Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Just got back from Altiss. They'll have the rear pads ready for the end of the week.
I cant afford another driveshaft this month, so the next one will have to be ordered in August.
Altiss had the biggest pair of monster sized turbo's I've ever seen. Matched pair, going on a 7L V8 engine, to produce 3000BHP.
96mm inlet, whatever that means x-)
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Rear pads are ready for collection from Altiss. I've had them machined down to 10.5mm. Collecting them this afternoon.
Went round Thruxton yesterday with Tiff Needell in his BMW M3. OMG it was fun. Didn't scare me, but the car control he has is mind boggling. Sideways with smoke pouring out the arches. He was asking about my Fiesta, and which tracks I'd driven, so I said Croft, Cadwell, Anglesey, Donington, Oulton, Silverstone, Mallory, Snetterton but never Thruxton. He asked if they were track days. When I explained I'd held a competition license for 25 years and I sprint the Fiesta, he then proceeded to show me how to do Thruxton 'in an M3'. Proper job. Guys a legend. Well worth the £125 for 3 laps.
He wanted to know what Zetecinside was, and what I'd done to the Fiesta. Sounded impressed.
The incar footage was ok, but there was a problem with the sound, and Tiff sent me a message on Twitter last night to apologise. There's a letter in the post apparently, possibly a refund or a discount off my next visit...
When I mentioned I'd be competing at the track at the start of 2011, in the British Sprint Championship, he went in to the office to see if he could get me some 1-2-1 tuition, but unfortunately they were fully booked all day. Bum!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Tiff really is a top bloke, I've met him once and was impressed by his general friendliness and readiness to talk.
Sounds like you had a great time mate, nice one!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Modified the rear pads for the 2nd time, to fit in the calipers.
Ground a radius on the inside edge of two of the pads, so that they clear the disk bell when fitted in the calipers.
http://www.zetecinside.com/xr2/pictures/20100710_1.jpg
http://www.zetecinside.com/xr2/pictures/20100710_3.jpg
http://www.zetecinside.com/xr2/pictures/20100710_2.jpg
Next I need to modify the pins that hold the pads in, because I've got the wrong ones for the calipers (pins are too long so I need to drill new holes for the retaining R clips)
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Rxd a letter from Thruxton this morning, apologising for the poor sound quality on the in-car DVD from last weeks session with Tiff.
They've offered me and the missus another free go each, so I'll get a session booked again in the next few months.
I'll also get some track tuition, as I'm sure to be competing at Thruxton in the BSC in 2011.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Thats good of them is'nt it:clap:
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Went to the ford dealers in Leicester yesterday, and they found me a spare hydraulic clutch hose retaining clip for the slave cylinder, so last night I fitted the clip and I can now finally bleed the clutch.
I've also finished fitting the Ferodo pads in the rear calipers. The four long sliding pins that hold the pads in place on both sets of calipers, were too long for the width of my calipers, so I drilled new 1.5mm holes in the pins for the R clips to hold them in situ (well I did two 1.0mm holes in two of the pins, then broke the sodding drill bit in the third pin, and after persuading the broken piece of drill out of the hole, so I used a 1.5mm drill bit to make the hole in the remaining two pins)
The pins were then cut to reduce their overall length, and are now holding the pads in place on both calipers, and the hoses are reattached. So I can also bleed the brakes (finally) and see if the raldes pedal box (so far untested) works with the hydraulic Fiesta ST clutch.
The clutch hose clip that fits in the slave cylinder in the ST gearbox
http://web12.twitpic.com/img/1305627...f90-scaled.jpg
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Bled the rear brakes last night. One man operation using a vacuum compressor rescued from the WEE skip at work.
Draws the fluid through from the reservoir, and works reasonably well. I had to take the calipers off and orientate the bleed nipples to the top to make sure that all the air was expelled.
