Introduction and progress so far

[Eddy]

Hey guys,

Having been registered on the site for quite some time doing a lot of reading, I thought it was about time to introduce myself.

I'm Eddy, 25, I live in East Kent and I'm building a Sierra based Roadster.

I had spent a bit of time looking for the right donor – I wanted a CVH to be able to easily change to a zetec at a later date.

Last March I picked up this little beauty for £220 - it even had tax and MOT!

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/27032011031.jpg

I drove it just under 80 miles home and other than a bit of blue smoke on the over run, and some wheel wobble at 60+ mph it performed quite well.

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/DSCF1878.jpg

It sat on the driveway for a month or so whilst I read up on stripping the donor and arranged a few tools needed for the job.

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/DSCF1876.jpg

The bank holiday weekend came and I recruited a couple of mates to help with the job. We managed to turn it into a bare shell pretty quickly

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/DSCF1955.jpg

I’ve made an album on photobucket which has all the pics (limited to four on here) for the project so far for those that are interested:

http://s6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/

After completing the strip, I paid my helpers with a well earned BBQ and a couple of beers.

Arranged for the local scrappy to come and get rid of the shell – initially they wanted to charge £50 to take it away, due to it having no ID but managed to persuade them to make the 5 mile trip for free.

Managed to sell a few bits from the donor that I didn’t need to help pay for it – Easily made back the cost of the donor by putting a breaking advert on ebay, and still have a few bits left in the garage to sell.

The plan is to use the CVH on bike carbs to get through IVA and swap to zetec afterwards. I want to keep the initial build quite basic which will allow me to carry out upgrades in the future. I will be buying a pre-welded rolling chassis kit once I’ve got my chartership exams out of the way at work, so hopefully after that things will progress a bit quicker.

Spent a bit of time taking the CVH apart - Given the bargain price of a HG kit and bolts, and that the engine would be easy to work on whilst on the engine stand, I took the head off to investigate. I found the combustion chambers and piston crowns to be pretty coked up, and the HG not to be too far from failing. I cleaned up the piston crowns with oven cleaner and have soaked the valves in gunk. Hopefully it should be alright with new gaskets / oil seals, oil / oil filter, and cam belt.

I had heard that the 1600 head can be used, so picked one up locally for £20. I’m not sure how true it is as there doesn’t seem to be a massive amount of information available other than a bit on the fiesta forums about people using the 1800 bottom end on their xr2s. It looks like it might lead to problems with the compression ratio given that the combustion chamber on the fiesta head is huge compared to the sierra one. Might need different pistons or skimming. If anyone has any info on this it would be greatly appreciated.

Since stripping the donor I have managed to collect a few parts - I managed to get a set of ZX6R carbs complete with airbox for £23 delivered, an exhaust manifold for £50 delivered and a set of escort gti wheels and tyres for £80.
Other than that I have cleaned and painted the gearbox, and had a go at setting up an electrolysis bath to de-rust the parts that need it, which seemed to work pretty well.

Slow progress I know, but I’m in no real rush. Although a track day a Castle Combe the other weekend has made me want to get it finished!

[K4KEV]

welcome to the forum Eddy....it looks like you are already well on your way, I think the main thing is to enjoy every aspect of the build and don't be afraid to ask questions on here, do search's as well and lots of pictures ...all on here love em, so good luck and keep stuck in;) .

[will_08]

You've made a good start there mate, keep it up:cool:

Will

[shh120m]

youve definatly got your priorities right with the green box of tools in the corner:p

[Johno]

Hiya,
Good luck with the build and keep us informed with loads of piccy's and post's...:cool:

Johno

[HandyAndy]

Hi,
As others have said, best wishes for your build, looks like you have made a great start, keep the build pics coming :)

cheers
andy

[Eddy]

Hey guys,

I've not posted for quite a while, but have been steadily collecting parts in the background. Today's part deserved a post though:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121106_201709.jpg

I took Phil @ Talon up on his xmas package offer and he was kind enough to deliver it in person. Top bloke - Could've spent hours chatting, but he wanted to get home for some grub!

Hopefully the build can gather some momentum now

[ayjay]

Top job --Well done .:)

Not sure about the bike carbs though.It could complicate things pre IVA. I got some with the same intention but stuck with the pierburg for now --it gets it running for now and I can fiddle about after IVA:)

[Eddy]

Its a bit late for that - I sold the pierburg!

