Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Re-routed the heavy duty battery cable, to the drivers side of the car, to make the engine bay look tidier. I need to go to Maplins tomorrow lunch time to get some heavier duty cable for the twin Spal radiator cooling fans, as they both draw up to 4.3A when running.

Solidworks model of the Duratec oil adaptor block is now complete, and Karl is producing a 2D drawing so I can get one made in the UK.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

More wiring - when will it ever end? Arghhhhh.

Tested the starter motor solenoid last night, to see how much current it would draw, and it blew a 10A fuse. With the ammeter in line, it draws anywhere from 12.5 to 15A! And thats just the solenoid! Who'd have thought it would require that amount of current, but then it does come in with a hell of a clunk when it fires.

I've made new looms for the radiator cooling fan and electric water pump wires, and I've included a heavy duty cable for the starter solenoid (25A). The wires for the alternator are also included, and I'll tidy it all up tonight.

No joy on the adapter plate machining front as yet. I'm trying to get a few quotes before I leap in.

BTW Maplins stock feck all of any real use, so I bought the cable on line from VWP. 8-)

[Graham]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

im not suprised on the starter solenoid current, just look at the thickness of that wire when it comes off the back of an ignition switch, which is why these days lots of cars have them wired through a relay

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I'm glad I double checked Graham. Could've been embarrasing. The starter switch is going to be in the same box that houses the power relays, so I'll make sure I relay the starter solenoid in too. The spark from the wires made me jump. I thought I'd shorted the battery out. 8)

Nearly finished the wiring. Doesn't feel like I'm getting anywhere at the moment, but I'll not lose sight of the goal.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've been quoted 15 hours to machine the adapter from the 2D print, so I've gone back to see if I can get hold of the 3D CNC model instead, which would drastically reduce the costs.

[cossie matt]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've been quoted 15 hours to machine the adapter from the 2D print, so I've gone back to see if I can get hold of the 3D CNC model instead, which would drastically reduce the costs.

15 Hours How much do they charge an hour if you don't mind me asking mate?

If you get me a block of ali and some dimensions I might be able to help you out there mate

PM me your number mate and we'll have a chat.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

PM sent

[mervhill]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Most sub-contract machinists charge around £40 an hour just for machine time, so I can't imagine that would be cheap Graham?

Matt's dead handy on a mill mate, he wont let you down

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Spoke to Matt yesterday, and sent him the 2D print. Karl in the USA is going to send me the 3D drawing and output file, so I can get it CNC'd properly.

Finished the battery cable + alternator + radiator fan and starter motor loom last night. All Nomex'd up and heatshrunk. I'll feed it inside the cockpit tonight, and start work on the inside of the car at last.

The front suspension is being produced this week (Karl again!) and so I can get the car off the Rutland setup, and on to the new setup when it arrives. Then I can measure the drive shaft lengths and get them fabricated to Gp A spec.

The Croft Sprint at Easter 2010 is the first event. I'm hoping to be at least a couple of seconds a mile quicker than before. I need to from the list of mods Matts done to his Duratec Escort.

Lots of boxes of bits waiting to be bolted on, but with any project, its a case of getting the 'timing' right.

[mervhill]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Graham, if you do end up needing to get it CNC machined then let me know. I have a lot of old contacts in the sub-con engineering industry, some of which I get on with very well so might be able to get it done for you less expensively.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Will do. Anything to keep the costs down...

I'll chase Rutland today to see how the rear axle is coming along.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Axle should be ready next week. It just needs powder coating, and the caliper brackets need anodising.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've got all the 3D stuff from Karl, what file do I need to get it cnc'd. An output file I assume.

[mervhill]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Depends which format it was made in fella. What most programs will do will be to convert .swf files (this is solid works format) and create cutter paths from the 3D drawing.

Contact the sub-contractor and they'll tell you which file they'll need

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've 3 files

.sldprt
.slddrw
.igs