Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: My Mk1 Fiesta XR2

Ordered a set of 320cc Pico inhead injectors from DTA this afternoon.
No luck getting a throttle position sensor with an input shaft, so I've had to order one from the only company in the world that sells them, at exhorbitant cost. 8-(

Removed the engine loom and the car loom from the car at the weekend, in preparation for the re-wire.

[Retromotorsport]

Re: My Mk1 Fiesta XR2

OOohh its getting closer and closer ..

[team_zi]

Re: My Mk1 Fiesta XR2

Just a bit of wiring left to do. And plumbing the radiator and oil systems in. Oh and sorting out the driveshafts. And plumbing in the clutch release. And making a new dashboard.

And the new front suspension is being worked on in the USA, and could be ready in the next month or so. But yes, it is all getting closer.

[team_zi]

Re: My Mk1 Fiesta XR2

ECU is now installed permanently. Now I can measure the length of the wiring looms.





Injectors from DTA are being returned tomorrow. Can anyone supply me with some IW031's for a good price?

[team_zi]

Re: My Mk1 Fiesta XR2

I've now got shielded twisted pair cable for all the sensors, heat shrink (blue) in 9mm and 6mm with 3:1 shrink ratio, and three more hall effect sensors for the wheels. Time to get in the garage and start making the loom.

[mk2stu]

Re: My Mk1 Fiesta XR2

have fun with that is it a basic loom that you just need to modify to fit or a 100% one off?

[team_zi]

Re: My Mk1 Fiesta XR2

Its a 100% one off. Bit daunting when you start, but as soon as the first wire is cut, the rest just falls in to place. I'm electronics engineer by trade, so its an aspect of the car I know I can do well. Just needs time + patience, and lots of diagrams + heatshrink +crimp tools + heat guns + etc etc.

Eleven sensors in the engine bay so far!
Water x 2
Air
Oil pressure and temperature
Crank
Cam
Throttle
Front wheel speed sensors (x2)
Lambda

Looking today at ordering ITT connectors for the bulkead. Shame they're in Olive Drab only.

[team_zi]

Re: My Mk1 Fiesta XR2

The throttle position sensor arrived yesterday from Active Sensors. £100 worth, but they're the only people that make them with an input shaft on the side. I've fitted it last night and used stainless M4 x 15 bolts to hold it in place. It has a 130 degree sweep, so i'll have some fun setting it up for sure.

I've made a hole in the bulkhead for the wiring loom connector. I'm relocating the two fuel hoses that run inside the car, to accomodate the wiring loom. With the zorst on the back of the engine, there's going to be a lot of heat given off, so everything needs to run away from the manifold, including fuel hoses and wires.

[team_zi]

Re: My Mk1 Fiesta XR2

Bit more work tonight, on my Birthday too! Now thats a treat and a half.

Pics of the sensor on the Titans.

[team_zi]

Re: My Mk1 Fiesta XR2

Bit more progress tonight. Added the crank posn sensor, and used some of the nomex sleeving. Waiting for adhesive lined heatshrink to arrive.

Going to use ITT Neptune 48way connector on the bulkhead.




Cables will be sleeved with more green Nomex. Routing will be sorted out once everything is finished.

[M508]

Re: My Mk1 Fiesta XR2

wow its looking tasty already. is the nomex the green overbraiding stuff?

keep up the good work

[team_zi]

Re: My Mk1 Fiesta XR2

wow its looking tasty already. is the nomex the green overbraiding stuff?

keep up the good work

Yes. The place where I'm based (Thales) uses it on wiring looms that they assemble for military vehicles. It gives such good protection against heat/fire. I can get the occasional offcut, but as its so damn expensive, they dont waste very much. Everything else I've had to source myself, heatshrink, connectors, crimp tools etc. Shopfloors aren't what they used to be as everything is outsourced thesedays.

I dont make looms for a living myself. I work in IT on a consultancy basis, so I dont get to play with hardware, but it is handy sometimes, working for a Defence contractor.

[mk2stu]

Re: My Mk1 Fiesta XR2

atleast you come from a background in electronics its gunna help to make the situation easier
hope everythinks going ok anyway

[M508]

Re: My Mk1 Fiesta XR2

i did look at buying a roll of nomex for mine. i know they sell it in 50 and 100m lengths and not being sure what diameter i'd need put me off a bit and also not knowing its elasticity if any i didnt want to be left with a load of something that was not really of much use! especially at prices like 250 quid a roll!!. just out of curiosity what diameter are you using or were you using?

altho i can see what your saying about looms. once you break it down into basics its not that complicated. you know what all the pins need on the ecu. either in or out. the rest is basic circuitry. power source.fuse. switch to turn it on and off. and ultimatley the object your powering.it just looks daunting as a pile of wire switches and relays on the floor!

really is a cracking little car

[team_zi]

Re: My Mk1 Fiesta XR2

Quite a lot of progress over the last week. Some more wiring completed. And I've been working on the alternator bracket, which just needs the MIG dragging from behind the car so I can weld it all up. Last night I woird up the throttle position sensor using an ITT Mini Sureseal connector (IP67) so the loom in the engine bay is almost complete now. Soon be able to turn my attention to the cockpit loom.

Managed to get some Englemann mirrors for the Fiesta, from Germany, and these'll go on over the next few weeks. I've also bought two M12 to 1/8NPT brass adaptors from Burtons, so I can get the two water temp sensors fitted and connected to the loom.

I've also bought 16 x M12 studs for the wheels, so I can replace the ever so annoying wheel bolts that the Mk1 and Mk2 Fiesta use. Nothing worse than trying to fit a wheel with spaces, using a bolt to locate the wheel + spacer + disk to the hub. Urgh.

And I've got myself a vice mounted metal bending gadget, that means I should be able to turn out angled bits of steel more precisely than wacking them with a hammer in the vice. Thats the theory.

Kustom engineering in the USA are now putting their new fiesta suspension in to production, and the Pro (competition) version will be available in another couple of weeks time (allows additional adjustments).







They're supplying me with a front kit, as well as the rear trailing arms and panhard (which are waiting to go on the car), and the quality is fantastic. Contact www.kustomengineering.com for more details.