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Thread: Dubai Mk1 Duratec

  1. #121
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    Re: Dubai Mk1 Duratec

    Looking really good - regarding the bump stops, don't they have any squish in them? I'd have thought that the bump stops would have some squish in them to ramp up the spring rate before the damper bottoms out hard. I'd be carefull with cutting them, atleast have a talk to the manufacturer first. Or else I fear that you might blow the shocks on a big hit or hard landing.
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  2. #122
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    Re: Dubai Mk1 Duratec

    Yep, I know that is a concern, however, the car will be used totally on the circuit, with no plans to rally it, so chances of getting airbourne are relatively small. My logic (sic) is that the bump stops are probably designed to cope with landings, forests, etc. So shaving 30% off them for tarmac use would probably cause no grief. Happy to be corrected on this by anyone with knowledge or opinion

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    Re: Dubai Mk1 Duratec

    Not too far from all the action then! When are you coming over mate, you might be able to get in some of the meets

  4. #124
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    Re: Dubai Mk1 Duratec

    Be there tomorrow afternoon for 6 days, anything local-ish would be interested in popping in

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    Re: Dubai Mk1 Duratec

    Not too sure if there is mate, anything i do see il let you know

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    Re: Dubai Mk1 Duratec

    loving this build, should be pretty unique over there I expect?

  7. #127
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    Re: Dubai Mk1 Duratec

    Well I thought I was unique until some bloke 60 miles away pitched up with 2 MK 1's and a MK2. Still at least I have some spares now and a fellow enthusiast to share notes with

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  8. #128
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    Re: Dubai Mk1 Duratec

    Nice lookin project mate! Looks like its gonna be a total animal when its done!

  9. #129
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    Re: Dubai Mk1 Duratec

    Been a bit busy of late, so not as much done to Svetlana as I would have liked, however got a few little jobs done.
    First, did the radiator cut out panel, decided to make it a bit wider, to get maximum cooling. So I cut away the standard mounts to create a gap of 505mm, then chopped away the area below for the radiator cut out panel.

    Widened the cut-out panel with a bit of sheet

    and then welded the panel in

    I can now fit a wider radiator than standard and also push it a bit further forward. Decided that it was hard to justify a £300 alloy radiator, so got a brass one made up to my design in Sharjah for AED600 (about £110). Big thanks to Mark from Serck in Sharjah for that.

    Next it was time to modify the Capri 2.8i Bilstein struts. The old pan and spring had been cut off ages ago, so now modifying for the shorter 300lb tarmac struts.

    First job was to cut the new bigger thread to M10x1.0. Drilled the old hole out with a 8.5mm drill, then bit of a bugger getting the tap into the hole, so I forced a 1/4 inch drive socket on the end of the tap, then ground down the side of the tap, so it would go through the track rode end hole.

    Then drifted the bronze insert down the tube, with a 32mm socket by about 6cm. After that cut about 6cm off the length of the tube using my circular steel chop saw. Quick tidy up of the ends with a flap wheel and job done.

    Once it was all welded up, a lick of paint, then on with the new crossmember, rack mounts, adjustable TCA's and voila

    Trial fitted the compression struts

    Now just got to figure out the exact position for the compression struts, somewhere about here

    Finally got my axle all cleaned up, copious amounts of wire brushing, sanding and elbow grease

    Think it looks OK tho'

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  10. #130
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    Re: Dubai Mk1 Duratec

    Nice work buddy

    Turn your steering arms over though!!! Look at the angles of the steering arms and tca's they should be parallel They either need to be turned over or turned over and swapped sides to get the crank right so they sit the rod end away from the disk

  11. #131
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    Re: Dubai Mk1 Duratec

    Funny that, when I mocked it up, I suspected they were the wrong way round

    Don't suppose you have a drawing with the various front suspension angles on them, i.e damper fore/aft angle, TCA fore/aft angle to X-member?

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  12. #132
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    Re: Dubai Mk1 Duratec

    Comp Strut Rod end should be the same height as the inner TCA bolt .. as your car is upside down, that looks too high, and when the cars on it wheels the comp strut will be pointing up towards the TCA and the car will dive like a penguin.

    And as Dave said , swap the steering arms over.

  13. #133
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    Re: Dubai Mk1 Duratec

    Thanks for that Gary, I know how much you love them , I have been playing with the Compression Struts mounting bracket a bit today and had it at the same level as the TCA bolt, however this left me no adjustment with the TCA running parallel to (or straight out from) the WCXM.

