FBY 974J Duratec install.

[dangerousdave]

great minds i thought exactly the same thing

[Ratters]

looking good matt soon be out & about

[mk1matt]

Cheers everyone
And the exhaust hanger is like that coz it ripped the boot floor out once on a speed hump
So to save welding it i bolted two plates either side of the rip

[cossymax]

Matt hats of to you mate,its coming along nicely

[mk1matt]

Well what do you know!!!! Another setback

You wait a year for something and when it arives it dont bloody fit!!!!!!!!!


O.k so its kind of my fault for making the engine mount in the wrong place but i didnt want to wait
The pump needs to go back another 45mm.




Now theres no way im moving the bracket on the car as its all painted and bufty
So sod it out with the angle grinder and away we go..........





And now it fits





Now in the true fasion of british engineering im going to make it strong enough to even hold a pinto up
So i thought i'd start with a nice rod inside..............






Fired up the welder and it just wernt happening
Turns out the wire is well corroded and the sleeve is fooked along with the tip and the shroud So away it went till i can get some more wire and a new sleeve

I will get some 3mm plate and in fill the notch aswel
Do you reckon this will be enough or should i go the whole hog and rib the outside aswell

[Broadmoor]

what drive belt you running matt? could'nt you have left it where it was and run its own belt , By extending the main pulley?

or run it lower like my mates N/A yb

[Dave]

I was going to say run it lower, but Broadmoor has edited his post.

[mk1matt]

Yeah a suppose i could of made a lower plate for it but that would of made the pump very low
As theres no real sump on the duratec and i have it in real low it may have put the belt and pulley in the firing line of any debris
I couldnt really go forward with it as the engine is already forward to clear the water rail.
Anyway ive cut the mount know
I reckon i can build the strength back into it
Cheers for the idea's though

[Broadmoor]

i forget sometimes your a bit tight for space in those old escorts also

I cant comment on strength as i know feck all about that

[mk1matt]

As for strength it only held in the car by 2 bolts so i reckon i just need to make it stronger than them
Which i'll do twice over

[351escort]

Doing a fine job Matt, Keep at it i wanna see it at brunters

[mk1nurburg]

looking good buddy, thats both of us that put our chassis mounts in at pretty much the same time only to later find something collided with them.
looks like your overcoming it fine with brute force and some grinding disks lol. keep it up mate.

[mk1matt]

Rainy day = afternoon in the shed
got down to halfords and got the bits for my welder and we were off


With new wire and a new sleeve my welding still looked like bird shit!!!!
But it aint going to fall apart





And in filled with 3mm plate..................





Cleaned up...............





And now it all fits





A quick trip to gary's this morning (i love wet days ) turned up these so i started fitting them up.
I fitted these on esme when we done the overhaulin so wasnt looking forward to






I'll post some pics of the progress tomorrow
Oh yeah when i was at halfords i picked up a new filter and some oil for the manta so i might change that tomorrow instead

[Little Ant]

one step closer matt

[Robscort]

Good stuff Matt, keep at it! Won't be much longer now. In fact, at this rate your car might be running before Gaz's...

[mk1matt]

Sunny day = afternoon in shed

Onwards with the anti tramp brackets
This has been my home for the last 2 hours
As you can see everything is within easy reach
And a grider for every job although using the one with the wire brush on uder the car is really not enjoyable!!!!!!!




After drilling the holes in my chassis(for the captive nut) i was pleasantly suprised at the thickness of metal left in my chassis
Brackets welded up in place Not pretty but i had the welder up nice and high so the penetration is good.
I dont know why but i just cant get on with welding upside down I guess i just havn't done enough of it.




And the other side...................
Yes dave and dave i know theres a fookin great big blob of weld at the bottom





Witht the mk2 atb in place i can know see that the old anti roll bar brackets need to come off the axle(but you lot probably already knew that)





Not too much of a problem as i wanted to take it off again to have a play with locating the axle on the springs better





And while i was doing that i was also soaking these..............





but i dont hold out much hope for getting the bolts out.
What im after is an old set of worn rear spring rubbers and these were all i could find in my shed. Anyone else got an old set kicking about? + the bits that go in the chassis?
I'll swap for a set of poly ones

More tomorrow popcorn: ............................

