Build Calendar
|
Date |
Event |
|
27 July 1997 |
Coy's
International Historic Festival -
Silverstone. The idea of building a kit car is first muted. |
|
7 Feb 1998 |
Visit
the factory, for the first time, for a test drive. Usual factory tour. Drove
the "Maroon Monster" (1800 SEiW).
We were not disappointed and virtually sold on the project. The problem was how much and when? |
|
06 Mar 1998 |
Westfield
Kit Build Manual received - We can study some of the details and form a
strategy. This was the first of several manuals until we got the right one. |
|
26 July 1998 |
Coy's
International Historic Festival -
Silverstone. We had talked about it,
off an on for a year. We have test
driven one. The decision to do it is made. The project is born. |
|
12 Dec 1998 |
Visit
the factory for another test drive and order the kit |
|
16 Jan 1999 |
Collected
the chassis and body starter kit from Kingswinford. Collect rear drive
assembly from Sierra 4x4 and Escort Mk IV discs from Dave Stanley at
Honeybourne |
|
17 Jan 1999 |
Chassis
on stands, body suspended from the roof of the garage. Started stripping the
Sierra 4x4 diff, drive shafts And brake callipers Wire brushes working
overtime cleaning up components from the Sierra. Removed and stripped lobro
joints |
|
24 Jan 1999 |
Most
of the discussion this week was around reconditioning the callipers from the
Sierra. We eventually agreed to buy Recon ones from our local garage on
safety grounds and cosmetic appearance. Diff Steam cleaned. Painting - diff. And aluminium panels on
the chassis with special primer and Satin Black Hammerite a pretty good
colour match to powder coating of the chassis. |
|
31 Jan 1999 |
Cleaned
and painted (gold) rear brake pad holders.
Obtained brake new pads, new boots (lobro joint covers) new hub nuts
etc. continued painting |
|
7 Feb 1999 |
Slapped
under seal on to underside of the floor panels |
|
14 Feb 1999 |
We've
been talking to the Factory about running the brake and fuel pipes down the tunnel
rather than straight under the floor as Westfield recommend. Fitted the first
components to the chassis (brake master cylinder and pedals) |
|
21 Feb 1999 |
Started
to assemble the rear suspension.
Fitting suspension bushes to wishbones was a struggle. A combination
of Penny washers, long bolts and brute strength. |
|
28 Feb 1999 |
Continued
fitting the bushes this week including diff mounts. We have chrome front
suspension, with bushes already fitted, except the RH lower wishbone didn't. Returned
it to the Factory for replacement |
|
7 Mar 1999 |
Fitted
steering rack and assembled front suspension. Discovered that both Chrome Upper
wishbones have a dent on the inside. Checked with Chris Masters. As we thought
Dents have been caused during fitting of the bushes. (Factory fitted in
chrome parts) send them back |
|
14 Mar 1999 |
Finished
fitting the front suspension |
|
21 Mar 1999 |
Removed
the diff to fit brake pipe down the tunnel.
Easier than we thought. Working with a piece of fence wire as a
template helped. Worked out all the bends and "P clip" fixing
points for rear brakes |
|
4 April 1999 |
We
obtained a length of fuel pipe and P clips from Unimaster and set about
bending and routing it down the tunnel. |
|
18 April 1999 |
Fitted
the rear brake callipers |
|
1 May 1999 |
Collected
prop shaft, wiring loom, fuel pump, fuel regulator & quick gearshift from
Factory. Went to Sierra Land, SE London,
to get MT 75 gearbox. Started cleaning up gearbox |
|
7 May 1999 |
Contacted
First Choice parts finder via the Internet for an engine. Borough came back with an ex Mondeo Zetec
2.0 l, 1000 miles, £650 + VAT. |
|
9 May 1999 |
Torque
tightened Lobro Joints, Laid out and fitted wiring loom |
|
11 May 1999 |
Engine
delivered. Carried out Survey all looks good except there is a hole in the
sump and no starter motor. |
|
13 May 1999 |
Replacement
sump and starter motor arrived. |
|
14 May 1999 |
Collected
Long range tank gearbox and engine mounts from Westfield. Talked to Chris
masters about blanking plates for gearbox. Realised our Zetec Engine was an
automatic! Stripped engine of alternator, air conditioning and power steering
pumps. |
|
15 May 1999 |
Checked
feasibility of automatic to manual conversion looks OK. Completed fitting of wiring loom down the
tunnel. Found badly crimped earth wire in rear of loom. |
|
20 May 1999 |
Flywheel
arrived (free of charge) Supposed to be 2.0 ltr but looks like 1.8. Checked
with Chris Masters we can use if we change the clutch kit. This is what we
will do. Got
0.3 mm skimmed off the flywheel to remove score marks. |
|
21 May 1999 |
Flywheel
fits but we will have to change the flywheel position sensor |
|
29 May 1999 |
Removed
flywheel replaced sensor housing |
|
12 Jun 1999 |
Mounted
Engine on Engine stand, removed sump, removed oil pick up pipe. Replaced sump
for protection, whilst we have the sump and oil pick up pipe modified. Painted long range tank and tank straps |
|
23 Jun 1999 |
Delivered
sump and pick up pipe for modification to Westfield |
|
5 Aug 1999 |
Collected
modified sump and alternator mounting kit. |
|
8 Aug 1999 |
Fitted
oil pick up pipe and new sump. The sump had to be modified slightly with a
file to get the oil pick up pipe past the baffles and fitted. |
|
20 Aug 1999 |
Delivered
the gearbox to Road & Race for refurbishing. |
|
26 Aug 1999 |
Collected
refurbished gearbox. A couple of synchromesh rings and a new sleeve. All that
was required. |
|
29 Aug 1999 |
Fitted
fuel pump, long-range tank and flexible fuel pipes. |
|
1 Sep 1999 |
Ordered
Monza wheels and Yokohama 205/50 x 15 tyres from Micheldever. We had to change to DTM wheels since chrome
Monza wheels will be at least 3 months. Any way we have decided we like DTM
wheels better. |
|
21 Sep 1999 |
First
chance to work on the car for weeks.
