My Zetec POP

[a.south1234]

hi there
this is my project which i started on the 7th december 2011
i am currently studying motorsport at uni, so i will try to put my knowledge to good use, i am only 19 and have only got experience from up keeping my mini mayfair. this project will probably move very slowly as funds are very short meaning a lot of parts will probably be fabricated.
since beginning of december i have managed to get.
105e axle
type 9 gearbox
2.0l blacktop
red esc box
zx6r bike carbs
escort front suspension
converted zetec rwd sump






































the plans for this is to have a 2.0 zetec running a type 9 gearbox, with standard 105e rear axle and suspension, and to run escort suspension up front, giving me disc brakes up front and a steering rack rather than the original steering box
cheers for any comments

[Blackvette59]

Well,I think you have done very well in such a short time......I always say once a project is bought,they don't eat or drink,and you are still young......just do it right and make it safe.Please keep us updated on progress,love 100E's.......

[ryan.minshall]

this will be good to see not seen a pop zetec yet keep at it dude

[Mad Max]

Looks awesome, keep us updated :P

[flowmetrics]

i love this car, i had one as teenager!
Keep going, very nice project

[a.south1234]

well this weekend not much has happened, i managed to get hold of a old retro ford sump so that's another problem solved, i was also having a word with the guy who sold it and he said for the engine mounts i could use old x flow mounts and cut them and weld them to a new plate that is bolted to the zetec, so it looks like the engine mounts will be a diy job.
i dont know how to weld either so i got my dad to teach me on the cup on the escort strut as this was a little rotten, and heres my work




and a couple of weeks ago i finished the rear axle and the x member and tcas here they r, still aint got a picture of the axle finished as it under a load of other bits






and heres the new sump

[caprimentle]

looking good fella, some nice work going into this

[a.south1234]

heres a better picture of my welding

[a.south1234]

just a small update managed to put my struts back together, they look rather clean





i was wondering what everyones ideas are about the height difference between the strut on the left that was already on the car and also has lowering springs in it, and the one on the right that is a standard escort strut. should i just make the front to escort dimensions and not worry about the height difference between the struts?





there is about 2" difference in height

cheers for the comments

[justinveal]

Some great work but I think you need to get some old scraps of metal and practice your welding a bit before you weld something as important as a suspension strut

[a.south1234]

i have been making progress slowly and i have welded up the rear of the car, i just need to paint it and bolt the axle back on.







i also have brought some v8 landrover engine mounts and have stated making the plates to bolt onto the engine.

still looking for a 1.8 cvh oil pickup pipe to fit my sump properally

and i have finally got a steering rack

not much else to report

[exboyracer]

Keep plugging away at it!

[a.south1234]

well its been quite stressful at the moment with exams at uni but i have slowly been doing some work, and now i have finished my first year at uni and i am officially a BUM to spend all my time at home working on my car until i find a job.



heres some rims i picked up for £40

[johnaboyy]

how you going to mount the top of your escort struts on the 100e?

[a.south1234]

my brother has a mk1 escort so i have made a template using his car, i have cut the tops off and have got some plates that im going to weld in place which will be the same dimensions as the escort, so if my measuring is correct it will have the same geometry as a escort

[johnaboyy]

my brother has a mk1 escort so i have made a template using his car, i have cut the tops off and have got some plates that im going to weld in place which will be the same dimensions as the escort, so if my measuring is correct it will have the same geometry as a escort

Could you stick some pics up when you get the struts mounted, interested in how you do it as i had to make a copy of retro ford 100e top mounts to fit my capri struts on my 100e Zetec and i dont like the mounts.
John.

[a.south1234]

will do, il post some pictures when i get home

[a.south1234]

these are my strut tops they have been re angled, i used dimensions from my brothers escort to work out the distances. they are not welded in yet but the general idea is there




my x member has also been welded so it can be bolted into the 100e,


the rear has been bolted back together and is now on wheels,


and the inside rear has been painted


and this is how i modified the 1.8 cvh oilpickup pipe to fit






cheers for the comments

[a.south1234]

little update
gearbox cleaned and painted

making adapter to use original starter

mock up of rims

strengthening pipe on inside of wing

bar to make strut tops even more ridgid

welded in just needed cleaning up


cheers for comments

[a.south1234]

update











cheers for looking

[caprimentle]

some good progress fella

[Blackvette59]

Keep chipping away....it will come.........nice project......

[a.south1234]

ive finished the steering today and started on the bike carb manifold, here some pictures i havnt posted yet



engine mounts before being finished



gearbox

[Mk1mexcos]

Keep up the good work
I built a 100e a little while ago , converted it all to escort front , I ran a 3.0 Essex tho
I converted my front struts to 2 1/4 and used conversion top mounts to stop coil springs rubbing on inside turrets ,
Looking good

[ryan.minshall]

looking good mate keep it up

[Graham]

nice one lots of good progress

re welding turn the wire speed down slightly or current up a bit, and use a slight side to side motion as you slowly move the torch forward, then the weld will flow into the parts being welded not just sit on top

[2010deathproofcapri]

Yeah, well said on the welding side of things! Looking smart tho! Im picking up my 100e sunday. Will be converting the front to escort with a xflow for now and 105e axle and 4 speed but its goin to be my daily! Will bee weekend work only and running thruout the week. I like what you done with the strut tops, id like to do that keeping escort dimensions but time and measuring skills will be slim!

[evans2822]

Nice project mate

[a.south1234]

cheers for the advice, and getting the right dimensions was made a lot easier by having my brothers escort on the drive

[Mk1mexcos]

cheers for the advice, and getting the right dimensions was made a lot easier by having my brothers escort on the drive

Yea I was luck as well had a mk1 on a spit in the garage lol
Keep up the good work

[gsexr]

Good to see the enthusiasm mate
Keep it going

[a.south1234]

small update
heres the bike carb manifold i made, i pressure tested it today and found like a billion holes, so im going to be busy redoing some welding





thanks for the comments

[a.south1234]

small update
radiator mounted






inner wings painted



mani painted

[caprimentle]

your plodding along nicely fella

[a.south1234]

small update
primed the rims

bulk head and gearbox tunnel made




can someone tell me if the this fan is close enough to the radiator, or if i need to add ducting, my brother says it might be a bit too far away, and should be mounted on the radiator

[evans2822]

Good progress mate

[2010deathproofcapri]

Hi bud, prob a daft question but what, if anythingneeds doing to the 105e axle to fit in the pop or are they straight swap? Obviously bar the brake lines and handbrake etc. Cheers, Jo,

[a.south1234]

my 105e axle was already fitted when i got mine, but from when i was researching you need to cut the perches off the 100e axle and then reweld them onto the 105e rear axle at the right distance, when doing this you need to remember to set the diff angle aswell
hope this helps

[Graham]

the fan wont be very efficient like that, its designed to be directly attached to the rad. it will also badly restrict airflow to the rad itself because its effectivly blanking off most of the air which could reach the rad

[a.south1234]

should i take it off or duct it? i have got another fan but it is smaller (about 8inches) and i can attach on the radiator