And at first I couldn't draw any fluid through, which baffled me for a while. Then I realised I'd pressed the pistons fully inside the calipers, which prevented any fluid from travelling around the inside of the calipers. Soon fixed by pressurising the calipers using the compressor, to force the pistons back out, and the once reconnected, bleeding commenced.
http://www.zetecinside.com/xr2/pictures/20100721.jpg
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Good work! It took eventually three guys to bleed my brakes.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Wowee. The only downside is i have to check the fluid in the reservoir regularly so i dont run it dry. The bottle on the floor captures the oil drained from the brakes.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
I had air in the rear main cylinder and it just did not come out until both the front and the rear brake bleed valves were opend simultainously.
One man pushed the pedal one opend the front and third opened the rear bleed valves. Did the job beautifully but I would have never thought that myself.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Bled the fronts on Friday evening, and then finished the lower rear engine steady bar, which braces the rear of the engine to the front bulkhead, using some brackets I migged and a simple adjustable steady bar using some threaded tube and M10 rod ends.
http://www.zetecinside.com/xr2/pictures/20100723_1.jpg
I'll have the brackets powder coated once I've proved that they'll stand up to the abuse. There is a second engine steady bar, that runs from the top of the gearbox, also to the bulkhead, so by lengthening one tie bar against the other, I can essentially lock the engine solid, thus preventing any movement.
Unfortunately Tony Law had to remove the tie bar in the picture to accomodate their manifold, and the tie bar was meant to sit in the centre of both the brackets. So for now I've added alloy tube spacers to the bolts that pass through the brackets, so I can torque them up without squashing the brackets.
I've also re-routed the flexible hydraulic clutch hose inside the car, so its away from the heat from the exhaust manifold on the rear of the Duratec.
I'll bleed the clutch next (home Weds) and then run the engine and make sure I can select gears. Wonder what the top speed on axle stands is 8-)
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Why do you need these steady bars? I'm just saying I'm afraid they may resonate quite a bit? And maybe provide some stress for the engine block or even vibrations on the internals.
Why won't the two mounts and the torque restrictor with HD bushing do the job? Or perhaps it would be possible to isolate the bracets in the bulkhead with rubber?
But on the other hand some people bolt their engines directy to the chassis.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Just makes all the windows rattle, nothing worse than that. My Zetec was locked in a similar way.
My Zetec install retained the Fiesta Mk1 engine cradle which in conjunction with Vibratechnics solid engine mounts, gave a pretty harsh, but effective means of keeping it still.
The Duratec is suspended from above, and I need some means of stopping it from moving. I'm not using the torque restrictor, so these are the next best thing. The M-Sport top mounts are stiff, but not as hard as the Vibratechnics mounts on the Zetec, so it may not be so bad. Time will tell.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Bled the clutch last night. Took about 3 seconds using the vacuum pump. Not sure how its supposed to feel when I press the pedal, and I've no indication of any movement like I would have had with a cable clutch. But there is resistance to the pedal movement, like I'd expect to feel, and theres no 'orrible noises, so hopefully its working. My concern is the size of the master cylinder to the capacity of the slave. I'm running a 0.75" master, which gives the least amount of fluid movement compared to the other masters I had lying around, so I'll only know when I try to drive the car at the weekend for the first time.
I also finished cleaning up the foor inner wheel arches, and sprayed them with some fresh stone chip.
http://www.zetecinside.com/xr2/pictu...8_nsr_arch.jpg
http://www.zetecinside.com/xr2/pictu...8_osr_arch.jpg
http://www.zetecinside.com/xr2/pictu...8_nsf_arch.jpg
M-Sport are sending me a pair of inner cv joint boots, which I should be getting today. When I went back to Ford for the complete boot kit, they were quoting 5-10 days lead time (minimum), so I politely declined.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Rubber CV boots have arrived from M-Sport, as has Kustom Karls decals for the car. I'll reassemble the NSF tonight, and get MrsB to help bleed the brakes one last time.