Fitted alternator. Removed engine from engine stand. Fitted flywheel
and clutch. Trial fit gearbox to check thrust bearing free play, which is
excessive. We need to get Westfield modified bearing |
|
23 Sep 1999 |
Collected
Wheels from Micheldever. Fitted them to car to check clearances. Had to
shorten rear wheel studs by 1 cm. |
|
26 Sep 1999 |
Fitted
modified clutch release bearing. Fitted Sierra sandwich plate, fitted gearbox
to engine. Made blanking plate to cover where Mondeo starter motor should be.
Fitted starter motor |
|
2 Oct 1999 |
Lowered
car down from chassis stands to axle stands fitted prop shaft |
|
3 Oct 1999 |
Installed
Engine and gearbox in to chassis |
|
4 Oct 1999 |
Torque
tightened Engine / Gearbox mounts and prop shaft, connected alternator and
starter motor. |
|
10 Oct 1999 |
Filled
gearbox and engine with oil. Carried out initial bleeding of brakes. Set
about polishing the exhaust system and temporarily fitted it to the car |
|
13 Oct 1999 |
Ordered
radiator and cooling hose kit from Westfield. |
|
12 Oct 1999 |
Picked
up Webcon Performance kit from Swindon Racing Engines. Alpha ignition
management system, inlet manifold and a pair of DCOE 45 carburettors |
|
17 Oct 1999 |
Fitted
inlet manifold, Carburettors and throttle mechanisms. Fitted accelerator cable.
Started to fit radiator |
|
24 Oct 1999 |
Fitted
radiator, fan and cooling system hose. Not exactly straight forward. |
|
30 Oct 1999 |
Discussion
this week centred on ECU and cooling pipe mountings. |
|
22 Nov 1999 |
Serious
retail therapy picked up most of the components for module 5, and those from
module 6 to get engine running. Ordered seats. Bought interior panels and
dashboard (ex demonstrator). Went to
Merlin, Castle Combed to get speedo transducer. |
|
23 Nov 1999 |
Set
suspension springs half way in preparation for lowering the car to the
ground. Trial
fitted the speedo transducer, made adapter to dispense with cable drive and
connect straight to gearbox. |
|
26 Nov 1999 |
Made
ECU mount. Hinged to top of passenger foot well for fixing to the dashboard
hoop. So that we can get access to it, if needed. |
|
28 Nov 1999 |
Got
the engine ready for running. Made a temporary dashboard out of cardboard. Bridged
the heater hoses. Made temporary mounts for header tank and fuel regulator.
Lowered the car to the ground. Torque tightened rear drive hubs. Adjusted the
handbrake. |
|
5 Dec 1999 |
Started
the engine. Engine runs but no tacho output. Gearbox oil leak. |
|
7 Dec 1999 |
Collected
Seats Windscreen pillars and catch tank. Fixed the tacho output problem. |
|
12 Dec 1999 |
Fixed
gearbox oil leak. Engine testing to initially set carburettors. |
|
2 Jan 2000 |
Engine
testing - During the test the engine stalled with flat battery. Alternator
not charging |
|
4 Jan 2000 |
Fault
diagnosis on alternator. Alternator body is not grounded, insulated by rubber
bushes on the lower mount and by powder coating on the adjustment arm.
Cleaned powder coating off at contact points to get good earth contact.