    From some diagrams I have seen before, it looks like the TCA's point forwards, in this case it should be fine mounted at the same level as the bolt hole.

    Also just confirming, the struts do hang at a 9 degree angle to match the top plates?

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    Re: Dubai Mk1 Duratec

    the tcas will be forward a bit depends on how much castor you run,and it might be easier making your own comp strut bracket to get the mounting point in line with the tca inner point, quality build so far

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  16. #135
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    Re: Dubai Mk1 Duratec

    So excuse the dumb question, but is the angle of the TCA fore/aft the same as castor angle, as it looks like 5 degrees forward seems like a good starting place

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    Re: Dubai Mk1 Duratec

    9 degrees castor is massive.. standard escort is around 1.5degrees.. you need to bolt a wheel on there, get it so it just misses the front bodywork as it turns .. max castor is always better, more castor less camber needs to used. then make the comp strut fit level with the TCA inner bolt

  18. #137
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    Re: Dubai Mk1 Duratec

    Hi Gary, the 9 degrees that I mentioned was in relationship to the strut top plate and wondered if that was the angle the strut also takes vertically.

    Anyway onwards, new rule for restorations, don't try and mock up your front suspension when jet-lagged or entertaining visitors
    Once I managed to not only put the Track Rod Ends on the right way up but also put the struts on the correct side of the car Yes you lot didn't even notice my brake caliper counts are facing forward

    So got out the trusty level bubble and put the Compression Strut brackets in place, based on the same height as the TCA bolt

    This position should work OK, however the TCA seem to angle forward a little bit with the compression strut adjustment at minimum, which I have seen in some diagrams, but can't find a quoted angle or measurement.
    Anyway, I took a conservative level position, that looks like this

    If all else fails I will shorten the rod, but I think it will be OK.
    Out with the Mig


    Job done, so much easier than welding bodywork.

    Next little job for today was the X-Member mounts upgrade with tube inserts. Was a bit of a pain trying to get the holes all lined up parallel for the tubes, but came up with a patented solution to check parallelism and Verticality



    Anyway all welded up and zinked, fairly happy with the result

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    Re: Dubai Mk1 Duratec

    Coming along nicely
    I can remember just standing there gazing at esme on the 3rd day of the overhauling and just not being able to understand anything in front of me Very similar to jet lag i reckon

  20. #139
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    Re: Dubai Mk1 Duratec

    Lot's of little jobs, trying to get the bottom of the car finished to get it back on its wheels, to fit the engine and gearbox (when they arrive)
    Put the radiator mounts in, couple of M12 bolt shanks cut and welded in



    Radiator fits like a glove now





    Just the side mounts to make now.

    Filled in the bit around the turrets for the firewall and shelf, which I will probably do in alloy.



    Cut off the spring hangars, decided to take off the side plates as well as one looked like it might have a bit of corrosion under the plate, sure enough...



    Was a pretty easy fix, but glad I did it.

    As I wasn't using my spring hangers, no need to skid them, well waste not want not, a couple of hanger skids, re-allocated to the link boxes.



    Not sure if it is an approved modification, but it does put a bit more longitudinal strength into the link box and skids it, just in case I mount a kerb or summit similar





    Purposefully left them open, so they don't collect grot and cause rust.



    Finally got around to welding in the strut brace



    Again pretty easy job



    So gradually working through a list of little chores, will throw the axle on again next week and finalise the fitting of the watts link bars.

    Only real thing to do underneath is to decide whether it is worth bracing the Watts towers (a la Gartrac), this car won't be doing rally's or jumps, so not sure it is needed

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  21. #140
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    Re: Dubai Mk1 Duratec

    Very interesting read..............and some nice work going on - great stuff

  22. #141
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    Re: Dubai Mk1 Duratec

    Making great progress!!

  23. #142
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Lot's of little jobs, trying to get the bottom of the car finished to get it back on its wheels, to fit the engine and gearbox (when they arrive)
    Put the radiator mounts in, couple of M12 bolt shanks cut and welded in



    Finally got around to welding in the strut brace



    Again pretty easy job


    Car is coming along nice!
    Looks like the strut brace is high, dos`it clear the bonnet?
    I can be very wrong here....

    Remi
    (Norway)

  24. #143
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    Re: Dubai Mk1 Duratec

    Hmm, hope you are but you never know..

    Had a look at Jon's Duratec and it looks like the same strut brace, I guess with the wing rails and wings on, it will look a lot better. Time will tell.