[mark]

Its a bit late for that - I sold the pierburg!

Its dead easy anyway, i did the same using megajolt ignition

It sailed through iva with the carbs left untouched from the bike

It was running lean though up in the revs but idle was spot on, I could'nt drive it about pre iva so didnt bother re-jetting until afterwards, then 170 jets seemed about right on the rollers

Mind you depending on what you want from the car the cvh probably wont be there for long anyway! mine lasted one summer before replacing it for more grunt

[Eddy]

I know who to come to when I need advice then Mark!

[Eddy]

Spent a few hours yesterday getting a coat of etch primer on the bare steel:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121112_091758.jpg

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121111_192949.jpg

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121111_193043.jpg

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121111_193031.jpg

I used Tractol 729 industrial etch primer in grey - It went on quite well by brush and dried very quickly despite the ~10 degree temperature.

Have a few bits to touch up that I missed, but reasonably happy with it as a layer to stop the thing rusting.

[AshG]

Where in Kent are you eddy? I'm over in rochester and there is a really good local club called southern kitcar club (skcc). If you need a hand with anything let me know. My roadster has been on the road for a few years now so I have ironed out most of the floors

[K4KEV]

must be a helluva iron Ash:D :D

[flyerncle]

Industrial me thinks.... My floor is 1.6mm thick.:)

[Eddy]

Where in Kent are you eddy? I'm over in rochester and there is a really good local club called southern kitcar club (skcc). If you need a hand with anything let me know. My roadster has been on the road for a few years now so I have ironed out most of the floors

I based in Birchington, near Margate. I work just down the a228 from you in West Malling though.

I'll check out the SKCC website, thanks.

Thanks for the offer of help - Much appreciated

[AshG]

Ben Copeland is down in margate also.

[twinturbo]

I spent a year in Rochester, Lived on Kings Avenu...

Sat on the castle lawn for my 21st....

[Eddy]

Few bits arrived from Phil during the week - He is sending bits through as they're ready:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121114_192305.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20121114_192305.jpg.html)

Got a coat of anti rust primer on the drums:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121116_195449.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20121116_195449.jpg.html)

Followed by the first top coat:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121117_085108.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20121117_085108.jpg.html)

Then I started looking at the manifold I need to make for the bike carbs:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20121117_102955.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20121117_102955.jpg.html)

Not sure if I should re-space the carbs or just go with tubes at an angle - Any opinions?

The tubes in the pic are from some scrap I had lying around - They match the ID of the carb outlet perfectly, but are thin so there is a bit of a gap between the silicone tube. Will this be ok (or even helpful in getting the angles to work) or do I need some thicker tube?

Cheers

[Eddy]

Been doing a bit more painting:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130106_122825.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130106_122825.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG-20130107-WA0000.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG-20130107-WA0000.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130106_122900.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130106_122900.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130106_122837.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130106_122837.jpg.html)

[Eddy]

Managed to get a bit of assembly done today, enough to get the back end rolling and the chassis out of the garage to allow for a well needed clean up.

Pics:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130323_160322.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130323_160322.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130323_155614.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130323_155614.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130323_155600.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130323_155600.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130323_155513.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130323_155513.jpg.html)

[rpjg1975]

Coming along well. Are they mondeo/escort gti wheels? I have a set of them on my focus but will probably be going on my roadster :D

[K4KEV]

yep thats damn good progress.....I'm nearly 3 yrs in and have never had it on wheels so well done that man

[Eddy]

Yeah, the wheels are escort gti 15s. I've seen them on a locost before and think they suit quite well

[will_08]

Well done Eddy, i'm hoping to be at this stage in the next week or so with some luck!

[rpjg1975]

Definitely work well. Mine are 16's so should fill arches pretty well :D

[mark]

Your front upper wishbones look upside down I think (can't see them that clear though so could be wrong), i did the same when I first rolled it out of the garage! Nice feeling isn't it :)

[Eddy]

You may well be right Mark, I chucked them on in a rush because I needed the shelf space!

[robo]

Not meaning to piss on your fireworks eddy but there is still a fair bit of fabbing to do and putting all the running gear on at this stage is going to make hard work of welding up all the missing bits unless you are handy at positional welding.

