Again I apoloogise for the lack of posts....I did go away on holiday for a week!
Well I have good progress to report.
Engine is back in on fully welded mounts - made from 6mm steel. I orginally used tube to connect the engine plate to the base plate, but this caused problems with getting the nut onto the mount. I got a local fabrication company to weld these up for me.
The coolant pipes are now complete. I used the swaged ends off a spare metal pipe from the Mondeo to make a blank for the heater pipe and the spur which goes into the water pump pipe and acts as a bypass for before the thermostat opens.
The GBS manifold had to be modified on the final bend as it did not exit at the correct angle to allow the silencer to fit. It is all now fitted with the silencer mounted on a modified Pinto exhaust bracket (call it recycling!)
Whilst on holiday I purchased another set of carbs - this time from a Kwaka ZRX1100. These sit more vertical than the ZX6 carbs and I have made a manifold to fit - the second version infact as the first was slightly too long and the carbs touched the brake master cylinder.
I removed all the rear panels and I have made a bracket to mount the fuel pump under the boot floor. Just needs wiring up.
Once I got all the main bits back in tonight I decided just to see if the engine would at least turnover - and it did! All I need now is an ignition system!
Monday 27 April 2009
Tuesday 14 April 2009
Getting there
I know there has been a lack of posts recently, but I am at last getting somewhere.
I had the propshaft extended by propshaft services in Bradford. Highly recommended. www.propshaft.co.uk
Trimmed and neatened up the rear of the floor before putting the propshaft back in. Would not quite go through the hole I had created, so had to lower the front of the gearbox, thus raising the back, to enable it to go in.
To make new engine mounts I fabricated a jig using some chipboard. I bolted in the existing Sierra mount with the adaptor plates, then measured out to move the engine forward 62mm, and also to relocate the mounting hole to the original one in the chassis. I used 6mm plate to make a base plate, and some 42mm, 3mm wall tubing to connect it to the original adaptor plates to the base plates. I also raised the engine on the mounts to try and solve the clashing exhaust/side rail issue.
I bolted up the original thermostat housing to the engine, casting aside the DIY water rail I had spent so much time on..... Dropping the engine back in the new mounts were spot on, with a few mm's clearance for the thermstat housing. The engine now looks rather high at the front....a quick bit of measuring shows the flange in the centre of the bonnet will need trimming, and the bonnet stay system I have will need to be removed.
Worked my way round the ancilleries. The CVH Sierra starter motor has arrived and fits the hole/trimmed sump nicely, and as an added advantage the wiring connections are the same as the Pinto. The coil pack bolted to a modified original bracket at the back of the engine.
The new engine position also means the original oil filter will not fit, as it would clash with the sterring column. A quick bit of internet searching found the Unipart GFE210 filter is the one to go for.... (Alternatives are Crossland 659 or Fram PH 2874). Picked one up today and it is the size of a tine of tuna, rather than the Red Bull can sixe item that was there before. The new one is just 65mm deep.
Wiring wise I have been stripping out the connecters from the Mondeo loom for the various sensors, and the Edis4 unit is now mounted on the bulkhead, so next step is to wire up the various sensors to it. I have also sorted the majority of the coolant hoses. I used the original flexi hose at the top of the pinto engine to connect the water pump to the original radiator bottom hose with a short length of 32mm steel tube (will replace with alloy). The original top hose from the Mondeo thermostat has been cut and shut to get the outlet of it to aim fowards. Just need a 32mm 90 degree bend to put on the radiator top connection, and a length of 32mm steel tube will connect the tube.
That ends the good progress.....
The induction side is still a headache. The ZX6 carbs are downdraft type. This means fo rhte floats, etc to work correctly they need to be at around a 45 degree angle. The next issue is they are not as widely spaced as the Mondeo inlet ports. And finally the brake master cylinder is still in the way of them being too far away from the engine. In summary, they won't fit with the brakes where they are now. The angle they have to be at along with stetching the spacing from carb to engine makes the flow want to go thru a 90 degree angle, which is not good.
