Well, I haven't done anything with the car since the last post. I've been too busy with other things :-).
At the moment I've been trying to find a fan belt that fits the alternator but can't get the correct length. I've been trying to fit a roller to take up the slack but with it being so cold in the garage I haven't had a real go at it.
Next step for me now is finding some decent wheels and tyres in the sales and getting some seats. That should get me pretty close to finished and give me the umph I need to get it to the SVA test.
I'm also trying to decide about arch mounted indicators as I really don't fancy drilling holes in the nose cone! Strange but true....
I haven't abandoned it yet, its just I'm thinking about the 32 year trials bike thats in bits on the garage floor and the scooter as afore mentioned! One big push should see me close, I really do want it on the road for the summer.
As its christmas eve, I'd just like to wish everyone a happy xmas and a prosperous new year.
Monday, 24 December 2007
Saturday, 10 November 2007
Today I have fitted the hoses for the coolant system, well some of them anyway. I purchased a 90 degree reducing bend to connect to the water pump and used a combination of B&Q aerial pole and some hose I got from the scrappy a while back. I still need some hose for the top connection as none of the bits I have are suitable. It needs to dip down under the light bar then up to the outlet on the thermostat housing.
The water rail has made installation of the top hose very straight forward, and its a very neat factory looking piece of kit.
I also fitted the alternator on the bracket I made last week as you can see in the picture. I need a trip to Halfords to get a belt and some water hose and hope theres no bling wheels on offer to tempt me.....
I have a plastic expansion bottle off a Corsa at the moment but I may splash out on a nice shiny ali head tank! Gulp!
Ive moved the radiator forward slightly to give more room for the bottom hose and it now sits up a bit higher. I just hope the nose cone fits now!
To solve the problem I had with brake fluid leaking I purchased two screw in/push on connectors and got rid of the bits of brake pipe and union setup. Hope it does the trick, there was brake fluid all over as changed them!
I now think thats all the mechanical stuff done and its bodywork and trim next bearing in mind the requirements of SVA. The wiring needs tiding up and I need to think about clocks. I still haven't decided what I want to dash to look like!
Wednesday, 31 October 2007
Well, thats the whole of October gone and I've done nothing with the car. How time flies...
I am quite amazed at the number of people who have come onto my blog here. Nearly 3,000 at the moment. Thanks very much everybody.
I have not abandoned this blog or the car build, I've just not done anything on the car since my last post. In fact since I came back off holiday in September!
In the last couple of weeks I've picked up a 100cc scooter and I've been fiddling with that. I got it dead cheap off ebay and it just needs some TLC and I'll be on the road with it. 100mpg is the attraction!! and the fact it's a 2 stroke. I love the ring ting ting....
Today I received a second hand water rail for the zetec and I've now got that on making it dead easy to fit the top hose to the radiator. The bottom one is a bit more difficult and I may have to buy a silicon reducing bend to attached to the water pump outlet that's a lot bigger (45mm I think) than the rest of the hoses.
While I was on a roll I have nearly finished the alternator bracket I started ages ago. It just needs taking off and welding up, a trip to Halfords for a belt and I should have it up and running soon.
Twice in the last month I've had to start the car to get it out of the garage and up the drive and I can report it starts first time and drive's quite good, even for the small push up the drive! The only thing that I'm not happy about is a small brake fluid leak from the reservoir connection. It only leaks after I've used the brakes but as its on the non-pressurised side of the system so I'm a bit miffed at that one.
I am quite amazed at the number of people who have come onto my blog here. Nearly 3,000 at the moment. Thanks very much everybody.
I have not abandoned this blog or the car build, I've just not done anything on the car since my last post. In fact since I came back off holiday in September!
In the last couple of weeks I've picked up a 100cc scooter and I've been fiddling with that. I got it dead cheap off ebay and it just needs some TLC and I'll be on the road with it. 100mpg is the attraction!! and the fact it's a 2 stroke. I love the ring ting ting....
Today I received a second hand water rail for the zetec and I've now got that on making it dead easy to fit the top hose to the radiator. The bottom one is a bit more difficult and I may have to buy a silicon reducing bend to attached to the water pump outlet that's a lot bigger (45mm I think) than the rest of the hoses.