Alternator now works. |
|
5 Jan 2000 |
Fitted
speedo Transducer to gearbox for testing. Began redesign work on Catch tank |
|
6 Jan 2000 |
Speedo
testing. Though there is output from the transducer, speedo does not read. Talked
to Merlin who supplied transducer advised to talk to VDO, which we were going
to do anyway, but it was too late to do it today. |
|
7 Jan 2000 |
Called
Westfield and VDO got the information for connecting up the speedo transducer |
|
8 Jan 2000 |
Connected
speedo and transducer, the VDO way, for hall effect transducers - Bingo, it
works and as far as we can tell accurately. Started major surgery on the catch
tank to get the best fit |
|
9 Jan 2000 |
Engine
testing completed - Carbs are balanced and exhaust emissions are well within
tolerance. Completed trial fitting of
catch tank. Tank and brackets painted, ready for installation. |
|
15 Jan 2000 |
Fitted
catch tank and windscreen washer bracket. Redressed handbrake cable for a
neater and safer installation. |
|
16 Jan 2000 |
1st
Anniversary - fitted air horns. Stripped exhaust and all temporary fitted
components to prepare for fitting the body |
|
22 Jan 2000 |
Retrieved
Body from the roof of the garage. Fitted rear wheel arches. Trial fit to
chassis. Trial fit scuttle to determine steering wheel cut out |
|
23 Jan 2000 |
Cut
out steering wheel aperture. Positioned scuttle to determine where rivnuts need
to be mounted on the chassis. Removed scuttle and bodywork. Drilled and
mounted rivnuts. Replaced bodywork. |
|
29 Jan 2000 |
Front
filler panels painted Sating black to match chassis. Panels fitted and trimmed
with black plastic sleeping to protect bodywork from sharp edges of panel.
This operation took several attempts to get the best fit between the panels
and the bodywork |
|
05 Feb 2000 |
More
trimming of front filler panels to improve body fit. Trial fit of scuttle.
But we were not satisfied with the quality of fit on the LHS. The locating
blocks do not align very well. Long
Range boot box does not fit. |
|
06 Feb 2000 |
Various
different manuals give different measurements for body fitment. We tired different combinations but decided
to talk to Westfield to get the definitive measurements |
|
09 Feb 2000 |
Having
determined that the boot box was for the kit build body and not ZK body, we returned
it to Westfield. At the same time we exchanged our Chrome Roll over bar which
was scratched for a new one. |
|
12 Feb 2000 |
We
repositioned the bodywork according to dimensions given by Westfield. Modified LHS the locating socket in the
scuttle to improve the fit quality.
Modified the nose cone to equalise the aperture and clearances around
the front upper wishbone mounts. |
|
13 Feb 2000 |
Modified
bottom corner of the flanges on the radiator to give better clearance of the
nose cone. Modified the returns on the
bonnet to improve trial fit. Investigated the fitting of an auxiliary
instrument panel between the dash and the top of the tunnel |
|
19 Feb 2000 |
Fitted
rear, fog and reverse lights. |
|
20 Feb 2000 |
Crimped
rear lamp connectors and fitted plugs.
Re-checked the position of Roll over bar and drilled pilot holes. |
|
26Feb 2000 |
New
boot box arrived Thursday. It was the correct one for our body, except that
it was cracked and the Gelcote crazed. Fitted heat shrink sleeving to tail
light wiring to protect it. Fitted
roll over bar. Improved the fit of the
rear wheel arches |
|
27 Feb 2000 |
Fitted
“P” Clips to tidy up wiring of taillights.
