Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[Zetec_RS]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've 3 files

.sldprt
.slddrw
.igs

.sldprt and .slddrw are the respective Solidworks files for the 3D model and the accompaning 2D engineering drawing.

.igs (or IGES - Initial Graphics Exchange Specification) are files intended to allow a 3D model to be transferred between differing CAD programs.

As above, contact your workshop for the format they require. If they require it in a different format then you can email the .sldprt file to me and I can probably save it into the chosen format.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Firmly back on track now. Designing the dashboard, and all the interconnections required to link the following items together

DTA S80 (+12V supply) and all wiring from the engine bay + wheel speed sensors + traction and launch control signals from the Dash + connection to Lambda Sensor and Gear Lever for flat shifting

Dashboard housing Stack instruments + warning LEDs for Oil Pressure etc + switches for traction and launch control + gear position indicator + Race Technology Dash3 display (+ 12V supply)

Race Technology DL1 datalogger - for logging data from the engine over CAN via the S80 ECU, as well as driving the Dash3 display (+ 12V supply) and reading water temperature and oil pressure sensors from the engine.

Camera + Recorder (+12V supply)

Control box with main battery isolator, and relays and fuses for all peripherals. ie power to radiator fans, fuel pump, lambda sensor, wiper, dashboard, ECU, DL1 datalogger, etc etc. This will also house the main ignition and starter motor switches

Looking like a bit of a wiring nightmare at the moment, but I have to do it right for reliability.

Sent off the SolidWorks drwgs today, for the Duratec oil adapter plate, to a CNC company in Leicester, for a quote.

Looking for a carbon fibre cover for the engine bay, to go over the space where the bonnet release catch used to sit. I've had an ally plate stuck on there, but want to replace it (I've seen another Zetec'd Mk1 Fiesta with the same mod, and it looks ace)

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Custom Carbon battery box arrived this morning.


Wiring loom from bulkhead to ECU started.


I guess I'll need the MSA log book renewing, given its got a different engine in it now?

[GavinR]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

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.

Hi Graham,

Where did you get the shielded cable from?
I'm having trouble finding any

I guess I'll need the MSA log book renewing, given its got a different engine in it now?

I wouldn't bother - DVY's logbook originally said Cosworth, then when I sold her she was fitted with a Vauxhall, so this was written on the logbook, now she's back home with the Cosworth I've just crossed out Vauxhall and rewritten Cosworth - none of this has been stamped by the MSA, they're just interested in a change of colour or owner

Thanks

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

STP is from www.rswww.com part no 528-2207

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Added in more wires last week, for the DTA ECU. Mounted on the dashboard, I'll have switches for Launch control on/off (push button), Traction control on/off (switch), Traction map dry/wet (switch), Traction aggressiveness %, which will be a 12 position rotary switch, with a resister ladder which effectively provides the analog input with 0 - 5V, in 10 steps of 500mV per step. This will allow me to rapidly select 0% - 100%, depending on the conditions on the day.


The feed to the dash now includes the above, and oil pressure, water temperature feeds from the engine for the Stack instruments, +12V and chassis gnd, +5V and sensor gnd for the traction control switches, tacho output from the ECU, and gear shift signal again from the ECU. Also has wires from the low oil pressure switch (1bar) and the alternator charge circuit. I dont think I've forgotten anything...


Should be getting my Duratec oil adapter plate this week, and the rear axle in another couple of weeks, as its away for powder coating and the caliper mounting brackets are being anodized.

I've refitted the manual battery isolator, and will be getting the stainless version of the pull cable, as mentioned earlier by Matt D.

[CNHSS1]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

hi Graham,
traction and launch control on the fiesta eh? thats gonna be mega with flatshift. Be interested what differenec it makes when you get it up and running as ive been toying with TC for mine for the damp/wet as slicks are hard work then, and the launch to make boost on the line. Does the DTA support ignition retard and more fuelling ie a switched launch map or simply a secondary rev limiter?
Carbon battery box makes you a tart though
Cheers
Craig
Scimitar turbo hilllclimber..

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I recognise that Avatar 8-)

http://www.dtafast.co.uk/S_80_PRO.htm

The DTA S80 Pro has a spec as long as your arm. It does retard igntion, then it cuts cylinders if that fails to bring the car back under control. Needs four wheel sensors wiring in, but thats OK as my new focus rear end has ABS sensor pickups already present, so I just need to find a way of monitoring the front wheels safely.

You can also use the launch button to set the rev limit on-the-line for takeoffs. So if you want 3000 rpm, rev it to that and press the button. Its all configurable via the PC software. Damn complex to get it all working 100% though. I hear a skid pan or wet grassy field is the best place to perfect traction and launch settings.

DTA has just released a pit lane speed limiter function for the S80 with its latest firmware release. Handy for some...

Once you go carbon, I hear there's no going back. The quality isn't anywhere near as good as my Performance Trim carbon/honeycomb bonnet, but then that cost a lot more.

[CNHSS1]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

cheers for the info Sir, will take a look.
hope to see the latest incarnation of the motor at a hill next season

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Started crimping the cockpit -> bulkhead connector crimps last night. 16 wires, down, only 30 to go. The loom is a little tight, so I'll remove the adhesive heatshrink under the Nomex to give it some more flexability. The new backshells I've found, use adhesive heatshrink to bond to the outer Nomex. Not tried them before, but they look a heap better than the 65mm long strain reliefs I used previously (and weigh a lot less)

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Finished the cockpit bulkhead 48 way connector last night.





Here's the battery box

[dobuy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Mil-Spec that is, what was wrong with snaplock connectors anyway

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Mil spec? Nope, these are the same cheap ITT Canon Neptune connectors as before.
Not wasting money on mil-spec stuff.

[M508]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

wow. even the attention to detail in the loom is fantastic.

Excellent work there Graham, it must be a good feeling knowing that finishing jobs like that means your another step closer to being able to get out and race again

keep up the good work

Ben.

[jason33]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

That loom is fantastic, really making me want to do my engine loom again!

Do you get those ITT connectors from work?

I use similar AMP connectors at work, but the backshells are rediculously long, these on the other hand look very suitable!