Just thoughts

Bob

[Eddy]

Not meaning to piss on your fireworks eddy but there is still a fair bit of fabbing to do and putting all the running gear on at this stage is going to make hard work of welding up all the missing bits unless you are handy at positional welding.

Just thoughts

Bob

I appreciate the comment Bob, and its something I put a bit of thought into before starting to assemble the running gear.

The garage I'm working in doesn't have a lot of space, so being able to wheel the car out will give me more space to work with.

The next things I want to get sorted are engine/gearbox location and steering column, which I can do with it on wheels.

The chassis will need to be stripped bare for top coat at some point anyway, so I will be able to manouvre it into positions to weld up anything I can't manage whilst its on wheels.

Assembling the running gear this early has also meant I can identify any problems with the chassis as soon as possible, rather than once I've added all the little bits - I posted recently about my rack not fitting and it turns out the mounts aren't wide enough apart, something that may have gone unnoticed for quite a while if I were doing things differently.

I don't think anyone's build will be in exactly the same order, this way just seemed to suit me best.

[Eddy]

Afternoon all,

I managed to get a bit of time to spend on the car this weekend. I got the steering column support frame in place, as well as CP16 and the uprated bearing. I've bolted the bearing straight to CP16 and the column feels rock solid. I also got the front assembled with dummy shocks to help me move it around.

I then turned my efforts to the engine, and sorted out the mounts. I have them in the zetec positions on the cvh because I plan to swap it over post test. This also means I can use the manifold I have that would occupy the same space as the usual cvh mount.

Few pics:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130713_170045.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130713_170045.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130713_122401.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130713_122401.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130713_174126.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130713_174126.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130713_174619.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130713_174619.jpg.html)

[Eddy]

Dropped the engine in today to mark up where the engine mount plates and gearbox mount plates need to go:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130721_115125.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130721_115125.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130721_120247.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130721_120247.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20130721_115822.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20130721_115822.jpg.html)

What distance should I leave between the gearstick and the chassis? I'll be modifying the chassis top rail that contacts the fwd cvh thermostat

[Oscar]

Very nice, looks like you're a little ahead of me. Might be watching this thread a little more closely ;)

[Eddy]

Thanks Oscar, I'm sure you'll overtake me - I live 50 miles away from my build!

[TheArf]

Looking well tidy there.

Arfon

[Eddy]

Just an update with a bit of progress.

Having got the chassis rolling and trial fitted the engine/’box to get their positioning sorted, I’ve stripped it all back down (surprising how quickly it can be done!) and finished off most of the welding.

In particular, before top coat, I’d like your thoughts on the adjusted top rail (for the thermostat), and adjusted passenger side engine bay diagonal (for the westy exhaust). Will they be ok, or is there something else I should do?

The bits I still need to do:

Seat support rails (now that I have seats and runners!)
Brake tabs
Rad mounts
Roll bar rear stay mounts

Is there anything I should add in addition to these?

Some pics (sorry about the quality, used my mobile):

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20131130_142007.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20131130_142007.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20131130_142015.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20131130_142015.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20131130_142021.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20131130_142021.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20131130_142034.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20131130_142034.jpg.html)


Cheers

Eddy

[SeriesLandy]

Hi Eddy. I've ended up taking the paint back off in quite a few places to stick some more metal to the chassis. Vin number is something you will have to weld in. Can't think of anymore at the mo.

[voucht]

Hi Eddy,
I think you should weld caps on the ends of the few tubes which are open like FF1, FF4, and there are a few others on the chassis (total of 12 iirw). Otherwise moist can enter the tubes which will be likely to get rusty from the inside.

There is a quite easy way to do it using small pieces of 19/20mm square section tubes you used for the transmission tunnel.

http://farm4.staticflickr.com/3745/11195705296_ea6a85b0cc_z.jpg (http://www.flickr.com/photos/99498333@N06/11195705296/)
IMG_2140_1 (http://www.flickr.com/photos/99498333@N06/11195705296/) par Voucht71 (http://www.flickr.com/people/99498333@N06/), sur Flickr

Even though I haven't use this technique myself on my chassis, I have tried it and it is soooo easy (I got it from a member on this forum, but after I did mine with small square plates I had to cut one by one... I actually regretted I hadn't discovered this good idea myself or known it before :( ),

I've made a thread on my blog about that, perhaps it can give you some inspiration...
http://vouchtroadster.blogspot.se/2012/05/boucher-les-tubes-tube-end-caps.html

Good luck :)

Very nice looking chassis BTW, very tidy :cool:

[Eddy]

Steve - I hadn't thought about that at all, I'd better get a letter off to the DVLA!