All systems go for a first drive at the weekend. :banana::banana::banana::banana:
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Quote:
All systems go for a first drive at the weekend.
goodo :thumb: looking forward to hearing your verdict on the changes
Re: My Mk1 Fiesta XR2
Hi boXXer. Yes I must agree with you. I love cute little car. :D
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
The rubber boots arrived from M-Sport (thanks Graeme) and tonight I assembled the near side drive shaft, and refitted the hub, having packed the inboard CV with good quality grease first. I then realised that I had a problem with the way that I'd fitted the Kustom suspension on the near side. Where the inboard heim (rod end) for the track control arm locates in the chassis leg, Karl had supplied a very neat brace assembly, that fits inside the original chassis leg box section, and runs forward to the tie bar mount. I'd not fitted the brace bar fully up inside the chassis, and there was a whitness mark on the alloy heim, which shows that when the car sits on the suspension, the heim had been resting on the uppermost section of the brace box. Still with me? My fault for not fitting it correctly. However, when I tried to push the box section further up inside the chassis leg, the brace that runs underneath the gearbox, hit the box, and the gear selector mechanism. Simples. I removed the brace and cut off the tube that runs forward. I've done exactly the same on the drivers side as my Duratec sump also hit the brace bar. So no great loss considering I'd not ran brace bars previously.
So with the Kustom box section now fully inside the chassis leg, I refitted the track control heim, and then re-assembled the front suspension. I then realised I hadn't yet torqued up the tie bar brackets, so I had to undo the fasteners for the radiator, so I could move it sideways to allow access to the top of the bolts that hold the tie bar brackets in place. Everything was then quickly torqued up, but I'd run out of time to give the brakes one last bleed, so I'll do that tomorrow evening, prior to trying out the clutch for the first time at the weekend.
http://www.zetecinside.com/xr2/pictures/20100729_1.jpg
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
All ready for it's first trip out at the weekend then ? :)
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Yep, FordFair on Sunday. If I can get gears, which I'll know in the next evening or two.
Then it'll be off to the rollers for a base mapping, and some power runs. Then I can start to drive her in anger again. Hoping to get a session at Donington in September, just to blow the cobwebs away.
Box and engine are still standard though, so I still need to fit the slipper, SCCR gear kit, and have the engine rebuilt.
Forgot to say that I had to change the rack, as the one on the car was toast. Gearbox was ruined by 7 years of competition use, and the tie bars were too short for the new wider track. New rack turned up on ebay, and I'd rather have a later Mk2 rack than a Mk1 rack anyday.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
How much wider is the track now Graham?
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Not a great deal wider, say an inch wider overall. But every little helps :D
Fed and watered the gearbox last night with Halfords finest (cheapest) gbox oil.
Aligned the steering so the wheels are pointing roughly in parallel.
Will fire her up tonight and get the engine up to operating temperature for the first time.
Then I'll check the bite point. Hopefully not leaving any '11's down the driveway.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
She'll be at Ford Fair on the XRTWO.COM stand if anyone can find us!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Didnt run the engine, as the neighbours had housesitters in and they have a 12month old, so I'd not be too popular if I started the old girl up.
I adjusted the gear linkage instead, with the assistance of Mrs B.
http://www.zetecinside.com/xr2/pictures/20100805_1.jpg
Feels much nicer than the old rod change. Much smoother.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
You must find it hard being so close? I'd be gagging to take it for a spin!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Clutch works fine. Drove the car under its own power for the first time in over 2 years today. Brakes are fine also, and ran engine up to temp. All loaded on the trailer and ready for Silverstone tomorrow. :dance::dance::dance:
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Quote:
Originally Posted by
grahamb Clutch works fine. Drove the car under its own power for the first time in over 2 years today. Brakes are fine also, and ran engine up to temp. All loaded on the trailer and ready for Silverstone tomorrow. :dance::dance::dance:
I can top that. I got to change to a second gear today!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
I managed 2nd gear too, at Ford Fair yesterday. I parked the tow car up in the trailer park and drove the Fiesta over to the xrtwo.com stand, and there and back I had a couple of opportunities to give her some beans, and saints alive, she pulls like a train.
I must get her booked in for the RR session. Intention is to do Trax in September, with some track time to boot.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
well done graham :clap: must have felt great to actually drive it after all those hours, but we still need some video proof of it running and in particular the 'giving it beans' part ;)
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
I'm sure someone must've video'd it, was getting lots of attention when I drove her :D
However, the xrtwo stand wasn't exactly at the centre of the venue, it would've been nice to have been on the island....
