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Discussion Starter #362
Not much been going on lately....
Helped my mate out yesterday fitting his engine back into his Fiesta RS Turbo...LOL. Was fun despite the weather.
However, was out this morning in the garage and managed to spray the drivers composite door....

As it came...


With a bit of primer....


Sprayed and lacquered...


Was a pretty reasonable job given that:-
1. I wasn't looking for a 'show' finish.
2. I was using rattle cans.
3. Garage ain't exactly a dust-free environment.

Just need to remove the original door and fit the handle and opening mechanism along with the polycarb window. I'm thinking this is going to be a bit of a bugger given the fact that the door is a hollow shell without any accoutrements. I'm sure I'll come up with some fanciful solution though :chuckle:

Also made up a carbon fibre panel...


to replace the one I made to hold the switches previously..


With all the things I need to place on a centre panel, I have run out of space so the carbon one will be full-length to accept the Dash 2 and DL1 fuses as well as the Syvecs Calibration switch that I have and other stuff..

Managed to fit the switches for the Dash 2 to my Sparco steering wheel. Idea is that I will use a 6-way coiled cable with a spare 6-way Deutsch DT connector that I have lying around. Going to get a panel mount DT receptacle so wheel can still be fully detached when needed.

Weekend garage foray over but a reasonable amount of stuff done.

TT
 

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Discussion Starter #363 (Edited)
Progress not as quick as I would like lately due to a bloomin uni assignment!!! :nervous:. Still, gave myself a few garage hours today to get my brain in a calm place :chuckle:

Have fitted the drivers door along with polycarb window and refitted SPA mirror...


Awful pic but you get the idea...Decided to fit the mirror on the window itself as it gives the best performance in terms of vision.

Decided to only spray the outside skin and keep it natural inside..


Door hung quite well initially but I think some mild tweaking is in order to get it 'just right'. The difference in weight of the composite doors compared to my (already empty) standard doors was nothing short of phenomenal!!! You really have to feel it to believe it :eek: Got myself some white door squares which will give it the pukka 'competizione' look :chuckle:

Yesterday saw my delivery of coiled 5-core cable so I set about wiring my newly mounted switches for Dash 2...



Rear....(actually a lot neater in the flesh than it looks here!)..




All wired in to a spare 6-way Deutsch that I had lying about..



Man, I love these connectors!! Have a panel mount receptacle for it which I'll mount in place of the fuel pressure gauge which will be getting removed as its redundant. Idea being that while the wheel can be removed from column when getting in and out, being on a coiled cable will allow for lots of movement. While I cant forsee the wheel needing to be completely detached, the Deutsch allows for that eventuality.

Will get cracked on at the weekend and get the passengers door, window and mirror fitted. The polycarb windows have been lying around for a bit and have some pretty hairy scratches in places. Seen some guides on the net for polishing out scratches on polycarb/lexan so will give that a try at some stage.

Next item on the agenda is making up a new injector harness. Will be buying some ID1000's on payday and have sourced some EV6 plugs so I will do a bit of rewiring so that the injectors are plugged directly into ECU. Have a plan to wire all on-engine and off-engine services separately using beefy Deutsch AS connectors on the bulkhead..



This will allow the engine to be electrically disconnected with 1 plug should it need to come out in a hurry. :nervous:

TT
 

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Discussion Starter #364
Managed to 'arrange' some time in the garage (unusual for a Sunday) and got cracked on...

Fitted the passenger door, polycarb and mirror....




As with the drivers door, i made up some plates for the inside to reinforce the hinge area...



The fit of the windows is excellent and I paid particular attention to getting them to fit under the weatherstrip. Should prevent any air (wind) from getting into the leading edge and forcing the windows out like some have experienced.

Also took the time to fettle the door striker plates so they now open and close in a fashion that resembles stock :chuckle: When they were both on, I applied my competition number backgrounds :D..



Now looks 'Motorsport' :chuckle:

Centre console fitted along with some edging I decided to go for....just smartens it up a bit as well as protecting the edges...


As I still had a bit of time left, I grabbed a bit of 4mm mild steel plate and fabricated it to facilitate the mounting of my proportioning valve. I inclined it a bit towards the driver in the spirit of ergonomics :D....




Just need to plumb it and we're sorted.

Another good day!! :thumbsup:

On another note, using some Mindmap stuff at work and decided to apply it to the car to get a sense of what's happening when. Very useful and in an easy to view format.



Gives you an idea of whats in my mind. Some bits are high-level while others are a bit more detailed (perhaps a bit too much). Its more a working document and things get deleted as and when completed.

Anyway...roll on the next garage episode :thumbsup:

TT
 

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Discussion Starter #366
Finally got fed up with arseing about with dodgy tools so bought a genuine Deutsch HDT-48-00.


With the amount of Deutsch crimping I intend to do it'll be money well spent. In keeping with my nose for a bargain, I managed to get these for £50!!! They retail new at over £200 so I'm happy...tested them and they work as if they were new!! :D

Also got myself an MSA rain light...


and was given a set of alloy OMP pedals by a mate...