Sylvain - I was planning to use waxoil and plastic end caps, but welding them seems like a much more robust solution. I've got some tube left so its free too!

Thanks guys

[flyerncle]

You would be surprised how little rust there will be on the inside of the chassis tubes even after a good few years as I found out after making my chassis 35mm overall too long :rolleyes:

[ayjay]

Dont forget to weld some tabs around the chassis to create earthing points;)

[Eddy]

Managed to make a bit of progress this long weekend.

Finished all the welding (capping off open ends, rad mounts, Roll bar stay mounts, brake tabs etc) and painted with etch primer on the bare metal, followed by undercoat. Whilst that was drying I cut out the floor panel from a template I had made. Here it is offered up to the primered chassis:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/FB_IMG_13979003780819377.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/FB_IMG_13979003780819377.jpg.html)


Then I applied the top coat, waited for that to dry and started fitting the floor - 164 4mm holes drilled, floor removed, sikaflex applied, floor replaced and rivets installed:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140420_105529.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140420_105529.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140420_115142.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140420_115142.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140420_121804.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140420_121804.jpg.html)

[Eddy]

Then I spent today reassembling up to a rolling chassis:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140421_095940.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140421_095940.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140421_114752.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140421_114752.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140421_114807.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140421_114807.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140421_114820.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140421_114820.jpg.html)

Thanks to everyone on here and LCB who provided info about capping ends, which jigsaw blades to buy for cutting ali, advising buying a lazy riveter etc - All this information made the jobs this weekend as easy as possible

[voucht]

Looks very nice and tidy Eddy, congrats! Looks like you're on the right track :)

[Eddy]

I’ve been making a bit more progress lately.

Got a set of brake lines with (a lot of!) help from Sylvain – Excellent service and thoroughly helpful chap. The brake lines, despite seeing some very positive reviews on here, exceeded my highest expectations. Everyone that has seen them has commented how nice they are. I’ll get some decent pics when they are fully fixed in place.

I finally made a start on fixing them in the transmission tunnel along with the fuel line at the weekend:

Put it on its side to get access around the diff area to run the fuel line.

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20140622_120816.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20140622_120816.jpg.html)

Clipped to ali strip in the tunnel

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20140622_145155.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20140622_145155.jpg.html)

Then a diagonal towards the rear to run the fuel line around the bottom rails to the corner of the rear tub where the pump and filter will go

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20140622_145200.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20140622_145200.jpg.html)

I’ve got plenty more p-clips to add, but its a start!

Also, bought AshG’s old bodywork/tank/dash etc off him, so its really starting to look like a car now:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/IMG_20140504_145707.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/IMG_20140504_145707.jpg.html)

None of it is fixed in place yet, but it makes me smile when I open the garage door!

Next up will be side panels, I think. Or maybe loom.

[Enoch]

That's all looking rather splendid, keep up the good work.

[AshG]

looking good. nice to see the bodywork on are you going to keep it black or paint it another colour?

[Eddy]

Whilst building, I'm going to keep it black - The garage is pretty small and it is constantly getting knocked/moved around. Its nice to not have to worry too much about damaging it, like I would with new fibreglass (or if I painted or wrapped it now).

When its finished I will look at options for paint or vinyl wrap. I'm quite liking colours similar to Porche's riviera blue at the moment, like this:

http://2.bp.blogspot.com/-aB6duV_lngY/Uy8enP3OxRI/AAAAAAAAA34/RDLLnbaJdXI/s3200/_DSC1647.jpg

But I do change my mind a lot!

[alga]

In my experience the abuse the bodywork got during the build is nothing compared to what it gets during normal driving!

[Eddy]

Hello all,

I haven’t updated for a little while, but have been steadily making progress in the background.

