb inlet or make a new one.

New water hoses are required as the blacktop water pump union is smaller than the zetec one, comes out slightly pointing backwards and as I'm sticking with the Ford thermostat housing new top hoses as well. Lots to do, should have it running by Sunday.....

noreply@blogger.com (Steve R) — Thu, 27 Nov 2008 22:24:00 +0000

Many hands make light work they say... and I must agree. Many thanks to Andy W for coming round tonight and giving me a hand on the very night I finally took the 1.8 out. Andy on one side, me on the other it was out in about 90 minutes.Took delivery of a brand new aluminum bellhousing Monday. With it offered up to the ST there was a very small amount of fettling to get the starter clear of the sump and that's where I left it for the cider, sorry, for the night!

I'm not going to be using the water rail I had on the 1.8 as I feel the original Ford housing works better and as I'm considering a heater this will suit it better. So some remaking of pipe work is in order and I will be plumbing the Focus oil cooler into the remote filter head. First I need to attach the new bellhousing, derust the flywheel I'm going to use and actually get the ST engine in!

I'll give the Mondeo clutch that I bought for the 1.8 a go but feel I may need to upgrade to some thing stronger. Time will tell. Old 1.8 out, new ST waiting menacingly to go in...

I'll be taking the opportunity to clean the engine bay out while there's plenty room. There's still mud and grass from the crash and fibreglass dust everywhere from the rebody so its an opportunity not to be missed.

noreply@blogger.com (Steve R) — Fri, 21 Nov 2008 13:40:00 +0000

Quick update, engine is ready to go in with new belts and oil/filter etc. Was intending to get it in this weekend but have bought a new aluminium bellhousing at the last minute and am waiting for it to come. Picking up my 'new' Rover 45 this afternoon as well.