Lifted the rear of the bodywork with a trolley jack, at the same time
as pushing forward to equalise rear wheel arch. |
|
28 Feb 2000 |
Returned
boot box again. Whilst at Westfield, picked up bonnet locks and dowels. Our
SVA testing station does not like over latches. Even if they are covered |
|
04 Mar 2000 |
Investigated
Pipercross filter to replace the JR filters and avoid cutting a hole in the
bonnet (not recommended for SVA). Riveted the bottom of the body to the
chassis |
|
05 Mar 2000 |
Re-aligned
body, bonnet and nose cone. Riveted body to upper rail of chassis. |
|
11 Mar 2000 |
Feels
like we are making significant progress on the body. Located and marked the Rivnut positions on
the bodywork and the scuttle. Mounted the scuttle. Aligned bonnet and Nose
cone drilled holes for locating dowels. |
|
12 Mar 2000 |
Continued
with nose cone and bonnet alignment. This is time consuming, as we are not
satisfied with the finished product. It is not bad but we feel it could be
better. |
|
13 Mar 2000 |
Collected
new boot box. Looks OK. Picked up SVA kit of rubber covers. |
|
16 Mar 2000 |
Measured,
cut and trimmed the new boot box around the roll over bar. Some trimming of
the RHS of the rear bodywork to get the boot box to fit centrally. Once in
place, the rear of the boot box is slightly bowed but weighted down with a
plank of wood and some tins of pint and we will see what happens when we come
to fit it permanently |
|
19 Mar 2000 |
Finally
got a satisfactory alignment of bonnet and nose cone. We needed to fit 2mm
shims under the nose cone to compensate for the body rivets under the bonnet |
|
23 Mar 2000 |
Fitted
bonnet locks. These are a new type and Westfield supplied templates to locate
them. |
|
25 Mar 2000 |
During
bonnet nose cone alignment we noticed that when the LHS of the bonnet was
aligned with scuttle and nose cone. The lower body panel was bowed. Removed
body rivets and realigned but could not get a satisfactory alignment until we
loosened the scuttle slightly. After that the alignment was perfect. Trial fitted the Windscreen |
|
26 Mar 2000 |
Odd
job day removed the nose cone to measure to gain access to the space frame so
that we could measure where the exhaust outlet was to be in the LHS body
panel Cleared
the powder coat from the spare wheel carrier nuts and bolts. The bolts will
be modified in to studs to fix the spare wheel for security. |
|
27 Mar 2000 |
Collected
the SVA compliant hub covers and Locking wheel nuts for the Spare wheel from Micheldever
Tyres. |
|
30 Mar 2000 |
Removed
the windscreen to cut the ventilation
/ demister slots |
|
01 Apr 2000 |
Cut
out the exhaust opening in the LHS body panel. Despite accurate measurements
as in the build manual the hole needed 10mm removing from the front to give
sufficient clearance for the exhaust pipe. |
|
08
Apr 2000 |
Took
another look at the windscreen fit. We are concerned about a 10 mm difference
between the heights of the hood studs from the Windscreen pillars, left to right.
Mounting the windscreen, equalizing the height of the studs produces a very
large gap under the windscreen on the LHS.
We decided to talk to Westfield Fitted
the lower bracket for the spare wheel carrier. |
|
09 Apr 2000 |
Chris
Masters at Westfield suspects that the Hood studs have been mounted on the
WRONG side of the windscreen. Suggests that we mount the Windscreen with the
studs on the inside to check. Sceptical as ever we do as we are told. The fit
is better but the studs are now on the inside. We will talk to Westfield about our
findings. |
|
11 Apr 2000 |
On
holiday in Madrid for 2 weeks. |
|
29 Apr 2000 |
Whilst
I was away Westfield confirmed the windscreen was incorrectly made and
supplied a new one. Fitted the windscreen filled the gap underneath with ¼”
high-density foam and silicon sealer. Difference in height is now only 1mm.
Left to cure. Fitted indicator side repeaters. |
|
01 May 2000 |
The
windscreen has cured and looks good.
Fitted the windscreen fillet and the wiper wheel boxes. After a lot of trial and error we achieved
and acceptable fit. Removed
the scuttle. Took the wiper wheel boxes off again and fitted the heater
ducting. Sealed with silicon sealer and left to cure. |
|
02
May 2000 |
Fitted
the windscreen wiper motor drive and wheel boxes |
|
03
May 2000 |
Fitted
heater to the scuttle using Westfield’s dimensions. Though the centres are
correct the heater is mounted too high and fouls a ridge in he scuttle
moulding |
|
04
May 2000 |
Investigated
alternative arrangements of the heater brackets but this moves the heater too
low. Decided to live with the holes drilled as they are and use spacers to
clear the ridge in the scuttle. Don’t like Westfield’s method of mounting the
heater pipes using the scuttle bulkhead. |
|
12 May 2000 |
Glued
heat shield material to the inside of the LHS body panel. |
|
13 May 2000 |
Fitted
exhaust manifold and system. Made a new plate for mounting the ECU above the
passenger foot well. This has two effects. It hinges down to gain access to
the ECU if required and prevents the SVA man with the 100 mm orb getting up
under the dash to complain about sharp edges. |
|
14 May 2000 |
Andrew
obtained a bulkhead plate from a Fiesta during the week. Using this, some
rubber grommets and pipe joiners from Halfords, we made a bulkhead connector
fro the heater pipes and drilled the scuttle accordingly |
|
15 May 2000 |
Started
to turn our attention the well-reported Zetec overcooling problem. How to
modifying the coolant pipes for the thermostat bypass to conform to Ford’s
Mondeo installation. |
16 May 2000 |
Fitted
heater bulkhead connector and pipe work |
17 May 2000 |
Fitted
interior panels Applied for SVA for 30th June at Bristol or
Leighton Buzzard |
18 May 2000 |
Trial
fit Scuttle and ECU mounting plate. Measured where LHS (Passenger) heater
duct will need to pass through the plate and cut an elongated hole so that the
plate will hinge up and down past the heater duct. |
20 May 2000 |
Positioned
ECU wiring and cut a hole fro the grommet in the scuttle. Positioned the Battery tray according to
Westfield’s measurements. (We were going to regret this). Drilled the scuttle
for the engine amplifiers and the washer tube and fitted these. Trial fitted
the header tank and coolant pipes only to find the pipes fouled the battery
tray. |
21 May 2000 |
It’s
obvious that the battery tray has got to be moved further outboard. After drilling out the rivets – silicon
sealer really sticks. I took ages and a lot of persuasion with a wallpaper
scraper to remove the battery tray and even longer to clean up the silicon
sealer. The battery tray was repositioned. The redundant holes filled and
sealed with silicon sealer again.
