Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Yes please, I'd love to see some pics of Tony's car. I think I met him at Silverstone in 2002, I can recall an immaculate Mini at the meet.



Fuel cell cover finished.
Folded it from 0.6mm steel (bought from B&Q for £6)







I used masking tape to mask the areas I didn't want the Sikaflex to stick to.

After 2hrs drying time, I removed the masking tape and it leaves neat seams.


It is now painted inside in Sunburst red (it is painted in red primer in the pics), and the underside will be painted in Dinitrol 4941 once fitted.

[david_white]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Doesn't that jaz tank still need a cover over the top? (or did I miss something) Looks very very neat but I seem to remember them needing to be firewalled or boxed in??
Congrats on the award

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

All in good time David The existing firewall cover needs a square hole cutting in the top, and a new cover then fabricating to sit over the top of the tank.

Photos of me fitting the first of the two running boards/side skirts last night.











I wore a dust mask when cutting the GRP and directed a fan at the work to blow the particles away as the dust is pretty awful stuff.

The boards will have end caps fitted when I've finished to keep the crud out and to make them more rigid. I have 140mm ground clearance now with the board fitted, so the plan is to lower them further by fitting flexible side skirts to the underside. Ground effect here we come

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Some more pictures of the Bosch 044 fuel pump install, and the tank install.

I used a hole punch to cut the holes out in the cool-it mat, to give clearance for the exhaust bolts in the picture

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The M12x1.5 -6 fuel pump adapter turned up this morning from Torques. But its too long. If you screw it directly in to the outlet end of the pump with one copper washer, the threads bottom out before the washer is compressed. If I leave the steel boss in the end of the pump, then the adapter screws in OK. Looks like I'm going to have to keep the steel boss fitted in that case. Which is a shame as its pretty heavy. I just need one M12 dowty washer for the outlet fitting to make sure it doesn't leak.

Some stainless M4 x20mm washers have turned up for the running boards, as have the M6 fasteners for the fuel pump and fuel tank.

For the pump and tank, I'm using button head fasteners so they don't protrude in to the airflow underneath the car.

[jonboy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Looking good graham, one thing though, is it the picture or is the earth on that pump a tad small ?

Very neat work throughout as ever though

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

It's 32/02 so is safe up to 16A iirc

[cossie matt]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The M12x1.5 -6 fuel pump adapter turned up this morning from Torques. But its too long. If you screw it directly in to the outlet end of the pump with one copper washer, the threads bottom out before the washer is compressed. If I leave the steel boss in the end of the pump, then the adapter screws in OK. Looks like I'm going to have to keep the steel boss fitted in that case.

Why don't you cut a couple of threads off then mate? You must have a hacksaw??? You of all people should know by now that things rarely fit out of the box!!!

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I actually did that last night Matt great minds think alike.

I also cut the M4 ring connector of the end off the fuel pump +ve, and counted 32 strands of copper wire, so it is definitely 32/0.2 which is rated to 16.5A. You did have me worried there for a moment though. I'll run a 10A fuse to see how that survives the current draw.

Is it worth fitting one of those check valves at the same time? To retain the pressure in the rail when then pump stops?

[Adam B]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

have you changed your mobile number?

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

PM'd

Pro-Lite 350 arrived from Earls so started on the flexible sections.

Wired in, plumbed in, just a couple more bits left to do to finish it off.



Video blog

[ryan.minshall]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

look good mate, but your garage is getting a bit messy now for you, so you must be busy. And yes that stainless fuel line does my head in too. keep up the good work mate.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Messy, its just good old work in progress...

The rear wing turned up today. Its 49" wide, approx 10" chord, and weighs very little indeed. Very happy especially as it only cost £100

Its off a BMW circuit racer apparently (not Graham's )



This is how I intend to mount it (like a Golf)


The drivers side running board is now fixed to the car, using rivnuts in the sills and M4 fasteners with 20mm penny washers. I'll bond them on with Sikaflex (equivalent) and make them permanently attached. I did toy with having them on quick release, but after experimenting with the fasteners, abandoned that idea.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

First running board is now finished and ready for fitting. I've cut the profiles on the ends to match the shape of the inner wheel arch, and I've also made a couple of support brackets, one for each end, to stop the board from moving. I'll use the Loctite bond/adhesive to stick them to the sills, and then 3 fasteners in to the sills will keep it in place.





Pictures of the rear wing I bought this week.




And the Goodridge connectors turned up this morning, so I'll finish off the system next week and run a pressure test to check for leaks.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I realised that the outlet for the fuel cell needed to run as low to the bottom of the tank as possible, to prevent fuel starvation, so I made a new section of hardline with a 45degree kink in it. This runs directly to the fuel filter.



The return to the tank is also hardline, but it exits vertically, then winds it way around the tank, and a short section of hose joins the two sections of hardline.



The hardlines run inside the car to the engine bay, one feeds the fuel injection rail, the other returns the unused fuel to the fuel cell.




It is -6 throughout, which is more than adequate for 200BHP. Its a crying shame that the boot is going to be hidden by aluminium firewall, but at least I know I did it all properly.

The pump runs, its much quieter than the Webcon pump, and didn't blow the 10A fuse, so hopefullly it'll not draw too much current which will keep the total load on the 49A alternator down.

More info can be found at www.zetecinside.com