While I was on a roll I have nearly finished the alternator bracket I started ages ago. It just needs taking off and welding up, a trip to Halfords for a belt and I should have it up and running soon.
Twice in the last month I've had to start the car to get it out of the garage and up the drive and I can report it starts first time and drive's quite good, even for the small push up the drive! The only thing that I'm not happy about is a small brake fluid leak from the reservoir connection. It only leaks after I've used the brakes but as its on the non-pressurised side of the system so I'm a bit miffed at that one.
Monday, 24 September 2007
Well, it feels like a long time since I did anything to the car. I've had a week in Spain where it rained for 3 days for the first time since April. Doh!
I've been collecting things from the scrapyard the last couple weeks and have a load of coolant pipes to make up the system and a nearly brand new reservoir from a 07 reg Corsa that was absolutely smashed to bits.
I've also picked up some bits for my daily drive, a Rover 220D. I picked up a tow bar so I can get the MNR around on a trailer when I need too. Then the wiper motor seized and I had to go back for that! I've picked up some other little bits and bobs along the way always keeping an eye out for a 6 cylinder Volvo.... :-)
I got back from holiday on the 15th and did intend going to the Donnington kit car event. However, we were a bit delayed getting back and the drive down to the midlands was just a bridge too far. From the reports I've seen I didn't miss much so I'm not that fussed in in not going this year.
At the moment I'm trying work out how I can use the clocks from an Astra. They are electronic are very thin at 50mm front to back. They have all the clocks and lights I need for SVA so I'm having a bash at making them work for my kit!
I've been collecting things from the scrapyard the last couple weeks and have a load of coolant pipes to make up the system and a nearly brand new reservoir from a 07 reg Corsa that was absolutely smashed to bits.
I've also picked up some bits for my daily drive, a Rover 220D. I picked up a tow bar so I can get the MNR around on a trailer when I need too. Then the wiper motor seized and I had to go back for that! I've picked up some other little bits and bobs along the way always keeping an eye out for a 6 cylinder Volvo.... :-)
I got back from holiday on the 15th and did intend going to the Donnington kit car event. However, we were a bit delayed getting back and the drive down to the midlands was just a bridge too far. From the reports I've seen I didn't miss much so I'm not that fussed in in not going this year.
At the moment I'm trying work out how I can use the clocks from an Astra. They are electronic are very thin at 50mm front to back. They have all the clocks and lights I need for SVA so I'm having a bash at making them work for my kit!
Monday, 3 September 2007
Hi, no major progress at the moment as I'm trying to resist an engine change. I'm quite taken with a Volvo engine. Its a 3L 6 cylinder job that is very compact and only 4 inches longer than a 4 pot engine and chucks out over 200bhp with a huge lump of torque. Some of them have single tubos attached and some have twin turbos attached. Heaven!It looks really good as well.
I've spent the last couple weeks collecting bits and bobs along with a silencer and link pipe from MNR. I'm sorting out were the coolant pipes will run and rather than spend a fortune on silicon pipes I'm going to gather some OE pipes from the scrappy to make all the bends. Then I can get some ali pipe bent to take out some of the joins out before I spend any cash on the shiny bits.
I really need to resist the urge for another engine but I know it will simmer away and if one comes along at the right price soon I'll be a having it!
Sunday, 26 August 2007
Engine/Alternator Mount.
The new engine mount and alternator bracket are complete. They are coated in Hammerite and drying off as I write.
I've made a new alternator bracket based on a design that's for a zetec SE. The mounting hole centres were different but the overall design is the same. I made the bracket to fit the Focus alternator I bought at the scrappy. The original one that came with the engine was slightly larger and heavier so the Focus jobbie was used instead. I used two of the M10 threaded holes in the block while sharing the back one with the new engine mount which uses 3 M10 holes in the block, AKA original Ford Crossflow design, I believe!
When I took the original mount off I held the engine at the required position using a jack under the engine. This way I made the two plates, one on the engine and one on the rubber mount on the chassis, joining the two together with a bit of tube. I spent a couple of hours making a wooden mount to get the angles right then transfered the dimensions to the metal bits. The whole lot was then welded together.