Ended the day with finally fitting and sealing the scuttle in
position. |
22 May 2000 |
Swansea
replied with the SVA follow up form requesting which parts we actually fitted
to the chassis. Returned the form now waiting for a data and a location |
22 May 2000 |
Made
a bracket for the fuel regulator so that it can be mounted on the scuttle.
However we are concerned with it’s position above the fuse boxes (Mr SVA will
go mad!!!) Attempted to refit the bonnet Now the scuttle is permanently in
place. The RHS locks fine but the LHS won’t lock for some reason. |
23 May 2000 |
It
looks like fixed part of the lock is wrongly positioned. To be sure we rechecked
the scuttle position and it is correct.
Spent a lot of time trying to understand why it fitted perfectly
before and does not now. |
24 May 2000 |
Made
brackets to secure the grill to the nose cone and bonded them in place |
27 May 2000 |
4
hours of toil and error we finally got the bonnet catch in to the right
position where it would lock and the bonnet was correctly aligned with the
scuttle and the body. Fitted the grill
to the nose cone. Refitted the battery clamp but first we had to fix the
rivnut setting tool we broke last week. |
28 May 2000 |
Made
a circular plate to fix the Westfield badge to the grill and riveted it in
place. Remounted the nose cone and adjusted the position of the nose for a
good even fit all round. Trimmed the profile of the radiator mounts to ensure
there was no interference and we centralise the nose cone. Tried to mount the cycle wings but the
brackets interfere with the front wheels.
We will need to talk to Westfield. Fitted the windscreen washer tube
to the bottle. Started work on fitting
the header tank. |
29 May 2000 |
Worked
on fitting the cover over the pedals.
Some filing and cutting was necessary to get a smooth fit. Protected
the lower steering column bracket with foam, glued in place. Covered the
chassis bar above the pedals with heating pipe insulation, cable tied in
place. (Both are SVA
requirements) Fitted the panel over
the pedals with Self-tapping screws.
Painted the panel satin black to match the chassis. |
31 May 2000 |
Panel
is now dry and fitted in place. Spoke to Westfield about the cycle wing
brackets. The advice is to bend them or fit 5 mm spacer and longer wheel
studs to the hub carrier. We didn’t
much like the prospect of bending the brackets so investigated fitting the
spacer and longer wheel studs. |
1 Jun 2000 |
Spoke
to Westfield again; Chris Masters says it is possible to change the studs
without removing or dismantling the hub.
Went to Merlin Motorsport and picked up 2 spacers and 8 studs. Removed
the old studs and fitted the new ones (slightly shortened) with the hubs
still fitted to the car. Fitted the spacers and refitted the wheels. Finally
mounted the cycle wing brackets all clearances are fine. Decided to glue the cycle wings to the
brackets. |
2 Jun 2000 |
SVA
test confirmed as 30th June at Leighton Buzzard. Made some spacers
out of MDF to same aerofoil cross section as indictor pods. Andrew
investigated modifying the cooling system to connect the thermostat bypass to
the bottom hose as Ford intended and not the top hose as Westfield do, to
prevent over cooling of the engine. |
3 June 2000 |
Recognised
we have a problem with the spacers for the indicator pods. Shape is correct and
contoured but holes cannot be drilled straight through to mount the pods.
Adopted an offset solution with studs to mount the pods on and offset screws
to mount he assembly to the nose cone. Undercoated the panels to fit over the
top of the tunnel. The manual says the hole for the gear lever is cut already
– Not true. |
4 June 2000 |
Colour
match (Hammerite Dark Green) for the indicator pod spacers not bad. Difficult
to get a good alignment and position on the nose cone. Tried to fit the panels on the top of the
tunnel but we did not have the correct size rivets for fitting the gear lever
gaiter or self tapping screws. |
5 June 2000 |
Yesterdays
prep work paid off. Andrew fitted the
gear lever gaiter using the correct size rivets. John Hopkins turned up
yesterday with some 32mm x 30 mm spacers for the seat belt harnesses. Filed
flats on the bottom sides to accommodate the rollover bar and the chassis
welds. Andrew made some A3 templates
for the indicator pod fitting. Accurately drilled the nose cone to suit.