[Dave]

Theres a fookin great big blob of weld at the bottom!

[dangerousdave]

Looks more like a severe miss than an unfortunate blob

Also i think i need to get my other bracket on now as its niggling at me Have you tried bolts in them yet, tried with mine today and noticed the thread in the nut is kinda square topped and it should be point, guess they use shit cheap nuts in mine lets hope i dont fuck them up when i whack a bolt in tight

[mk1matt]

Right off with the axle again
And off with the arb brackets. I have another axle casing without the brackets but by the time i'd changed the shafts, diff and cleaned it up it was hardly worth it.

So brackets off carefully making sure i didnt cut into the axle tube
I wont weld the atb brackets on the axle until i have more of the car asembled so i get the correct ride height and position of axle.
It will probably be one of the last jobs know but at least when the time comes the axle is ready




While reasembling i took this photo Dont know why but i thought pop up would apreciate




Went shopping saturday morning so i have another table of joy (you can see from the photo that i left my camera in the shed over night again )




I think 8k should do me this year Will take a bit of jiggery pokery to get it to fit but i like the look.





One of the problems with my lightened flywheel was that it was made to take a AP racing clutch that was the thick end of 300 quid and theres a back order on them too One call to burtons later and they said they had some new pressure plates made up for there flywheels and to pop in coz they might fit. It did So for a hundred quid i got the pressure plate and a pinto clutch plate for a fiver




Got the fittings for the slave cylinder too Because i've moved the gearbox and engine forward i should be able to reach the bleed screw out the top of the bell housing.




When i came to fit the bell housing the slave cylinder wouldnt fit over this part of the gearbox
So i sat and looked for a bit and wondered what was wrong





So then i decided it wouldnt hurt if i done this....................I hope





And know it all fits perfect The oli seal is still in place so i cant see a problem in cutting the sleeve down Anyone see a problem????





And back in the car
Prop back on tomorrow night and if i get a chance to get to fords and buy some new flywheel bolts engine back in too





And heres a little insight into next winters project for all of you who spotted it in the table photo





I'm really starting to enjoy myself again know

[Mk2Matt]

Nicely done there Matt Glad to see the enthusiasm hasn't simply returned, but you're enjoying it too! Keep it up

[trig]

Nice update bud well done.

[Robscort]

Good work Matt! It will be good to see the engine back in there once and for all (hopefully).

[mk1matt]

Right so a quick stop at fords and i got some replacement flywheel bolts
I did have to cut them down abit because the lightened flywheel is narrower than the duel mass jobbie its replacing
Quick look up on the internet and torqued them upto 83lbs/pound







Then when i went to fit the clutch using a spare t9 shaft to line it all up and realised i was missing a vital componant So back to fords and looking on the computer it doesnt look like the duratec runs one with the fwd gearbox. Luckily it looks like the same spiggot bearing that ford have used in the x flow and the pinto for years so they will have one in for me tomorrow






Next i fitted up my custom made water rail and instant gasketed it on, then to try the egr blanking plate i got
Bugger. Theres not enough room for the back bolt let alone the pipe. Never mind on to plan b.................





This is the other end of the egr and the hole on the left is 14mm. My dad to the rescue again has the tap to thread this 3/8 bsp i think he said and is in the process of making me an alloy plug to fit





That was about all i could do to the engine until i get the other bits so i switched back to the rear and replaced these............................





With these....................................





Then feeling the cold abit i bought my instument cluster into the kitchen to try and fit the rev counter
Well thats the easy bit done





First try and its looking like its going to be a piece of cake





The job was not made easy by my "helpers"





But really was a piece of cake
I'm well chuffed with the look
Only dodgy moment was trying to find away of cutting the glass Only to remember i had a diamond blade for my angle grinder Lets just say i was lucky




And we wont talk about the hour i took fitting the rev counter in the middle only to try it in the car and realise you could see less than when it was on the left

If i can get the spiggot bearing tomorrow and it fits then hopefully engine in tomorrow pray:

[RChambers]

Good progress Matt. The pinto spigot should fit as it fits the zetec too. I guess Ford use the spigot hole to machine the cranks even though the new fwd gearboxes don't have a spigot bearing. Handy for us fiddlers though

[mk1matt]

Nice of mazda to play game too then

[oldskooler]

brillant thread this, gonna be a nice motor. i take it you plan on stroking the duratec by the look of them pistons.

[Graham]

nice one matt good to see some progress

[Drizz]

Arh a fellow braintreeite i see
With a bit of luck you should see it tare arsing around a roundabout near you soon

Ahhh you from here too then?

[Mr Burns]

It's gonna be awesome.

[mk1matt]

brillant thread this, gonna be a nice motor. i take it you plan on stroking the duratec by the look of them pistons.

Cheers And not sure on how far to go with it yet but whatever it is it will be next winter as i have missed my car more this year than i ever thought i would

Ahhh you from here too then?

Not originaly but i live out panfield way now

It's gonna be awesome.

Good to see you posting lawrence and thanks

[mk1nurburg]

looking spot on matt.... the updates are coming thick and fast again like the old inspiration days lol.
with the car painted like it is, engine and transmission nearly sorted the start up is deff creeping near!!

[Drizz]

Not originaly but i live out panfield way now

I look forward to seeing it about then!

[mk1matt]

Got the spigot bearing sorted and the clutch on and so turned my attention to blocking the egr


Time for a jono moment
A little bit nervy drilling into an alloy head between a water way/ the side and a head bolt





Borrowed a 3/8 bsp tap off my dad and with plenty of cutting fluid (actually penetrating oil worked better with the ally ) took my time and it tapped a treat





Thread cut and its about an inch deep.





I have the choice of two plugs this one is a steel plug which will wind all the way into the block.............




Or this one which my dad made out of alloy and can be cut down to size






Is alloy in alloy better or would the steel one be better
It never needs to come out again.
Any oppinions popcorn:

[cr500dom]

Alloy plug and Loctite

[Retromotorsport]

I'd go alloy as well.. same or near as damm it expansion rates

[Dave]

I would have said alloy as those iron ones usually rust, which would eventually burst your head.
What is this one made of though?

[mk1matt]

I'm not sure dave never really took much notice
The engines sat around for a good few years now though and it hasnt started rusting yet.

Anyway i went with the alloy
Cut it down and then cut a groove in it so i could tighten it I put plenty of lock tight on The end of it and some silcone sealant near the groove end. I wasnt sure about the silicone but when a friend told me they use it on turbo flange's i thought why not I just hope it holds pray:







Its back in and wont be coming out again hopefully It would of only took me 5 mins to fit aswell but i had a bit of trouble lining the pinto clutch up
This is the first time its been all bolted up solid with the clutch and gearbox and ive had a good look round and have clearance everywhere I am going to strugle to fit the hose on the water rail and i reckon before i bolt the tb's on i will bleed the clutch. Its tight but i can get a spanner on the bleed as the engine is know. I'm well chuffed with the height of the engine should make up for the fact i had to move it forward Plus its well light anyway





I dont think it looks out of place ...................





And the modified engine mount which i will be keeping an eye on for the first few miles popcorn:






Next on the list is an alternator which is going to have to go on the oppasite side of the engine to most just hoping it will miss my dry sump tank then its on with planning the plumbing of dry sump and rad and sorting the belt route out
Gonna be trial and error for the next few weeks.
Pretty much like the last year then

[Drizz]

Good man!

[Robscort]

That's a lovely sight! Good work Matt!

[mk1nurburg]

sweeeeeeeet job matt!