Heres the new mount cooling off after welding. I'm surprised how rough the welds look as they look a lot better in the flesh! They are done with my 20 year old stick welder thats a bugger to get going but gives a nice smooth weld once its arced. I would really love a Tig, once I win the lottery!
In order to fit the rubber mount I need a hole in the side so I can tighten the M10 nut. I drilled a couple of 10mm holes before I welded it and I made the hole big enough to accept a socket with a milling bit in the electric drill.
With the hole enlarged so I can get the nut on the thread and a socket in to tighten it up, I trial assembled the bracket and mount. balancing the welding seems to have held any distortion at bay and it all went together perfectly!
With the jack out and every thing resting in place the alternator now has a home with a decent amount of room for adjustment. There is plenty of room above for the coolant pipework as well.
This is the alternator bracket, (sorry for the blurry picture, I really do need a new camera!)
I bought a metre of 30x30x3mm angle in B&Q to make it.
The two mounts for the alternator are perfect for belt alignment and there is a captive M8 thread for the adjuster arm at the front.
I don't have an adjuster arm but a trip to the scrappy should get me one off a Ford Fiasco that should do the job perfectly. While I'm there I'll try and get some wheel nuts as I only have 3 on each wheel. The original owner of the donor must have saved the locking nuts for something else :-)
I took it all off and gave it a nice black coat of smooth Hammerite. I'll give that a couple of days to dry and then I'll be moving on to the cooling side. In the meantime a bit more wiring to get the back lights and horn working.
I've made a new alternator bracket based on a design that's for a zetec SE. The mounting hole centres were different but the overall design is the same. I made the bracket to fit the Focus alternator I bought at the scrappy. The original one that came with the engine was slightly larger and heavier so the Focus jobbie was used instead. I used two of the M10 threaded holes in the block while sharing the back one with the new engine mount which uses 3 M10 holes in the block, AKA original Ford Crossflow design, I believe!
When I took the original mount off I held the engine at the required position using a jack under the engine. This way I made the two plates, one on the engine and one on the rubber mount on the chassis, joining the two together with a bit of tube. I spent a couple of hours making a wooden mount to get the angles right then transfered the dimensions to the metal bits. The whole lot was then welded together.
Heres the new mount cooling off after welding. I'm surprised how rough the welds look as they look a lot better in the flesh! They are done with my 20 year old stick welder thats a bugger to get going but gives a nice smooth weld once its arced. I would really love a Tig, once I win the lottery!In order to fit the rubber mount I need a hole in the side so I can tighten the M10 nut. I drilled a couple of 10mm holes before I welded it and I made the hole big enough to accept a socket with a milling bit in the electric drill.
With the hole enlarged so I can get the nut on the thread and a socket in to tighten it up, I trial assembled the bracket and mount. balancing the welding seems to have held any distortion at bay and it all went together perfectly!With the jack out and every thing resting in place the alternator now has a home with a decent amount of room for adjustment. There is plenty of room above for the coolant pipework as well.
This is the alternator bracket, (sorry for the blurry picture, I really do need a new camera!)I bought a metre of 30x30x3mm angle in B&Q to make it.
The two mounts for the alternator are perfect for belt alignment and there is a captive M8 thread for the adjuster arm at the front.
I don't have an adjuster arm but a trip to the scrappy should get me one off a Ford Fiasco that should do the job perfectly. While I'm there I'll try and get some wheel nuts as I only have 3 on each wheel. The original owner of the donor must have saved the locking nuts for something else :-)
I took it all off and gave it a nice black coat of smooth Hammerite. I'll give that a couple of days to dry and then I'll be moving on to the cooling side. In the meantime a bit more wiring to get the back lights and horn working.
Tuesday, 21 August 2007
Alternator
I've been wanting to put my alternator under the carbs above the oil filter mounting. Most people move the thing there when installing in this kind of RWD vehicle.
However, the space is very tight with a chassis tube dissecting the area and the steering shaft that gave me so much trouble with the oil filter is in the way as well.