Fitted to extra brackets to the nose cone to stiffen the grill fitting.
Examined the ECU wiring to see if we could make the Webcon Mondeo harness a
better fit for the Westfield. |
6 June 2000 |
Refitted
the grill to the nose cone. Much stiffer and less chance of vibration no that
it has six brackets to hold it in place rather than 4 as previous. Assembled
the indicator pods and spacers fitted them to the nose cone. Despite all our
efforts they are not symmetrical. LHS points upwards. The spacers are partly
to blame. Further investigation was needed |
7 June 2000 |
Decided
to make new spacers for the indicator pods.
Same cross section but this time straight, so that bolts would pass
from the nose cone through the spacer in to the indictor pod mounting
nuts. Trial fitted the spacers and
pods. Much checking with spirit levels and plumb bobs. LHS is still 5 – 7 mm
too high. Discovered the pods were not
identical. (We knew they were RH and LH and had positioned them on the
correct side) The holes in the pods were not identically placed which meant
because we had used Westfield dimensions again, identical to each side the
pods were in fact at different vertical places on the nose cone. |
8 June 2000 |
Examined
the pods again to find the mounting holes in the LHS were misplaced by about
5 mm compared to the RHS. Equal to the problem. Repositioned the holes for
the LHS pod in the nose cone accordingly and refitted. The alignment now
good. Fitted
the ECU to it’s mounting plate and connected the wiring loom. Striped out the wires for tacho (that
needed to remain in the scuttle) and fed the power leads to the engine
compartment. Secured the harness to
the scuttle with cable ties and sticky pads to ensure they were tidy and
clear of heater outlet, clear of the heater and the hinge plate still
operated correctly. Secured Washer
pipe to scuttle. |
|
Dismantled
the ECU wiring loom in the engine bay to remake it. The loom, originally made
for a Mondeo, needed to be tailored to fit the |
|
Attached
the Earth connection to the ECU and covered with heat shrink sleeving.
Connected the pull up resistor to the tacho connection and reconnected the
tacho leads. Disconnected the |
|
We
had an additional branch welded to the lower aluminium pipe between the water
pump and branch connected to the heater. Finally mounted the indicator pods,
spacers and secured the wiring with sticky pads and cable ties. |
|
The
plumbing between the heater around the back of the engine and connecting to
the modified pipe work proved to be trouble some Andrew and I had several
attempts to get a neat installation that did not foul wiring, other pipe work,
coil mounting bracket and did not kink sundry rubber pipes - We can see the
problems There is too sharp a bend in the Westfield pipe from the engine to
the heater inlet and the Thermostat bypass is below the chassis component and
the pipe has to come up and over to connect to the new pipe work. To be continued ……… |
|
Went
to CAFCO to see if I could find a suitable right angles pipe for connecting
the heater to the engine pipe work.
Found a QH pipe (ex Avenger) that might do |
|
The
QH pipe will work if cut down Ordered 2 more (1 spare) Mounted the header
tank. |
|
Extended
the wiring for the air temperature sensor. Loomed it up with the throttle
positions sensor wires and protected the loom with spiral wrap. Secured the
wiring to the carb with “P” clips mounted using the cover securing screws.
Mounted the air temperature sensor in the RH air filter back plate. Removed
the dash and added the wiring for the fog light tell tale. Corrected the parking position of the
windscreen wipers by dismantling the motor gearbox and repositioning the
plastic stop wedge by 180 degrees.
Reworked the heater and coolant hoses to get the best possible
installation. Fitted the fog light tell tale to the dashboard Re-assembled
the dash and all the wiring and tested. Wipers now park in the correct place
and fog light tell tale operates correctly. |
|
Unhappy
with the position of the tacho wiring in relation to the heater pipes, we
undid the loom and extended the wired to achieve a better fit with more
clearance. After some discussion with |
|
The
body realignment only produced 2 to 3 mm improvement. Andrew experimented and
cured the problem by fitting rubber tubing to the carrier to finally
centralise the spare wheel position. Secured the dash panel in place. |
|
Measured
and mounted the spare wheel securing studs. Had to move the fuel tank forward
to get sufficient space to gain access to the inside rear of the bodywork to
secure the mounting bar. We used
studs not bolts for added security. Spare wheel when mounted was central both
vertically and horizontally. SVA
detail fitted 5mm beading to the fog lamp surround. |
|
Went
to |
|
Cut
the holes in the boot box for the seat belt eye bolts. Filled the coolant
system with 50/50 mix discovered a couple of leaks which could be fixed by tightening
hoses. Most serious leak was from the blanking plug we put in the aluminium
pipe where the thermostat bypass would have fitted. Drained the coolant and
made a new blanking plug from a ½ BSP adapter and an M10 bolt, sealed the
assembly with PTFE tape. Refilled the system, leak cured. Since the engine had not turned for 6
months, took the spark plugs out and turned the engine over on the starter to
prime the oil galleries. Fitted rubber
piping around the return edge of the rear number plate. I left Andrew to
start the engine. Andrew reported fuel gauge not reading, temperature gauge
not reading, radiator fan permanently on once the engine was up to
temperature. |
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Put
4 more gallons of fuel in the car and the fuel gauge reads OK. We fitted and earth strap to the engine
temperature sensor the gauge now reads.