Since my last post I have:

Made the side panels
Made the rear panel
P-Clipped the front brake lines
Put the engine back together after having the head skimmed with new gaskets and a shortened sump
Finished off a few bits of welding – Added dowels to the column extension, a couple of bits on the peddle box, and made the inlet manifold
Mounted the radiator/fan and most of the plumbing

When I got to this point, I couldn’t resist the urge to bodge a few wires on, chuck in some fuel and see what happened when I turned the key.
Aside from being a bit of a child and wanting to hear my toy make some noise, it was quite important for me to give this a go – The engine hadn’t been started for 3 years and 5 months and it had been apart for 3 of those. It was also now using bike carbs with a bike fuel pump and running EDIS/Megajolt for the spark, both of which were untested. I really just want to know if it was all OK before going any further with the CVH lump.

So....

I wired up the crank sensor, coil pack and EDIS (I am waiting on a TPS connector and usb to serial adapter for use with the MJ, so limp mode only for now). Took a lead out and used it with a spare plug to see if it was sparking – Nothing. Scratched head before realising I’d missed an earth off! With this attached there was spark.
Wired up the fuel pump. Gallon of fuel in the tank. Ignition on, fuel pump was initially loud, then quiet when it had primed the new lines. Turned the key only to have it turn over and backfire loudly. After this happened a few times, and following some more head scratching, I swapped the two wires to the coil pack over and turned the key. IT STARTED!!!

Obligatory video:

https://www.youtube.com/watch?v=EEb1-lLYD0I

Since the video I have fitted the side panels, made an under scuttle panel to mount the loom to, fitted the nosecone, and fitted the proper exhaust.
The next steps for me are going to fit the rest of the bodywork and roll bar, tidy/permanently fix the wiring, and get back to the position where it starts again. Then I’ll be on the hunt for some shocks, a prop and some rear lights!

As it sits now:
http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20141204_162924.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20141204_162924.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20141204_080058.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20141204_080058.jpg.html)

Cheers
Eddy

[Eddy]

Afternoon all,

Another long gap since my last update. I’ve continued to make progress:

Fitted the front wing stays
Drilled and tapped the front hubs/mushrooms for a second fixing point
Fitted the rear arches with p trim
Fitted a prop
P clipped rear brake lines
Heat wrapped the exhaust manifold
Installed the rear lights
Roughly cut out the dash and boot panels
Made the rear bulkhead panel
Made a panel for the front of the scuttle
Probably a few other things I've forgotten!

A couple of reasons for this update though…..

I picked up some black Team Dynamics alloys (used to belong to Ben on here, who sold them to Bob on locostbuilders, who I got them from) and had them fitted with some Toyo T1Rs. I was hoping they would be a bit lighter than the Escort alloys they were replacing…. Escort alloy with worn ‘Camac’ tyre 14.7kgs, Team Dynamics Monza with new T1R 16.1kgs. I was a little disappointed that they weigh a little more, but I guess they are 6.5J wide as opposed to 6J and a little bit of weight in the trye. I do think they suit the car a lot better though.

I wrapped the side panels and rear panel in gloss black vinyl. The rear panel didn’t go too well – It was the first thing I’d ever tried to wrap. I pulled all the backing off in one go before placing it, which made it a bit of a nightmare - I have ended up with a crease under the fog light and another that will be hidden by the rear arch, but I think it is good enough for now. I am very happy with the side panels though – They came out really well and were surprisingly easy to do. I stuck a bit of the vinyl on towards the back of the car and left the backing on the rest, and once I adjusted the angle so I was happy that it was lined up all the way to the front of the car, I pulled the backing back on itself and the vinyl stuck to the aluminium as I went. After that it was just a case of smoothing out any bubbles with a felt edged bit of plastic before cutting and folding over the edges. It may have been easier with better quality vinyl and if my heat gun didn’t decide to set fire to itself at the start of the day, but for a total cost of £40, I’m chuffed with the results.

These are the pics I took as I was going, and one with the car reassembled, I’ll get some better ones when I can roll it out of the garage:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20151128_135907.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20151128_135907.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20151128_114909.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20151128_114909.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20151128_123727.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20151128_123727.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20151128_144838.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20151128_144838.jpg.html)


Next up, I’ll be making the transmission tunnel panels, finishing the roll bar, securing the tank and properly wiring everything up ready to start AND move under its own power.

[SteveH1]

Japers that looks good fair play
I also like the wheels.

