Mk2 RS200 Story so far

[donnie]

Thanks Andy, it’s been a long haul and being away from home for the last 5 months due to the pandemic didn’t help progress. Back at it now so will update the thread soon

[donnie]

Right, finally back in the garage and back to the clutch and brakes so start of with hooking everything up, using a mixture of hard and Braided pipe



First it’s hard pipe from the servo to the bulkhead





Next it’s get the link pipes in place



Reservoir bottles now hooked up





Pedal box back in and connected





Next it’s hard pipe in the bay and to the backend







Now it’s the rear callipers, I have fitted the with the bleed nipple at the top and handbrake cable routed from the underside, some people fit them the other way but will be easier to bleed this way





Next it’s the braided lines non the rear end and that’s the hard ware done



Next it’s move back onto the engine and box as I wasn’t sure how good the box was so went for an updated type 9 with a 2.98 1st gear, larger oilways and bigger bearings

Casing modified for the lay shaft



Layshaft fitted



Bigger bearings



Larger oilways



Next, hydraulic clutch



Bellhousing back on and hoses connected



Ready to fit up again



Stripped the clutch again just to make sure it hadn’t bonded to the flywheel and now back together again









Next it’s fit the exhaust manifold and starter as it’s easier doing it now



Plan next week is to get the engine back in it’s rightful place and start hooking it up

All going well, more updates next Sunday

[Zakspak]

Great to see you back on it Donnie, usual neat work there.
What brake line clips are you using for the hard pipes? I was considering a similar method combining the break and fuel pipes at the same attachment point as I can’t find a suitable single fitting clip for both.
Cheers

[Baron von Teuchter]

Hi Donnie,

It's looking great, was it Graeme Morrison that painted it? I'm out between alford and huntly and looking for somebody to paint my rs2000 from a bare shell too, had bad experiences with various local paint shops over the years!

Hope to see you and this yellow beaut at a show sometime, think Allford has been cancelled this year sadly.

Cheers
iain

[donnie]

Thanks Iain and yep it was Graeme at retro restorations that painted it. Went to the fist Allfords day at Alford many moons ago and saw his work as he had a while Mk1 RS on his stand, quality was great so decided to go with him

[donnie]

Cheers, used the standard 3/16 ford brake pipe clip but made up some small plates which I drilled 2 holes in, 1st hole was for the brake line clip and second was to allow me to mount it onto the fuel line separator clamps

[Baron von Teuchter]

Thanks Iain and yep it was Graeme at retro restorations that painted it. Went to the fist Allfords day at Alford many moons ago and saw his work as he had a while Mk1 RS on his stand, quality was great so decided to go with him

Yeah his workmanship looks top-notch!!

[SimonD]

I have the same pots for my car, they look fantastic don't they

Lovely car btw

[donnie]

Thanks Simon. I had the standard girdling bottles originally and then found these and just had to have them as they would blend right into the bay, which they have

[donnie]

Now to get the engine back in, first I changed the work up crossmember and fitted the original RS crossmember with the retro ford engine mounts









Now in she goes



Alas, even with the gearbox raiser it’s too close for comfort for me



So it’s back to the worldcup crossmember and no issues with clearance







Happy with that now so it’s time to fit the steering rack, anti roll bar and front legs



First it’s dress the quick rack with the boots and track rod ends



Now in it’s rightful home



Finally the steering column



Now the TCAs and anti roll bar



And now in place



Next it’s the struts





Now for the Front brakes





Now with 4 wheels on the wagon for the first time in a long time





Now of the stands and on her wheels



Going to need to adjust the coil overs and lower it a bit more as it’s sitting higher than I want



Gearstick now



Quick shifter fitted



Back where it belongs



Time to dress the engine bay



Next in the throttle bodies












Happy with progress but alas that’s all for now



Back under the cover till next time

[donnie]

Progress over the last while has been limited but moving in the right direction

First the plumbing, changed the expansion tank to the 3 outlet type rather than the 4 outlet type I previously had

Old expansion tank



Now replaced with 3 outlet and plumbed in



Oil / water cooler on the st170 filter housing plumbed in



Notice both hoses are heading towards the bulkhead, didn’t want one up front running across the front so routed it round the back of the engine and then connected to the lower radiator hose





