Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[STEVE H]

Re: My Mk1 Fiesta XR2

All i use is the original rear damper bushes,it does nothing to the shell but i do have a strut brace welded between the turrets on the car

[team_zi]

Re: My Mk1 Fiesta XR2

The rear axle is coming along nicely. RPV are turning down Ford Focus disks to 6mm to suit the Hi Spec rear calipers, and removing all the unwanted metal from the axle.

Just ordered the bits for the oil cooler and oil filter install.
2 x -10AN 90 degree forged swivel-seal
2 x -10AN to 1/2" BSP Male/Male adaptor
3 Metres Pro-lite 350 Hose
4 x -10AN 90 degree tube swivel-seal
1 x 10 row oil cooler, wide
2 x -10AN cooler adapter

I'm ditching all of the stainless steel over braided hoses, as they're heavy compared to the Pro-lite 350, and not as flexible. And they take your paint off where the stainless touches the bodywork.

The fuel hoses inside the car will also be replaced, as they 'breath' and I'm fed up with sniffing fuel vapours all the time.

I'll stick all of the old stuff on ebay.

Once the above is installed, and I can get oil pressure, I'll plumb in the radiator.

Working on the design of the wiring control box inside the car prior to commencing the 2nd harness. Contemplating solid state circuit breaker to make it all tidier, and trip fuses that can be reset by pushing buttons.

[team_zi]

Re: My Mk1 Fiesta XR2

OK, so the latest conundrum is one of clearance. I dont have enough space between the Eurospeed (Oz) oil filter take off plate, and the front cross member, to fit my -10AN 90deg hose ends.

I've enquired about male hose ends, but these dont come in BSP (the threads in the Eurospeed block are BSP), so I've ruled them out.

It looks as though I need to get a block of aluminium, to bolt to the engine block, that routes the oil galleries downwards at 90deg to the floor (vertical), with 1/2 BSP threads, so I can then use M-M adaptors and the 90deg hose ends I bought. [So it would replace the Eurospeed adaptor plate shown].

Anyone fancy doing a bit of CAD work for me? I need a CNC format file so I can get Altiss to machine this for me.





Mocal remote oil filter housing, and sandwich plate, with two of the three sensors fitted.

[dangerousdave]

Re: My Mk1 Fiesta XR2

Can you not fit them to the plate with the plate removed, or is it right tight there? How about fbh'ing/chopping and plating the xmember further back or are those 2 holes for a mount of some sort?

[team_zi]

Re: My Mk1 Fiesta XR2

Even if I fit the 90degree hose ends to the plate, and fit the plate, this doesn't allow for any movement of the engine, and I dont want them sitting against the cross member. 10mm clearance or better is desirable when dealing with oil fittings. Chopping the cross member is an option, but its a lot of steel to cut, and there are more elegant solutions I'm sure.

My fag packet drawing shows what I need.

http://www.zetecinside.com/xr2/download/duratec_oil_filter_take_off_plate.pdf

If I could get someone to make an adaptor for me, of my design, to route the oil galleries down to the ground, then I could fit the fittings underneath. Sorted.

[Graham]

Re: My Mk1 Fiesta XR2

graham, what will you be using the car for? i thought it was a sprint car, so im suprised to see you running oil cooler mirrors etc?

[team_zi]

Re: My Mk1 Fiesta XR2

graham, what will you be using the car for? i thought it was a sprint car, so im suprised to see you running oil cooler mirrors etc?

Sprint / Hillclimb is its primary useage (as has been for the past 17 years.)

However, I do enjoy track days, and may also step up to Ford Saloon Car champs in the next few years. Or even the one you race in Graham, depending on finances. So mirrors and oil coolers would be fitted for those events. At the moment, she has no mirrors (and hasn't since 2005) nor handbrake etc, so weight is kept to minimum.

Ignoring the above, I still need to plumb in the remote oil filter housing, so if we can get back on 'track'

[team_zi]

Re: My Mk1 Fiesta XR2

Karl at Kustomengineering in the USA is working on an adaptor block for me. He has the outlets on the top, and I've asked for a vsn with them underneath (to aid CofG)

Login as guest, no password.

http://www.3diw.com/login.asp?u=273a3&f=44435290

[team_zi]

Re: My Mk1 Fiesta XR2

Removed the Rutland -ve camber rear axle last night, which is now Sold, along with the Fiesta Centre disk conversion, cossie calipers etc.

Fitted the 1bar low oil pressure sender to the sandwich plate.

I cant seem to get either the 1/2 BSP or the 1/2 NPT adaptors to screw in to the Mocal oil filter housing. The BSP adapter screws in approx 2 turns then stops, and the NPT adapter only around 1 turn. I reckon its a BSP filter housing, but the threads aren't tapped correctly.

I had this problem before, with the 1/2 BSP -8 adapters. I could never get them to screw in far enough to squash the O-ring, but it didn't seem as bad as it is with these -10 adapters. I'll either shorten the adapters and chamfer the ends, so when its in it butts up against the mocal housing, or get myself a 1/2 BSP bottom tap from BernieSwiss (Ebay) and tap the threads properly to take the full adapter length.

[team_zi]

Re: My Mk1 Fiesta XR2

Ah, its an NPT housing, hence the BSP's never fitted that well (though they never leaked). Not liking the fact that the 1/2 NPT adapter sits so far out of the filter housing, so I'll retap it to 1/2 BSP using a bottom tap.

[cossie matt]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Graham,

If it's a normal Mocal Remote filter head, from memory it is probably -10 in the filter head as well which is an AN thread so neither NPT or BSP will fit.

I'm pretty sure it's a parallel thread in the housing where the NPT is a tapered thread which will explain why it doesn't go in very far. Be careful just running a tap down the hole as you could end up with very little thread left and end up firing it out under heat and pressure and wrecking your nice shiney engine in nano seconds.

The adaptors should screw all the way in to the Hex with a dowty seal or ali washer behind the hex head to do the sealing.

HTH

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

'Sok, I've confirmed from the model number that it's an 1/2 NPT housing Matt. Fear not, it'll be done right. I did try the -10 fittings, but they dont even go in the ends of the housing.

Wired up the heavy duty cable to the starter motor and alternator last night, and tonight I'll run the wires round for the two alternator wires (charge and +12V), and the starter solenoid, and the two electric fans, and the electric water pump (though I've not fitted one yet).

Sold the rear axle and disk conversion last night, which is another £310 in the kitty. I weighed the rear axle, and the complete assembly, including pads, disks, hubs, calipers, came to a whopping 26.5KG. I hope the Focus axle conversion doesn't weigh a lot more.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The 1/2 BSP tap came in the post. Tapped one of the holes, and the other will be done after the kids are in bed. Wifeys out with the Girls tonight so I get extra time in the garage tonight. Yeah.

The 1/2 bsp and npt are both 14tpi so tapping npt to bsp is very easy. Plenty of metal left in the threads. No worries about the Adapters coming out.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Retapped the threads in the Mocal remote filter housing, from 1/2 NPT to 1/2 BSP. I may turn the housing through 90 degrees to allow the sensors on the sandwhich plate to point forwards instead of towards the engine. Its a Capri 2.8 V6 oil filter, the extra capacity aids filtration.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Drawing of adapter block with oulets on the underside, in solidworks, is nearly complete. If all goes to plan, will get the adapter plate CNC'd this week.