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
She's booked in at Northampton Motorsport for Friday August 27th, for the suspension setup and engine map/power runs.
Unit 52, Rothersthorpe Crescent
Northampton
NN4 8JD
9am start :D
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Changed the remote oil sensor plate last night, for the blue Mocal item.
http://www.zetecinside.com/xr2/pictures/20100822_1.jpg
Hoping the Mocal plate doesnt leak.
The one I used previously, an ebay copy of the Mocal plate, had a poorly fitting rubber seal. This Mocal plate seems to be of a higher quality. Time will tell.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
A set of four IW031 injectors are all ready to be fitted tomorrow at the RR session.
I'm getting really nervous about it, I just hope it all holds together.
And I'm in this months Classic Ford magazine on the Fiesta Icon's page, top left. What an honour!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
The anticipation is nerve wreckirng isn't it?
But don't worry Graham It will hold. The Duratecs are mighty reliable engines. Just keep the revs in a reasonable level. Is this an off the box engine or has it been worked on?
I always find consolation in the fact that if it will blow up on the rollers it would have blown in a race too. Better on the rollers than on a race track.
What is the realistic power expectation?
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Ahem
200bhp & 160 torx at 7000rpm
Hell yeah
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Very nice indeed mate! That's a great result!!! Bet you can't wait to drive it now eh? Did you get any videos of the session?
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Quote:
Originally Posted by
grahamb Ahem
200bhp & 160 torx at 7000rpm
Hell yeah
That's excellent, well done Graham :clap:
I bet you can't wait to be driving it now :D
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Those are very impresive figures for a tiny Fiesta!!! I believe you are going to have your hads full with this one.... And I mean it in a good, good, way.
And if you ever feel like you may need more there a hundred more horses waiting to get out of an Duratec 2.0.
What a beast. Excellent job Graham!
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Not bad for an amateur eh.
Troy worked his magic on the car.
Corner weighted, then alignment which showed up a .problem with the 2nd driveshaft, which as I suspected is too long and binds which prevented us getting the castor and camber on the near side. So I need to order a shorter one.
On the rollers we still had the oil leak from the filter housing and stripped it all off the car, rebuilt it with dowty seals after modding the filter housing, and that fixed the problem.
Troy already balanced the bodies, and I'd fitted the larger injectors before the session, so the engine ticked over at 650rpm, and starts on the button.
Several power runs highlighted a problem with an earth somewhere. My car kept causing the dyno to reset, so after some headscratching we earthed the car VIA jump leads to the dyno chassis and that cured the fault.
Dyno runs showed a cooling issue but it turns out I'd plumbed the header tank in to the wrong hose so I need to sort that out.
Red lined at 7k but if we move it to 7400 and run a straight cut box, I reckon we'll get 210 easily.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Took lots of video on my camera.
Two from my camera phone are on YouTube
Www.YouTube.com/a269fej
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
And the car weighs 695kg without me up.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Quote:
Originally Posted by
grahamb And the car weighs 695kg without me up.
:D:D:D 3,475kg's per a horse power NOT BAD!!!:D:D:D
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Quote:
Originally Posted by
Roadsport :D:D:D 3,475kg's per a horse power NOT BAD!!!:D:D:D
i'l say or to put it anotherway 287bhp per ton
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Blimey, thats going to be fun. Need to concentrate on the gearbox next.
Going for Quaife internals, with the LSD.
Whats everyone else's power to weight ratios?
And yes, I'm going on a diet. :D
The Fiesta was causing the rolling road computer to trip. Troy said he'd never seen it before. We had to earth the car to the dyno chassis, to cure the problem. Most peculiar, considering the Fiesta never missed a beat. I reckon it was static being generated by the wheels on the dyno, but its hard to tell where it came from. There was a voltage differential between the Fiesta and Ground, and grounding the chassis fixed it. Its a new install at Northampton Motorsport as they've just moved premises, so it could be an earthing loop somewhere in their mains setup.
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber
Well done Graham, good to see it all coming together
Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber