cheers , I only ask as I've done i n a couple of CV joints , which left me stranded out in the woods...
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cheers , I only ask as I've done i n a couple of CV joints , which left me stranded out in the woods...
did you try contacting the companies i suggested?
SBD replied today, 2weeks later, and quoted around £500 for the whole setup.
8.5" steel lightweight flywheel and 215mm clutch plus cover. Hopefully I can use the ford clutch slave.
Karl is running a Titan flywheel so I also asked them for a quote.
Shipping costs could hurt from the USA.
And I need one that fits and works, so ts less of a risk if I stay in the UK.
The new shorter cable came today from Quaife. Brand new, and its now the exact right length.
http://www.zetecinside.com/xr2/pictures/20110414_1.jpg
http://www.zetecinside.com/xr2/pictures/20110414_2.jpg
Titan have given me a discounted price for their ultra light (8.5" clutch) flywheel, which should fit the Duratec without any mods. Weight is 3.7Kg without the clutch. I wonder what the std flywheel weighs.
tried ttv for a fly wheel?
i've had a couple off them, one was custom and had it within 2weeks,
also they list quite a few for the duratec.
I'm going with Raceline and the Titan superlight flywheel, which uses the 8.5" cover and clutch from AP, and means I can use the standard Ford Fiesta ST clutch slave. The superlight weighs only 3.7Kg, so thats a few more Kg shaved off the car :D And Raceline are a known entity, and sound keen to help if there are any problems.
Got the gear lever tower back from www.altiss.com today. :thumb:
It raises the lever 5" off the floor. Made from Aluminium, beautiful bit of workmanship from Nigel. :clap:
http://www.zetecinside.com/xr2/pictures/20110416_1.jpg
http://www.zetecinside.com/xr2/pictures/20110416_2.jpg
http://www.zetecinside.com/xr2/pictures/20110416_3.jpg
http://www.zetecinside.com/xr2/pictures/20110416_4.jpg
That looks very nice. Stiff and light.
After 2 days stuck with the kids (aka the Weekend) I get time to play in the garage tonight, so I'll re-assemble the cable gearshifter and fit the tower to the floor tonight.
Weekends suck big time. The kids spend all their time fighting over me, finding stuff for me to do, that takes me away from their sibling. Very stressful, and its not like I couldn't find something to occupy myself with. Two weeks of this over Easter! I may end up sleeping outside in the garage. :D
Quaife has omitted to fit the threaded section to the end of the replacement gear selector cable, so I can't screw it in to the gear lever base.
So spent the evening fixing the lever tower to the car floor.
I'll call Quaife tomorrow.
Yep, its definitely missing the threaded steel barrel that slides on to the end.
They even sent me the nut, but forgot the barrel.
http://www.zetecinside.com/xr2/pictures/20110417_1.jpg
Better news, the diet is working. I've lost another 3lbs in the last 7days.
The missing barrel is in the post. :D
http://www.zetecinside.com/xr2/pictures/20110417_1.jpg
This is what it'll look like when I've finished bolting it to the floor, and repairing the floor from previous different gear levers.
http://www.zetecinside.com/xr2/pictures/20110417_2.jpg
I cant post pics at the moment. Is it just me or is there a fault on TS thats preventing them from appearing?
http://www.zetecinside.com/xr2/pictures/20110417_2.jpg
Looks great Graham :cool:
Looks like there is a problem with img links on here at the moment, I tried it in the post above and the picture isn't appearing for me.
Not to worry, sure the bof's are working on it. Probably a lack of disk space as it appears to cache copies of files from external sites.
Suspension is finished, Karl is just painting it and pressing the bearings in, and its ready to be FedEx'd over from the USA.
Made an ally plate last night to fit over the hole left from the previous gear lever. Sprayed it sunburst red, and I'll stick it down with silicon sealant tonight. Then I'll finish fitting the new tower to the floor. The steel threaded barrel from Quaife should be with me today, so I can get the cable assembled and tested. Then its time to take the engine and box out again, so I can change the f/wheel and clutch, and then when the suspension arrives, its all going back together.
Just need to get my finger out with wiring in the gear position indicator.
First event is hopefully Snet double header at the end of May, but there's a lot going on at work in May, so I may be out and about as usual racking up the mileage on the Legacy instead of working in the garage.
I'm enjoying a week at home this week. Garage time every night!
The missing threaded section turned up from Quaife, so I fitted it to the cable last night, then assembled the shaft that sits inside the gear lever housing, and assembled the gearlever back together again.
http://www.zetecinside.com/xr2/pictures/20110419_2.jpg
http://www.zetecinside.com/xr2/pictures/20110419_3.jpg
http://www.zetecinside.com/xr2/pictures/20110419_4.jpg
Next job was to secure the gear lever tower to the floor of the car. I used 4x M6 rivnuts in the base of the tower, and bolted it through the floor using stainless socket head screws.
http://www.zetecinside.com/xr2/pictures/20110419_1.jpg
The gear lever now sits on top, with the cable passing through the bulkhead in to the engine bay. I'm going to relocate the hole, so the cable avoids the exhaust manifold on the other side of the bulkhead.
all looking super tidy graham :cool:
and the pic links seems to be fixed now, so doing it the normal way should work :thumb:
Nice tower you've made there :thumb::D
Looks better in ally I reckon :D
Suspension is being shipped tomorrow from the USA. Still waiting for Raceline to call today to confirm the f/wheel and clutch costs (yes, I'll be sitting down).
Engine and box are coming again out over the next few nights.
Lol, my mate with that nova was round last night and there were a few comments made about the copy ha ha.
I think he now wants a match up against you, small block vs big block and all that !
Removed the engine and box last week, and discovered a crack in the chassis rail on the drivers side where I'd modified it to clear the crank pulley (10 yrs ago).
http://www.zetecinside.com/xr2/pictures/20110428_0.jpg
So I took the opportunity to brace the chassis, and also add gussets to the TCA box section to add some rigidity.
http://www.zetecinside.com/xr2/pictures/20110428_1.jpg
http://www.zetecinside.com/xr2/pictures/20110428_2.jpg
http://www.zetecinside.com/xr2/pictures/20110428_3.jpg
http://www.zetecinside.com/xr2/pictures/20110428_8.jpg
Quite a scare, but spotted in time I hope. If I hadn't removed the engine and box, I'd never have spotted it.
The Titan flywheel has also turned up, only weighs 3.7KG and is the lightest flywheel I've ever held. Also gone for an AP Racing 8.5" clutch and cover, and ARP rod bolts. Fitting these at the weekend and then the engine is going back in.
http://www.zetecinside.com/xr2/pictures/20110428_4.jpg
http://www.zetecinside.com/xr2/pictures/20110428_5.jpg
http://www.zetecinside.com/xr2/pictures/20110428_6.jpg
http://www.zetecinside.com/xr2/pictures/20110428_7.jpg
The suspension has arrived at Leicester parcel force depot, so just waiting for the postcard so I can go and collect it. Took 4 days to clear customs at Heathrow.
whats the idle speed likely to be , with such a light flywheel?
tbh, flywheel weight doesnt have a massive effect on idle speed, most full race engines on ultra light flywheels will still idle ok at about 1000 rpm on one, more of an issue is trying to pull away without stalling or lighting the tyres up when your not "going for it"
I've accomplished feck all this long weekend, after I discovered today that the wrong clutch has been supplied by Raceline. Its centre is too large to fit on the Fiesta gearbox input shaft.
But I did find that after discovering that fitting the gearbox, I couldn't turn the crank by hand, I needed to Dremel some ally away from inside the gearbox, because the larger diameter Titan flywheel hits the inside of the gearbox. :D
Then I realised that I needed to make 3 x 2mm spacers to move the starter motor out from the larger Titan flywheel to allow the starter motor pinion to engage/disengage correctly. Why on earth does the Fiesta ST have a smaller flywheel, clutch cover, and different starter motor to the Focus/Mondeo!
And I sprayed the engine bay where I'd modified it, with Red paint. :D
So not a complete loss of a long weekend, but I'm deeply disappointed this evening not to have the engine & box reinstalled. (The open bottle of Merlot is softening the blow)
And the new f/w is 5kg lighter than the one I removed, so its not all bad news.
Just been on the phone to Burtons, and purchased an AP CP5354-15 paddle clutch to replace the Type 9 clutch that Raceline provided me with. Burtons say that the 5354 clutch will work with the CP5905-500 cover. Delivery by the weekend.
Raceline have asked me to send the Type 9 clutch back for a refund.
So I'm sticking with the taller flywheel, but changing to a paddle clutch to avoid any slip.
And just to confirm, yes the Fiesta ST uses a 4mm shorter flywheel than the Duratec engined Focus and Mondeo. Nice!
the spec of this festa is emmence.
did you eva expect it 2 b this gr8 wen u 1st started???? where do you gt some of your ideas??? trully a cleaver chap and hats of 2 u
Thanks. Its turned in to a bit of an obsession. I'm always looking for ideas from others, and spend many many hours thinking about how to improve the car. Presently, with the new box, I hadn't anticipated having to go back to square one with the suspension again, so thats set me back a few more months. I just hope when I wring its neck, that its rewarding and fast enough to drive. If not, then I'll be going down the Turbo or Supercharger route, with a 2.3 block.
Big heavy box of suspension collected this AM from Parcel Force in Leicester. Checked the contents and there's two of everything, which is always a good sign. Pics later.
Just waiting for the clutch plate and ARP rods to appear in the post and I can crack on with the install again.
The cerametallic Paddle clutch has arrived, Burton are as good as ever in delivering on time.
Now if I'm really lucky the rod bolts will come today too, in which case I'll be burning the midnight oil over the coming nights.
Its my lucky day. The rod bolts have arrived :D
Drained the sump last night, and only discovered that a) the sump plug was loose, and b) I only had 2litres of oil in the sump. The joys of not running a dipstick. :D
Most of the oil leaked at the rolling road session when we couldn't stop the remote filter housing from pissing oil everywhere, must have lost a litre until Troy stripped it down and cured the leak. And the remote housing and Capri filter accounts for more than a litre, so I'll make sure when I refill the engine I measure how much I put back, and make a short dipstick calibrated to the amount in the sump.
I'll be putting the engine on its side this afternoon, to remove the sump. Just seeing if I can scrounge some RTV from work, as I'm sure B&Q white sealant isn't going to cut the mustard.
I may even go for an equivalent photo of me holding the engine, like Matt took, but although the engine is pretty light, even I don't think I have Matt's strength. Unless I photoshop it of course.
Hi Gray
I've used a few and have found Loctite 5910 Premium Black Silicone from Halfords the best. Designed for exactly what you need it for, I'm pretty sure it's what Ford use judging by it's looks post use and characteristics. Comes in a toothpaste style tube, about £7
HTH
I used Blue Hylomar in the end Matt :D Should be more than adequate, but thanks for the tip.
Pics from changing the flywheel to changing the rod bolts
Removing the original ST clutch and flywheel from a couple of weeks ago.
http://www.zetecinside.com/xr2/pictures/20110508_16.jpg
http://www.zetecinside.com/xr2/pictures/20110508_17.jpg
http://www.zetecinside.com/xr2/pictures/20110508_18.jpg
http://www.zetecinside.com/xr2/pictures/20110508_19.jpg
This is where the larger Mondeo sized Titan flywheel hits the gearbox bellhousing. It was already ground away, and I just had to take another 1mm slither off. I believe that just the Focus and Fiesta use the smaller diameter flywheel.
http://www.zetecinside.com/xr2/pictures/20110508_1.jpg
Changing the conrod bolts next. They require torquing up to 45ft-lbs.
http://www.zetecinside.com/xr2/pictures/20110508_2.jpg
http://www.zetecinside.com/xr2/pictures/20110508_3.jpg
The Fiesta ST sump is already baffled for fast road use.
http://www.zetecinside.com/xr2/pictures/20110508_4.jpg
http://www.zetecinside.com/xr2/pictures/20110508_5.jpg
Using blue hylomar to re-seal the sump
http://www.zetecinside.com/xr2/pictures/20110508_6.jpg
Refitting the sump (17 bolts hold it on)
http://www.zetecinside.com/xr2/pictures/20110508_7.jpg
http://www.zetecinside.com/xr2/pictures/20110508_8.jpg
Fitting the new AP paddle clutch and AP cover to the Titan flywheel
http://www.zetecinside.com/xr2/pictures/20110508_9.jpg
http://www.zetecinside.com/xr2/pictures/20110508_10.jpg
http://www.zetecinside.com/xr2/pictures/20110508_20.jpg
The Quaife gearbox back on the engine
http://www.zetecinside.com/xr2/pictures/20110508_11.jpg
My gearbox steady bar bracket that I made from adapting a standard bracket.
http://www.zetecinside.com/xr2/pictures/20110508_12.jpg
http://www.zetecinside.com/xr2/pictures/20110508_13.jpg
Lifting the body to allow the engine and box to be slid back in underneath from the driver side.
http://www.zetecinside.com/xr2/pictures/20110508_14.jpg
http://www.zetecinside.com/xr2/pictures/20110508_15.jpg
I'm concerned about the depth of the new clutch cover. The clutch release bearing is pressing against the clutch with the box bolted to the engine. Not enough to induce clutch slip, as the release bearing is spring loaded, almost as if it is supposed to rest against the clutch. I'll bleed the clutch first and make sure its working properly. Then if I'm happy, I'll start bolting everything back on.
I need to fit the neutral gear selector cable before I can refill the gearbox with 75/90 and then spend some time adjusting the length of the main gear selector so I can get it in to gear properly. Zorst, radiator, fuel, electrics, all 10 minute jobs so I should have it running by tomorrow evening.
Fingers crossed the new suspension clears the end of the box. Mr Hammer is waiting in the wings if it should still interfere. :D
:popcorn:
Clutch works, feedback through pedal it feels good.