[Eddy]

Getting some time to work on the car at the moment.
I have changed the main jets in the ZX6R carbs to 160s, checked the needle height and the circlip is sitting in the middle slot of 5, and adjusted the air/fuel screws to 2.5 turns out. Megajolt is connected up running a map I found online for a 1.8 cvh and bike carbs and the TPS has been calibrated.
It seems to start pretty well, especially when using the choke, but it boggs down a bit if you open the throttle quickly. It does get there if you open it slowly though. From reading some bike forums, this could be dirty idle jets - Anyone got any other ideas?

I did fill the cooling system, but had a load of leaks. I have bought a few new gaskets and blanked off a couple of take offs I no longer need, so hopefully I can have that sorted and get it running up to temperature to see if it is any better then.

In the mean time, a video:

https://youtu.be/J8b4KOHnzss

[Eddy]

Another few months since my last update.

I have made some more progress:

Brake system filled with fluid (and inevitable leaks fixed!)
Short shift fitted
Bracket made for acewell speed sensor (magnet still needs to be fixed to prop)
Made a bracket for the bottom of the radiator and underside of nosecone
Fitted some 25mm hubcentric spacers/extended studs to the rear
Fitted some shocks purchased from Matt (rapidtornado)

Some pics as it stands now:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20160827_182959.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20160827_182959.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20160827_182642.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20160827_182642.jpg.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/Screenshot_20160827-184008.png (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/Screenshot_20160827-184008.png.html)

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/20160827_182811.jpg (http://s6.photobucket.com/user/eddycorsa/media/Donor%20Car/20160827_182811.jpg.html)

[flyerncle]

Try dropping the needles a notch/raising the needles a notch and dirty/blocked idle jets will give you no progression on to the main jet.

Nice car

[Eddy]

I can't believe it has been 4 years since my last update. I had been living and working a long way away from the build, but finally managed to buy a house with a garage (albeit very narrow!).

Following the widening of the garage door opening to its maximum to allow the car to fit in, I had the car transported up:

https://lh3.googleusercontent.com/meiGf-Gj78EithXUM4e5sYeUlQKrhaLJ9Gz8CX2Ke8DEXW7M0T4gjp2S BsQyNSGazffZ3c0R0yZAR-2DHhSmjTHr5DkKAGBnVj6O84wA1yaqSs-CdcnOB8POorScgXxvruhnvvDIUAc

https://lh3.googleusercontent.com/wHpFNHeed6A9dhwkT_unC4XIGh-DG-liuO7eHGz0bx2XkpRVLeJbJ1IxhNMYDZEldj-ccriza-rgHuoyP2aokqVqRrbiQAYu5hsVJfk-Q5BU88UMtQNCBK83klaM5cjvhzMFO7SZJtI

https://lh3.googleusercontent.com/EM2Rqtd6UF0bQmwuIVJC9FKL1Bd-ObSHAkZxD5URX1y7EzTE14Un-KjfLrypBvQLWbKQLjwcbK-GlZSmDWdG9ulMHjPG-Da_GFTlDuACUwRXz9pQfX6bBVJYrsSZPB2yLOUZJY7w-mk


I have also written a 'to do' list to get the car finished as follows:

Roll Bar
Finish rear stays
Finish holes in roll bar
Drain and vent/remove fuel tank
Bolt roll bar to chassis – open up holes where needed
Tack weld rear stays in place and check bolt locations/aesthetics
Fully weld back stays
Use die grinder set to smooth all welds, then sand flush
Flapwheel/Acetone prep
Etch primer
Black Paint

Dash
T nut bolts through dash panel and fill any holes
Fit acewell and fog light switch aluminium panel with the right sized hole glued to dash panel
Router/rasp/sand edges
Seal with paint or varnish
Cover
Install

Alternator
Bolt on pulley to alternator
Measure belt size and buy

Electrics
Sort out fast indicator flashing – LED relay or higher wattage bulbs
Rivet ali to frame and rivet cable tie mounts to ali
Cable tie electrics to mounts
Tidy electrics under scuttle
Create Earth points where required
Check reverse light switch and wire up handbrake switch
Redo fuse/relay panel – Maybe relay blanks in between the relays to spread them out for mounting
Work out horn with IVA steering wheel
Fuel gauge wiring should be checked
Check orientation of speed sensor
Araldite magnet to prop and cable tie
Wire in wideband lambda sensor
Properly route and shorten crank sensor
Shorten alternator cable
Wrap everything in conduit and loom tape