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    Re: Dubai Mk1 Duratec

    Highlighted a problem area in red, the heat from the exhaust will harden the steel on the inner wing and eventually it will crack with heat fatigue. I used to see the exact same issue on Sunbeam Lotus...The amount of inner wings i had to repair thru this was just silly.

    I strongly suggest some form of heat shield is made or a redesign of the manifold to pull it away from the inner wing before the inner wing is damaged.
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by ocztony View Post
    Highlighted a problem area in red, the heat from the exhaust will harden the steel on the inner wing and eventually it will crack with heat fatigue. I used to see the exact same issue on Sunbeam Lotus...The amount of inner wings i had to repair thru this was just silly.

    I strongly suggest some form of heat shield is made or a redesign of the manifold to pull it away from the inner wing before the inner wing is damaged.
    Yes it is rather close... I'm going to get the manifold ceramic coated and fit a heat shield.

  27. #146
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Hmm, hope you are but you never know..

    Had a look at Jon's Duratec and it looks like the same strut brace, I guess with the wing rails and wings on, it will look a lot better. Time will tell.
    Yep, there's enough room on mine. You could lay a bonnet over the top to put your mind at rest... As long as you have the hinge end and the slam panel for reference then you'll be able to tell how much room you've got.

    I'm sure it'll be fine though.

  28. #147
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    Re: Dubai Mk1 Duratec

    Well the good news is the bonnet fits just fine over the strut brace, about 5mm of clearance and that is without tapping the strenghtening ribs

    Decided to do a bit of strengthening on the taller of the watts towers, with a tube to the rear chassis rail and also drilled a hole in the boot floor and bout a tube from the watts tower all the way through the floor to the side of the wheel tub.



    Fitted the wing drip rails and as always the second one was a lot easier than the first. Had to do a little bit of panel beating to get the footwell panel up to meet the rail, but worked out OK.


    Then had the pleasure of mounting my Smith & Deakin GRP bubbled wings. With a bit more panel beating on my repairs at the bottom of the screen, they hung on there quite nicely. Am going to fit them on with either rivnuts or captive nuts and bolts. Need a bit more work on the fitting, but pretty close already.



    Then off to Sharjah to do a bit of shopping and picked up a wee 2006 Duratec 2.0L. Not a cheap as I would have liked cost AED3500 or about £625. But it was easier than shipping one in. No idea about the mileage, but looked pretty good from outside



    So got it home and slid it down a plank out of the car, next problem, how to lift it onto an engine stand for strip down

    Well much easier to strip on floor and pop on the stand after it is in pieces, so about an hour later...



    Engine looks minty inside, with bu**er all wear on the big ends or cylinder walls, so looks like it should do fine.

    Note the scrap bin on the right

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  29. #148
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    Re: Dubai Mk1 Duratec

    I've got one in my bedroom looks like that

  30. #149
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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Well the good news is the bonnet fits just fine over the strut brace, about 5mm of clearance and that is without tapping the strenghtening ribs
    Sorry.....

    Remi
    (Norway)

  31. #150
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    Re: Dubai Mk1 Duratec

    No worries Remi, I would rather people question what I am doing that accept it, as I am still learning here

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    Re: Dubai Mk1 Duratec

    Been a while since the last update, had to do a bit of work, so that got in the way

    Cobbled together a firewall/rear bulkhead to isolate the boot area for racing.



    Patented sheet metal bending in process, would have been nice to use a proper folder, but it did the job



    Held in with self-tappers for the moment, but will probably rivet it up once everything is finalised. Also filled in the holes in the rear window to roof side panels, with riveted alloy plates. Finally in the same picture, welded plates into the lower window panel, then a leetle skim of filler.


    Got some 7x13 inch Cheviot Hotwires from www.trademe.co.nz for £100. Gave them a good sandblast, will give them a lick over with matt black 2-pack paint when I get round to do the rest of the car



    Been doing a bit of bodywork, while I wait for the gearbox to arrive from the UK, so decided to blend in the bubbles. Used the glass impregnated filler for most of it and a lick over with fine bondo where required. The glass stuff is nasty to work, keeps clogging the sanding discs up until you are through the skin of each new filler application.



    Gave them a quick lick over with a rattle can primer, will probably have a little more to do on them when I get to painting the car, to get a perfeck finish. Also filled in the welded up fuel filler.