Suspension braces fitted, they clear the gearbox and sump this time. Gear linkage connected.
Suspension fits.
Radiator plumbed in.
New throttle cable outer fitted.
Osf hub and axle bar fitted.
Engine bay wiring loom fitted.
Fuel and.oil lines attached.
Busy yesterday. Fitting the new Kustomengineering suspension, I notice that Neil from CF had also fitted them to his s/c mk1, as the June copy of CF Magazine has an article on how to install the kit.
Seeing as this latest setup from Karl is different to my last one, I used the article as a guide.
First problem, is that my kit came only with two 'rod end spacers' to fit on the Tie Bar bracket (page 93, picture 9), so the kit as far as I know, is only supposed to use one of the collars on each tie bar, not both on the one tie-bar bracket.
So fit a single collar between the brace and the red alloy heim, and not on top of the heim. That's how I've done mine and its fine. The thread depth in the tie bar bracket is deep enough for the M19 bolt to clamp tightly against the spacer/heim/brace so this confirms what I think is right.
http://www.zetecinside.com/xr2/pictures/20110512_1.jpg
http://www.zetecinside.com/xr2/pictures/20110512_2.jpg
Second problem the brace on the passenger side was 1cm too short to reach the tie bar bracket. So I had to lengthen the brace by cutting it, inserting some steel tube of the correct diameter, and welding the tubes back together. This could be because my car is shorter on one side to the other, or when Karl put the complex kink in to the brace to clear my Sequential gearbox, it was shorter than he anticipated. Either way, not insurmountable, and its on the car.
http://www.zetecinside.com/xr2/pictures/20110512_3.jpg
The good news is that the suspension clears the gearbox by around 2mm, and I still need to push the engine and box backwards towards the front bulkhead which will give me additional clearance. Its always the same when re-installing an engine, in that it can creep forwards when its first bolted up.
So on to getting the Radiator plumbed in, fuel lines and oil lines attached, engine bay wiring loom re-connected, throttle linkage repaired (the outer slipped at NMH and it created about an inch of free pedal play before the throttle opened), osf hub and axle on. Made a new gearbox steady bar, as the one I made with heims at either end was too harsh. I've now adapted a tube so the bar has an insulator on one end, and a heim on the other.
http://www.zetecinside.com/xr2/pictures/20110512_4.jpg
Just the nsf hub and axle to replace, and I need to fit the rest of the zorst. The neutral gear cable needs replacing which I'll do this afternoon.
Add water, open the garage doors, and she should be good to go
http://www.zetecinside.com/xr2/pictures/20110512_5.jpg
:popcorn:
All done. Loaded up on the trailer, and just need to book myself in at NHM for a suspension setup, and a couple of hours on the dyno to see how much more we can squeeze out of the standard engine. Now the rod bolts have been changed, I'm less concerned about caning it. And since I cured the overheating problem, we can keep running without having to let it cool down between sessions.
http://www.zetecinside.com/xr2/pictures/20110515_1.jpg
Time to send off my championship registration, get some tyres ordered, and send off a few cheques for events.
great to see it back as a whole car :cool:
hope all goes well on the rolling road and i look forward to your first event report (just dont forget the pics) :popcorn:
Thirded :cool:
Ran the engine, all sounds ok. Throttle response is much quicker with the race flywheel.
Bled the front brakes. Nearly done for classic ford show.
i shall be over for a dribble at cf:thumb:
I'll bring my deckchair. Hoping for fair weather.
http://youtu.be/ehTvNAGDv04
Booked the Fiesta in at Northampton Motorsport on June 14th for a good going over. Expecting more than 200BHP this time. Ordered another 5litres of 10W60, and a couple of other bits from DT today. A fuel pressure gauge to so I can keep an eye on the pressure, and a mechanical fuel pump to allow me to fill the tank in the Fiesta more safely than struggling with the weight of a 20 litre Jerry Can.
Spent an age trying to get the suspension to align last night. It still hits the gearbox, and I had to move the strut tops out on both sides to cancel out the -ve camber. NHM will have a good challenge on their hands to get the suspension sorted out this time. :D
good stuff, but have you actually changed anything that will give you more power?Quote:
Booked the Fiesta in at Northampton Motorsport on June 14th for a good going over. Expecting more than 200BHP this time
It's now running the straight cut gearbox, and I have fixed the overheating problem, and fitted ARP rod bolts so the upper RPM limit can be raised from 7000 to 7400, or higher.
ok, it wil be interesting to see if you've gained anything, you might have a bit more power at the wheels from the gearbox but as the rollers meassure run down losses the flywheel fig shouldnt change as a result of the straightcut gears