Interior/Panelling
Make panel for passenger foot well
Finish Riveting panel behind seats to chassis with tiger seal, and tiger seal any exposed bits near diff
Fit transmission tunnel top and sides with gear and handbrake gaiters
Rivnut transmission tunnel sides
Make panel over pedal box, rivnut on to allow access
Work on panel under megajolt
Make engine side panel for scuttle fit nicely over fuses and relays/cabling/steering column
Remove Steering Wheel and fit Ford one
Fit battery tray
Rear tub tray – Make cut outs for roll bar, round edges with sander, make fixing points with countersunk screws and t nuts, seal with varnish/paint, cover
Tether fuel cap
Fit edge trim to seat belt holes

Running
Put battery on charge
Clean out carb jets – Soak in carb cleaner overnight
Install alternator belt
Drain water, rinse through and replace with new
Drain old fuel and dispose
Get new fuel in Jerry can
Top up oil
Get megajolt working on laptop
Check TPS and map on megajolt
Wire up choke to bonnet release
Get it started, idling and up to temperature
Check for leaks and fix them
Check thermostat works
Check fan works
Balance carbs with syncronometer
Adjust needle height if necessary
Test charge from alternator
Fix fuel pump and drain out old fuel, leave lid off to vent tank
Fill gearbox and diff with oil (Gearbox oil - 75/90 semi synthetic GL4, Diff oil - GL5 "Hypoid" Gear Oil Ep75/90)

Mechanical
Fit lock nuts on diff mounts
Try and fit coil pack bracket or make new one
Add brace bar to engine bay and weld vin number on
Check brakes are working and bleed again if needed
Loctite on rear upright to hub bolts – Take a photo for the IVA man
Lock nuts on maxi ball joint etc
Adjust holes on alternator mount to clear inlet manifold and sit straight
Make further bit of alternator mount bracket and buy and install a belt
Bolt on front wings
Finish mounting rear arches with p trim and silicone, cut mounting bolts off with dremel
Fix seats in place
Make boot lid and cover
Bolt in place and fit lock nuts on pedal box
Drill hole in floor for brake pedal stop and install
Cut out and fix panel over pedal box and passenger footwell panels
Install battery tray and lock battery down
Pull through extended wheel bolts further
Second fixing point drill and tap on front left
Lock nuts to ball joints on front suspension (check thread on maxi ball joint with thread gauge)
Swap to lock nuts on all suspension including camber adjuster and rack extensions
Add Lock nuts to bottom of engine mounts
Adjust geometry and set ride height - Front: 5.5° caster, -2° camber, ~1° toe in. 110-120 mm ride height. Rear: 0 caster, -0.5° camber, 0 toe, 120-130 mm ride.
Have prop shaft balanced/tested


Plenty to be getting on with, but hopefully having the car at home will make it easier to get the little bits done when I get a spare hour here and there.

Cheers

Eddy

[twinturbo]

Looks like the garage was just about wide enough for an Austin 7, which used to be the minimum standard long after they had passed away.

[Tatey]

The car is looking good, it is always nice to move the car into a new home so you can actually work on it!

My car has now been in 5 different homes and moved 6 times...

I have seen people use wheel dollies when space in the garage is a bit tight as it allows them to push the car right against the wall to give some space to work around it:

https://www.sgs-engineering.com/wd4000-450kg-wheel-dollies-set-of-four?gclid=CjwKCAjwzvX7BRAeEiwAsXExo41JVRszyLcTnfK c0zCrcwhDGgzTy48KXPm80U0VjYR-EQYjH2FUahoCPhcQAvD_BwE

[jps]

A good list! I've got a similarly long list, and I think it's good to
a) work through ticking things off so you can see you're making progress
and
b) plan so you're not endlessly duplicating - at least any more than you do..!
I have seen people use wheel dollies when space in the garage is a bit tight as it allows them to push the car right against the wall to give some space to work around it:


When I just had a bare chassis I had a rectangular frame of scrap 1mm 20*60 box with some castors on. I put a wooden pallet over the top, then the chassis on top of that - for exactly the purpose you describe. It helped a lot.

With the engine, box and diff now in I suspect it would struggle with the weight - but it's certainly a bit of a pain to push it in and out sometimes!

[twinturbo]

mine has a little 4 wheel trolley under the rear. I have more room but it makes moving it much easier.