Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[Roadsport]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I believe you mentioned you could move the powertrain more to the left?
Or could you drill a new hole in the hub end bracket and move the fauling strut futher from the box?

[Roadsport]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Thinking caps on everybody.
Any suggestions? Put a kink in the tie bar so it goes under and around the gearbox?

Or maybe modify this bracket to mount the strut more to the right?

[wellys]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Could u just extend the bracket down to reach where the rod is sitting now or is that too low

[Tristan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

kink the bar , it's bent on a lot of cars from the factory.

[martinpallot]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Moving the braket is going to change the geometry so I would throw that idea out the window. Kinking it is the best option but a sharp kink will make too much of a week spot. I would re-make the bar longer with a gradual bend along its length.

[Graham]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Moving the braket is going to change the geometry so I would throw that idea out the window. Kinking it is the best option but a sharp kink will make too much of a week spot. I would re-make the bar longer with a gradual bend along its length.

agreed

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

More progress last night. Bolted the intermediate drive shaft back on, and the lower rear engine steady bar bracket.

Karl from the States has been in touch, and agrees that relocating the tie bar mount on the TCA would be the best option. I undid the tie bar and moved it towards the end of the TCA, and that does give me more clearance, sufficient to allow me to run without having to bend the tie bar, which is undesirable anyway, as the force exerted through the arm under braking and acceleration is considerable, and the path from the TCA to the front cross member must be in a straight line, so as not to place any bending loads on the rod ends (heims).

Karls asked for a couple more photos of the setup with the tie bar moved, and will fabricate a new TCA for me.

My concern as ever, is how much right lock I'm going to lose with the relocated tie bar.

The front suspension has always been the cars Achilles heel. The fitment of a five speed box in the Mk1 was never on Fords mind, and the Tie Bar arrangement is a design dating back many decades.

We've tried a kit from the Fiesta Centre, that wrecked the cars castor, and as Dave Walker wrote, ended up with a 'Zig Zag Fiesta' (see the last ever CCC for Daves 'workshop' on my Fiesta)

We then tried a custom tubular steel setup, with heims and a spherical bearing, but this broke at Snetterton whilst I was being a hooligan on the kerbs, so that went in to the scrap bin.

This third iteration is the best attempt yet at solving the weaknesses with the setup, and has proven the best by a long chalk. Karls sold dozens of kits and the results are looking fantastic.

The biggest issue for me, is getting full lock with the tie bar in situ. The steering rack already has lock limiter on it to prevent the rim from hitting the tie bar on full right lock, and I reckon phase four should be to completely do away with the TCA and Tie Bar, and go for the more modern setup as used on most FWD cars these days, with a simple wishbone arrangement.

I'll get the TCA modified to clear the gearbox, and sketch out the next generation. There's already a lot of interest on the various forums, but yet again, I'm pioneering, but if it means keeping the Fiesta marque going for another decade, then thats not a bad legacy to leave now is it?

Something like this Focus OSF arm (for example), aft mounted, would suffice. Made from tubular steel, using the existing inboard TCA mount, and an additional 'weld on' bracket for the aft mount. Simples.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Going to rethink the lower engine steady bar at the rear of the Duratec block. I've ordered a 2nd hand lower rear gearbox mount off ebay, and I'll make a mounting to fasten it to the floor. My lower mount was too high (above the height of the sump) and wasn't really preventing the engine and box from rocking fore/aft.

Karl is making a new TCA and a new Tie Bar mounting bracket for the passenger side, and is also making new brace bars, so I can re-triangulate the front tie bar bracket back to the TCA inboard chassis mount.

Re-fitted the drivers side front suspension this evening. Used more heatshrink on the drivers side axle-bar to keep it from rusting. Thats both sides protected now.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

More pics

Front suspension on the drivers side now fitted back on.


Taking the Quaife gear lever apart to remove the shifter cable [to send the cable back]




The shifter cable is 7 foot long, and only needs to be 5.5 foot so Quaife are going to provide me with a shorter one.
Its bloody heavy! A bit too heavy duty too.


The lower gearbox mount will fit on the standard 3 fixings that are used on Mk6/Mk7 gearboxes.
The Quaife gearbox is built on the side of a standard Duratec IB5+ gearbox casing, which is why the underside looks like any Fiesta Mk6 box.
I just need to work out how to fasten the steady bar to the floor/chassis.


Got my first chance to watch the F1 on Sunday in the kitchen on Freeview, whilst the kids watched their CBEEBIES nonsense in the lounge.

[Dan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

great work as always

but you do realise the tv should be in the shed not the kitchen

[zip]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Oil adapter plate has arrived, as designed by Custom Karl and CNC machined by BR & D Engineering in W.Sussex.

http://www.brdengineering.net/

This will allow me to fit the oil lines to the Duratec. They both point down towards the ground, and are tapped to 1/2BSP

Hello Graham,

Regarding your oil adapter plate. How much thus it build out of the block?
Thanks!

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Hi Remi

Got your PM

Here's the PDF file.

http://www.zetecinside.com/xr2/download/Oil%20Adapter%20Bottom%20BSP.pdf

Let me know if you want the IGS file.

G

[zip]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Hi Remi

Got your PM

Here's the PDF file.

http://www.zetecinside.com/xr2/download/Oil%20Adapter%20Bottom%20BSP.pdf

Let me know if you want the IGS file.

G

Thanks for the pdf file.

I have to take some measurement on my car, and I will get back to you.

Excellent work on the Fiesta!

[mervhill]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

great work as always

but you do realise the tv should be in the shed not the kitchen

Not necessarily, the kitchen is where the food and beer is

[jonboy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Looking good.

Where did you get your carbon control box from ? the one in the footwell ?

I have a mate that makes a similar tie bar and tca setup for Vauxhalls, he has the same problem with wheel clearance on lock but its not that bad that its become a problem, the tie bar brackets are lowered anyway to keep the bars level and the whole thing seems to work very well.





He also made a tower for his Quaife shifter as it sat quite low, it nows sits nearer the wheel which seems to make it more comfortable to use.



Its a great build, he has had a browse at yours at likes it a lot but doesn't personally use the forums to put any comments.

Would be good to see the 2 cars up against each other at some point.

Edit :

Link to his build :

http://www.pngclub.com/forum/showthread.php?t=110574