So, I'm going to take the nearside engine mount off and fabricate a bracket to hold the alternater just around the sump line under the water pump outlet. This is the original Ford mounting point but I cant use the original bracket as its HUGE, with a pas pump and idler roller.
There seems to be plenty of room down there and there are some more threaded holes further back on the block to move the mount back. As it is the fabricated mounts that came with the kit are not at the same position on the block with this one I intend to move a lot further forward.
Once I have the alternator bracket I will use its rear mounting as the front hole for a new engine mount that will only need to be moved back around 40mm or so
.
The mount will go back onto other threaded holes in the block and give enough room for the alternator in front of it under the pump outlet.
The mount will still be a little further forward than the other side so I don't see any problems in the thinking.
On the plus side its now just a small run to the battery cable on the starter for connections.
However, the space is very tight with a chassis tube dissecting the area and the steering shaft that gave me so much trouble with the oil filter is in the way as well.
So, I'm going to take the nearside engine mount off and fabricate a bracket to hold the alternater just around the sump line under the water pump outlet. This is the original Ford mounting point but I cant use the original bracket as its HUGE, with a pas pump and idler roller.
There seems to be plenty of room down there and there are some more threaded holes further back on the block to move the mount back. As it is the fabricated mounts that came with the kit are not at the same position on the block with this one I intend to move a lot further forward.
Once I have the alternator bracket I will use its rear mounting as the front hole for a new engine mount that will only need to be moved back around 40mm or so
.The mount will go back onto other threaded holes in the block and give enough room for the alternator in front of it under the pump outlet.
The mount will still be a little further forward than the other side so I don't see any problems in the thinking.
On the plus side its now just a small run to the battery cable on the starter for connections.
Sunday, 19 August 2007
Back end finished...
Well, it's took all weekend to do but the arches are on as in my last post and now the lights are fitted. It wouldn't have took so long had it not being for Durham picking up their first bit of silverware (cricket) and MotoGp being on this morning.
Slow but sure progress at the moment. More cash required now....
Slow but sure progress at the moment. More cash required now....
Saturday, 18 August 2007
Arches Update.
After consultation from members on Locostbuilders I decided to take the arch off and put the correct ones on each side.
Not too much of a problem and the spare holes on the offside are covered by the arch anyway. A bit later I'll fill the holes with Tigerseal or something like that.
With the arches on however my standard Ford alloys don't fill the arches and look a little out of place. They are only 5.5" so I reckon some 7" wide ones will be better. Later though because I can't afford any new ones!!
Not too much of a problem and the spare holes on the offside are covered by the arch anyway. A bit later I'll fill the holes with Tigerseal or something like that.
With the arches on however my standard Ford alloys don't fill the arches and look a little out of place. They are only 5.5" so I reckon some 7" wide ones will be better. Later though because I can't afford any new ones!!
Friday, 17 August 2007
Rear Arches
Had a go at fitting the rear arches last. With all 4, front and back wrapped in bubble wrap I simply distinguished the front ones from the back and unwrapped one.
Only being able to work on the offside due to the other side being against the wall I offered it up and spent ages making sure it was central on the wheel.
Drilled a few holes, cut the rubber trim to fit and bolted it up. Checked it was all square and central, more holes and bolts, around 9 in total, drilled to avoid chassis rails. Well, some of them anyway :-)
Stood back to admire it then the doubts crept in... steep angle at the rear? Consulted some owners pictures on Locostbuilders and I could see I had put it on the wrong side.......
.
As you can see the steep slash is facing the rear when it should be in front of the wheel. I'm just pondering on leaving it as is only being a bit doubtful of what the lights will look like.
Only being able to work on the offside due to the other side being against the wall I offered it up and spent ages making sure it was central on the wheel.
Drilled a few holes, cut the rubber trim to fit and bolted it up. Checked it was all square and central, more holes and bolts, around 9 in total, drilled to avoid chassis rails. Well, some of them anyway :-)
Stood back to admire it then the doubts crept in... steep angle at the rear? Consulted some owners pictures on Locostbuilders and I could see I had put it on the wrong side.......
.As you can see the steep slash is facing the rear when it should be in front of the wheel. I'm just pondering on leaving it as is only being a bit doubtful of what the lights will look like.
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