Had a couple of spare hours yesterday so got around to fitting the lower main hoop brace for the cage. Had to relocate my battery box a couple of inches forward of its current location which meant seats out etc. *sigh*


So, loads to be getting on with this weekend....as well as sorting out the wiring for the centre console switches, bulbs and fuses....Joy!!!

TT
 

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Discussion Starter #368
This weekend has been a bit light on effort compared to previous ones.

Managed to get OMP pedals fitted, rain light fitted and wired into the centre console, proportioning valve all plumbed in (I replaced all the rear brake lines while I was there!!).
I also took the time to remove my fuel cooler and duct....I have never been overly comfortable with how low it sits to the tarmac. So, I removed it all and did a bit of cutting and modifying and voila...it now sits just above the exhaust line and should be out of harms way :)

On another note, I have decided to start a second, more long-term project of building myself a 2.1 Cosworth YB form bits sourced off the net. I've decided to purposely buy bits and pieces i.e bare block, bare head etc as opposed to complete assemblies as I think a bit of modding here and there will be in order :chuckle:. Aim is to get a complete, working unit built up on the engine stand over, say 18 months...really not looking to fire it all together in a big hurry. Should be fun.

TT
 

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Car is looking awesome! Do you think you could paint and use Fibreglass door cards on a road car or in the leash is it obvious that they're fibreglass?
 

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Discussion Starter #370
Car is looking awesome! Do you think you could paint and use Fibreglass door cards on a road car or in the leash is it obvious that they're fibreglass?
Well, in mine they're VERY obviously fibreglass :D.

Are you talking about putting F/G door cards on std doors? The reason I ask is that my F/G door internal was flat and had a flange so the doorcard would sit flush. On a std door you would have to have a moulded section which followed the contours of the door innards, especially if you intended to use the std interior trim pieces such as door pull etc.

I would say this WOULDN'T be straightforward on a road car, especially if you were looking for a reasonable level of finish.

TT
 

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Discussion Starter #371
Over this weekend I have not been too productive (well, not on the GTR front anyway!! :) )..

Replaced the blue switch on my steering wheel as I found that, when testing for continuity, it failed. It seems I had fried it when soldering the wires :chairshot. So, new switch acquired and soldered by a mate (who's soldering is WAY better than mine :D)

As I mentioned a couple of posts ago, I am looking to build myself a mix-and-match Cosworth YB from bits I can pick up cheaply...Already got an Escort cam cover and Sierra 4x4 plenum....



The plenum has been modified to accept Toyota coil-on-plug packs and has a rear breather which is what I wanted anyway. Also, despite my thinking that this was going to be VERY long-term, I have already secured a '200' block (the more desirable 4WD one), 4WD head and throttle body for a whopping £385 (yup, £385 for block, head and TB!! from separate vendors though)....not bad for a weeks work :D :squintdan. That's about £1600's worth of parts there....I kind of feel like a thief :D

I will probably start another build thread just for the engine in case anyone's interested. Don't want to fill this one up with crazy Ford stuff!! As an aside, on doing some research into YB's it made me laugh just how cheap 4 pot parts are compared to Skylines and how 'backward' they are technology-wise. Seems most stick like glue to ancient Pectel management when FAR better stuff exists. My intention is to use some of my techy knowledge when it comes to parts etc for this motor.

Next GTR jobs involve wiring...such as Dash 2, injector loom and coil loom. If im honest, Im putting these jobs off as I HATE wiring but I suppose I should just bite the bullet, get it done and stop whining!! :chairshot

TT
 

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Discussion Starter #372
For those interested, I have started a new Cosworth YB build thread HERE...

No workings on the GTR planned for this weekend :mad:. Although I MAY get on and mould a composite housing for my Dash2 race dash. We'll see what happens...

TT
 

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Well, in mine they're VERY obviously fibreglass :D.

Are you talking about putting F/G door cards on std doors? The reason I ask is that my F/G door internal was flat and had a flange so the doorcard would sit flush. On a std door you would have to have a moulded section which followed the contours of the door innards, especially if you intended to use the std interior trim pieces such as door pull etc.

I would say this WOULDN'T be straightforward on a road car, especially if you were looking for a reasonable level of finish.

TT
I have one off dry carbon door cards which marry up to the original fixtures. Just wondering if they would match up to FG doors for added lightness!
 

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Discussion Starter #376
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matt moore!
yep Andy your name was mentioned, totally awesome car.

Built YB dry sumped.

over 400hub bhp running not a lot of boost.

needs some more time on the dyno.

lovely car I want one V6 powered thou I think.
 

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Discussion Starter #379
Is that a spaceframed MKII Mark?? Outer wings and arches look MKII but underbonnet e.g inner wings/bulkhead definately aint MKII....

TT
 
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MK 1 shape fully space framed double wishbone front suspension.

SHP Engineering | Concepts | RSR Escort
www.shpengineering.co.uk/rsr-escort. ...RSR Escort The SHP designed vehicle code name RSR Escort follows original Ford styling but has ...
 
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