I had looked at a floor mounted brake pedal kit from OBP. This would be two master cylinders, with brake bias adjustment, etc. But by the time I had purchased reserviors, etc the total cost was going to be the thick end of £200.
Today I speaking to Richard at Robin Hood. He was very helpful, and have come to a resolution on the exhaust pipe. We went on to discuss the general engine swap over issues, and when talking about the brakes he said they had developed a clutch/brake pedal kit which turned the master cylinder round to face the other way, therefore getting it out of the way of the induction side of the engine. I am waiting for him to email me a price but this may well be the solution to some of my problems.
I had the propshaft extended by propshaft services in Bradford. Highly recommended. www.propshaft.co.uk
Trimmed and neatened up the rear of the floor before putting the propshaft back in. Would not quite go through the hole I had created, so had to lower the front of the gearbox, thus raising the back, to enable it to go in.
To make new engine mounts I fabricated a jig using some chipboard. I bolted in the existing Sierra mount with the adaptor plates, then measured out to move the engine forward 62mm, and also to relocate the mounting hole to the original one in the chassis. I used 6mm plate to make a base plate, and some 42mm, 3mm wall tubing to connect it to the original adaptor plates to the base plates. I also raised the engine on the mounts to try and solve the clashing exhaust/side rail issue.
I bolted up the original thermostat housing to the engine, casting aside the DIY water rail I had spent so much time on..... Dropping the engine back in the new mounts were spot on, with a few mm's clearance for the thermstat housing. The engine now looks rather high at the front....a quick bit of measuring shows the flange in the centre of the bonnet will need trimming, and the bonnet stay system I have will need to be removed.
Worked my way round the ancilleries. The CVH Sierra starter motor has arrived and fits the hole/trimmed sump nicely, and as an added advantage the wiring connections are the same as the Pinto. The coil pack bolted to a modified original bracket at the back of the engine.
The new engine position also means the original oil filter will not fit, as it would clash with the sterring column. A quick bit of internet searching found the Unipart GFE210 filter is the one to go for.... (Alternatives are Crossland 659 or Fram PH 2874). Picked one up today and it is the size of a tine of tuna, rather than the Red Bull can sixe item that was there before. The new one is just 65mm deep.
Wiring wise I have been stripping out the connecters from the Mondeo loom for the various sensors, and the Edis4 unit is now mounted on the bulkhead, so next step is to wire up the various sensors to it. I have also sorted the majority of the coolant hoses. I used the original flexi hose at the top of the pinto engine to connect the water pump to the original radiator bottom hose with a short length of 32mm steel tube (will replace with alloy). The original top hose from the Mondeo thermostat has been cut and shut to get the outlet of it to aim fowards. Just need a 32mm 90 degree bend to put on the radiator top connection, and a length of 32mm steel tube will connect the tube.
That ends the good progress.....
The induction side is still a headache. The ZX6 carbs are downdraft type. This means fo rhte floats, etc to work correctly they need to be at around a 45 degree angle. The next issue is they are not as widely spaced as the Mondeo inlet ports. And finally the brake master cylinder is still in the way of them being too far away from the engine. In summary, they won't fit with the brakes where they are now. The angle they have to be at along with stetching the spacing from carb to engine makes the flow want to go thru a 90 degree angle, which is not good.
I had looked at a floor mounted brake pedal kit from OBP. This would be two master cylinders, with brake bias adjustment, etc. But by the time I had purchased reserviors, etc the total cost was going to be the thick end of £200.
Today I speaking to Richard at Robin Hood. He was very helpful, and have come to a resolution on the exhaust pipe. We went on to discuss the general engine swap over issues, and when talking about the brakes he said they had developed a clutch/brake pedal kit which turned the master cylinder round to face the other way, therefore getting it out of the way of the induction side of the engine. I am waiting for him to email me a price but this may well be the solution to some of my problems.
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