Next time to fill the system



Next it was tidy up the throttle bodies as they looked scruffy





Repainted



Back on the car



Next was the exhaust so that’s the underside done now



Next it’s the lights, mirrors and gutter trims









Next was lower the front as I had set them a bit high

Before



After



Next was the mirror and gutter trims



Followed by an original set of door cards





Next it was a bit of daylight for the first time this year







Next was power, now that didn’t go to plan





Everything pre ignition working, sidelights, hazards, horn, interior lights but that was it

As I have the battery in the boot and a JB under the dash for the main lives, if battery, starter and alternator the engine would spin but no spark and nothing working at ign 2 stage ie fan, wipers lights and so forth so flecked up with the harness somewhere so look at it next time back and hopefully get it running only leaving the interior to finish

Till next time

[katana]

http://uploads.turbosport.co.uk/getr...SizeRender.jpg

Where does the expanded water go now? Expansion tank should be part filled for that reason.

[nursebetty]

What pedal box is that one?

[donnie]

Rix pedal box

[donnie]

Set the expansion tank in the early days when I was going with the standard radiator but went big header tank and left the expansion tank as was so good point but don’t really think it will be needed now or will I need to raise it higher than the header tank

[katana]

Set the expansion tank in the early days when I was going with the standard radiator but went big header tank and left the expansion tank as was so good point but don’t really think it will be needed now or will I need to raise it higher than the header tank

It will if you fill both to the brim like that! And Ideally if retained (and used as an expansion tank) the rad should have a 'blank / springless' rad cap so pressure is generated by the other tank.

[donnie]

So drain them slightly it is, radiator already has a blank springless cap so that should be fine.

[Zakspak]

You’ve made great progress there Donnie. It’s really come alive with the lights fitted. Good work ��

[donnie]

Thanks Zakspeed, agree as it’s starting to look like a finished car now

[rustyshell]

Impressive work going on there!!

[donnie]

Thanks big fella. Yours will turn out the same as it’s impressive in red, just don’t take as long as I did to rebuild it :-)

[rustyshell]

Impressive work going on there!!

Yep fully agree.... what's the target date for getting it all done..... not to long me thinks.

[donnie]

Plan is to have her ready for next for next summer, hopefully be running next time back then it will be the interior followed by all the teething problems

[mk2 stevie]

stunning donnie,

[prox]

Looks very fresh

[rustyshell]

Hey, hope you don't mind ........... can you advise what size (internal diameter) fuel pipe did you use, also did you consider using the nylon fuel line instead of braided?

[donnie]

Don’t mind at all and that what the forums are for as they are good for advice. I used -8 from the tank to the pump and them -6 from the supply and return. I went braided but not required

[Zakspak]

Hi donnie, hows things ? I’m guessing you didn’t manage to get your 1st engine start in December as you’d hoped ? That or you’ve been a real slacker not letting us all know about it

[donnie]

Time was limited to a shift in the garage so not a lot done. Ended up rebuilding my heater with a new motor and matrix so good for another 40 years ��

As for getting her running, I wish. Power to everything now but not firing, ECU has power but alas remains red even when cranking. Have sent the ECU down to Emerald for a health check so need to get another crank sensor just in case that’s the problem. We will see next time back and fingers crossed will get more time in the garage

[jimmy2006]

looks the nuts

[Zakspak]

Well it’s another step closer. Understand the lack of time situation, but you have had a go.
Fingers crossed for when you’re back at it. Hopefully it’s just a duff crank sensor. ��

[skmotorsport]

Awesome work donnie. Much love to detail! Some good tips for me!

[donnie]

That’s what I like about forums, they were a great help during my build and glad the thread can help others

[donnie]

Finally up and running even got it out for a shakedown





Just need to tidy up the loom, put the interior back in, a session on the rolling road and then some fun

[donnie]

Finally up and running, even got her out for a shakedown





Just need to tidy up the loom, put the interior back in, a session on the rolling road and then some fun

[katana]

Hosting pics using Photobucket no longer works so no piccies visible!

[donnie]

Ah well that’s that fecked then

[rustyshell]

Glorious.....so happy to see this!!!!

[skmotorsport]

Great Job Donnie, she looks fantastic!

[RS2OOO]

A project to be proud of, looks amazing.