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    Re: Dubai Mk1 Duratec

    looking good

  34. #153
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    Re: Dubai Mk1 Duratec

    i really do like those bubbles they look supercool some nice work there matey!
    if it aint broke, break it!

  35. #154
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    Re: Dubai Mk1 Duratec

    Well again been procrastinating and doing remarkably little, as work got in the way Also waiting for my gearbox to arrive from Blighty, before I can finish the metal work.

    Did a bit of a tidy up on the inner wings with a little skim of filler over the welds, used as little as possible, fairly happy with the result



    Even the cut outs in front of the strut repair panel look reasonable



    Decided it was time to trial fit the block, using the Retro Ford WCXM mounts, needed a tiny bit of ferkling to get the holes all to line up, but block went in nicely







    Rear of head sits pretty close to heater bubble



    Mind you the engine looks like it is sitting at a fair angle, so won't be able to tell until the gearbox is on and all mounted up, with a little 'levelling' push there is a bit more room. I will chop away a bit more of the lip below the bubble, hopefully that will be enough





    Fair bit of room below the crossmember, not sure if the Raceline all internal pumped Dry Sump will fit in there, due to the rack mounts and rack itself



    However Roger from Adelaide has a nice solution available soon



    Finally the strut brace has lots of room below it, so no need for an exotic low level cam cover, as per the Caterham. Think I will stick with the lovely stock plastic one


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  36. #155
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    Re: Dubai Mk1 Duratec

    Decided to do a quick mod to the firewall to give me enough room for the rear cylinder block water outlet, so chopped off the lip and welded it up



    Quick lick over with the flap wheel and looks a bit better now



    Well gearbox finally arrived in Dubai by FedEx



    Its's a 6 speed box off a Duratec engined 2007 Mazda MX5 (NC model) supplied by Dave at RetroFord

    Popped the cylinder block on the crossmember, then hung the box on the back, note the box sits at a 10 degree angle, as the MX5 Duratec sits at an angle in the engine bay. This of course means the box will sit at 10 degrees in the Escort tunnel, but is not really a problem.



    So dropped the car down onto the engine and box, spent a fair bit of time cutting and fettling the hole in the tunnel and the brace to get it all fitting correctly





    It's a about 1cm off centre at the moment in the tunnel, but should be able to tweak it straight by playing with the crossmember mounts.



    Likewise not sure of how high up in the tunnel the tailshaft should be, I have put it all the way up to the floor brace, might have to give Dave a call to find out.

    All looks good in the engine bay, although the engine sits at about a 4-5 degree angle (nose up) with the box jacked up as much as possible, so will need to investigate if that is OK as well





    Clearance at the back of block is now good



    So now just have to think about how I am going to make a mount for the box, as it sits down a bit from the floor and of course has a 10' tilt

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  37. #156
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    Re: Dubai Mk1 Duratec

    There's a Serck in Dubai? Is that pipeline valves?



  38. #157
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    Re: Dubai Mk1 Duratec

    Thats some top class fabrication work there Dobuy
    Boost...the natural enemy of traction

  39. #158
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    Re: Dubai Mk1 Duratec

    Thanks Phil, nice to see someone is watching

    MF, the Serck place is in Sharjah, not Dubai. One of the senior managers there is a serious Petrolhead and was very helpful in organising a radiator for me.

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    Re: Dubai Mk1 Duratec

    Getting there And to have a heater bowl that rust free on a shell is just a dream
    That gearbox looks very deep too???? Will there be any clearance problems if the car is run very low??
    Whats the advantage over a t9?

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    Re: Dubai Mk1 Duratec

    Yeah I keep looking at the heater bowl and wondering how it can be so good and is there anything lurking underneath, but it seems solid at every inspection, so sleeping dogs and all that

    No doubt the 6-speed NC Mazda box is a biggie, but I bought it because there Type 9 is really way beyond its design limit at anything over 220bhp, I plan for about 280bhp. The cost of buying a bellhousing, clutch slave and CRB and uprated Type9 that could handle 250bhp was about double the £850 a virtually brand new box cost me from RetroFord. As the bellhousing is built in things are simple and there is any number of uprated clutch packages available for the MX5. Finally it has, I believe the same internals as the RX7 turbo boxes, which can deal with big horsepower and have lots of ratio's available.

    However as you point out it sits a bit low and weighs 45KG all up so it is not light. The bottom of the mount looks low in the pictures, but it not the lowest part of the. It all sits up above the chassis rails, so will not be the lowest part of the car.

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