Its being a nightmare. This is the sort of period during a full build where cars end up as 'unfinished projects' on ebay. So what particular walls have I run into?
Brake Pedal Conversion
Once I got the Zero brake kit aligned it became obvious the brake lines would collide with the steering column and its mounting bracket.
This is the unti without the master cylinder attached. A possible solution is to use a shorter master cylinder which may give more clearance.
Another alternative I am looking at is to move the old pedal mounting plate back to either create space for a very shor master cylinder (such as Fiat Punto) or to have a cross bar move the master cylinder across to miss the new plenum.
Injectors/fuel rail.
Lined up the fuel rail and injectors on the new plenum chamber. Initial problem is the fuel rail comes into contact with the rocker cover, especially the vent tube from it. Due to the design of the chamber it angles the injectors backwards. I have looked at fuel rails off later Mondeo's but believe these are from Duratec engines rather than Zetec so unlikely to fit. Going to email the seller (Pepper Performance) for advice.
Radiator
See next post.....
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