Andrew picked up an orange top fan switch from the local Ford
dealer. Checked the part number with
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We
re-did the bodge to the carpet to improve its appearance and were more
satisfied with the end result. Fitted the seats. Repositioned the windscreen
wipers so that they parked correctly. Re-fitted
the nose cone and tested the indicators. Noticed that the water temperature,
oil pressure and fuel gauges have condensation inside them also the Water
temperature gauge remains reading after the engine has been switched off. But
does zero the next time you switch on wit the engine cool. Wired the rear number plate light. We discovered that with the number plate
mounted the |
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“D”
day as far as SVA is concerned and we decided we were on track and it would
be “GO” on Friday. Set up the tracking if the rear suspension. Checked the
wiring of the temperature sensor and gauge all OK. If the gauge continues to
stick it will be sorted after SVA. Chris Masters Says |
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Fitted
the LHS cycle wing. Rechecked for tightness front and rear suspension bolts. Fitted
interior mirror and the crash pad.
Adjusted the position of the handbrake cables to ensure clearance from
brake and fuel pipes. Fitted the boot box and interior trim. It looked like out Aeroquips on the front
brakes were too short at full lock and fouled the cycle wing brackets. Our Aeroquips were mounted on the chassis
brackets provided because we have a non-ducted nose. Unpacked the exhaust guard to find a
jubilee clip missing. |
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On
Chris Masters recommendation I checked the steering rack 2.5 turns lock to
lock, it is OK. I undid the Aeroquips from the bracket. Bent the bracket slightly
with a hammer and a piece of wood to gain a little on the length. Reconnected
the Aeroquips, routing them under the cycle wing brackets and with a slight
twist in them to produce good clearances all round. Re-connected the fixed pipes, which required
careful bending and repositioning by hand. Bled the brakes. Andrew did a test flight to check the
brakes and to see if the car would negotiate the speed bumps down to the main
road without grounding. With the engine warm, we rechecked the emissions at
idle (950 revs 2.6 CO) and we were within tolerance. Adjusted the nose cone
to eliminate a rattle against the chassis. Stuck rubber on to bonnet locating
points on the scuttle and nose cone. Definitely improves the fit and
appearance. SVA item - Fitted spiral
wrap to the Aeroquips and covers to all the suspension nuts and bolts. |
29 June 2000 |
SVA
–1 Missing Jubilee clip for the exhaust guard arrived and the guard fitted.
Chris master said set it towards the rear of the car to cover up as much of
the rear exhaust clamp as possible.
Chris also told us that two very large covers were for covering up the
front ball joint locking nuts and similarly two smaller ones for the track
rod end locking nuts. We replaced the
spiral wrap provided by Westfield for wrapping the front Aeroquips with some
stuff we obtained from VWP. Andrew set about sticking rubber and covers over
everything we knew, or suspected, might be picked up by the tester as not
being radiused sufficiently. Andrew
and I took off the front exhaust clamp (with difficulty, since we did not
want to disturb the exhaust system.) so that I could radius the edges with
the Dremel and the grinding stone tools.
Washed the car and loaded up the support vehicle (My rover 820) with
nuts bolts, screws, washers, electrical connectors, grommets and bungs. If we
need 1/50 of what we took we were dead.
Suddenly we were done. in plenty of time to walk round the car and see
if there was anything we had forgotten and get an early night. |
30 June 2000 |
SVA
Day. See the SVA report. After 3 hours, the car passed first time and we are
awarded an MAC. – Phew. |
03 July 2000 |
Contacted
the reading VRO – He (Mr Jepson) does not want to inspect the car for a Q
registration. Send the VED+ £25, registration fee, and major receipts for the
car (Kit and Engine). Form V55/5 (first registration) and 627/1 (build up
report) and it should be done in 2 days.
Removed the carpet to send back to Westfield |
05 July 2000 |
New
carpet is ready and will be returned today. Replaced the Westfield steering
wheel with the removable Racetech one. Removed the rear number plate carrier
turned it 180 degrees and refitted it. Rewired the number plate lamp. The
Spare wheel is secured on studs with locking nuts and can be removed past the
number plate. It actually looks better this way up with the number plate lamp
covering more of the bottom of the spare wheel. |
06 July 2000 |
New
carpet arrived today with two huge reels of Velcro tape. Removed Seats and
Seat belts removed the rear bulkhead carpet. Cleaned off all the old
double-sided tape with white spirit. Refitted the rear bulkhead carpet. Prepared the chassis to refit the tunnel
carpet. |
07 July 2000 |
Registration
notification and tax disc arrived today Q146ACF. Went to Halfords and had
some number plates made. Rear Euro plate, to save putting GB stickers on the
car, with 3D lettering and customised
- E.M. Engineering. Standard plate on the front with 3D letters to
match the rear. We got away with a
Euro plate on the back because we have a 1 in the number. |
08 July 2000 |
Fitted
the tunnel carpet, refitted the seat belts and the seats Whilst doing this we
noticed a couple of corroded rivets on the LHS side trim panel. We replaced
them. After SVA we had notice some electrolyte spillage from the battery
whilst the car was parked on the slope of Andrew’s drive. We had cleaned this
up but suspected some had trickled back on to the rivets. We checked the battery voltage and this
seemed OK whilst the output of the alternator on charge gave13.5 volts. We suspected that the battery may be
slightly overfilled and this and expansion coupled with the slope caused the
spillage. Checked the carb balance and richened the mixture by ¼ turn we will
check the flat spot on a test run.
Cut rubber mats to protect the carpets from muddy feet. Fitted the
rear number plate. Removed the nose cone and the spacers for the indicator
pods. |
9 July 2000 |
Rerouted
the wiring for the front indicators and secured using cable ties and sticky
pads. Made some aluminium plates fitted with 6mm rivnuts, secured behind the
“chin” of the nose cone with 3 mm peel rivets. Fixed the number plate brackets to these
plates. Fitted the number plate. Refitted the nose cone and connected the
wiring. Whilst the nose cone was off
we fitted black rubber edging around the underside of the nose to finish if
off and protect the fibreglass. We also fitted HD foam to the chassis to
protect the nose cone and eliminate a vibration rattle. Re- adjusted the ride
height. The suspension had settled 10 mm. Andrew fixed a leak on the RHS
inner Lobro joint. The grease appeared to be leaking out under rotational force.
We will continue to monitor it. Topped up the engine oil. |
11 July 2000 |
Tested
the throttle position sensor and adjusted it.
Road tested it and richened the mixture a couple of times. No real improvement in the flat spot. We are
now sure we need a rolling road session ad possible re-jetting of the
carbs. Data we have collected seems to
suggest that this is a common problem with 2.0 l Zetec engines on DCOE 45
Carbs. |
12 July 2000 |
Apart
from test-driving yesterday, and last night my first opportunity to drive the
car. Went to Westfield to return the steering wheel. Picked up a set of side
screens whilst I was there. Spoke to Chris Masters. Chris praised the quality
of the build and especially the bodywork seams. He approves of the SVA
checklist (see SVA section). Chris
supplied us with the Westfield recommended jet for the carbs. An enjoyable if
blustery drive without side screens. |
21 July 2000 |
Carried
out some post SVA and 500 mile mechanical and safety checks. Nothing to
report. Started the pre flight checks ready for Coy’s Historic Motor Racing
Festival at Silverstone on Sunday |
22 July 2000 |
Andrew
called to say that, one of the bell shaped
covers on the top of the carburettors was missing. I Don’t know how I missed
this yesterday. Unless we can get a replacement Silverstone is off. Andrew located one at Thruxton and went to
get it. Andrew fitted the new cover and retuned the engine back to square
one. He had had the opportunity to talk to Ray West at Thruxton and we have
decided to book the car in for a rolling road session. Pre flight checks
completed, Andrew brought the car over to my place so that we do some demo
runs for the rest of the family who were visiting, and coming to Coy’s |
23 July 2000 |
Andrew
and I went to the Coy’s Historic Motor Racing Festival at Silverstone in our
own Westfield. A great day looking at
some magnificent machinery and some excellent racing. Lots of admiring glances and comments on
the car. The day was climaxed by Chris
Smith (MD of Westfield Sports Cars) coming 3rd in the race for pre
1966 Grand Prix Cars in a Lotus 21.
Well-done Chris. - For us an
ambition achieved |
25 July 2000 |
Rolling
Road session booked with Ray West at Thruxton. |
29 July 2000 |
Removed
and resealed the exhaust system. Started to fit lockable boot lid |
02 Aug 2000 |
Trial
fitted hinges and boot lid locks |
03 Aug 2000 |
Completed
fitting of boot lid. Fitted the hood frame. Completed rolling road pre flight
checks. |
04 Aug 2000 |
Rolling
road session at West Tuning ,Thruxton. Carbs re-jetted with richer idle jets.
Peak Power Output 168.6 Bhp. Car much
nicer to drive, but still has a minor flat spot. |
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