Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Looks like there is a problem with img links on here at the moment, I tried it in the post above and the picture isn't appearing for me.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Not to worry, sure the bof's are working on it. Probably a lack of disk space as it appears to cache copies of files from external sites.

Suspension is finished, Karl is just painting it and pressing the bearings in, and its ready to be FedEx'd over from the USA.
Made an ally plate last night to fit over the hole left from the previous gear lever. Sprayed it sunburst red, and I'll stick it down with silicon sealant tonight. Then I'll finish fitting the new tower to the floor. The steel threaded barrel from Quaife should be with me today, so I can get the cable assembled and tested. Then its time to take the engine and box out again, so I can change the f/wheel and clutch, and then when the suspension arrives, its all going back together.

Just need to get my finger out with wiring in the gear position indicator.

First event is hopefully Snet double header at the end of May, but there's a lot going on at work in May, so I may be out and about as usual racking up the mileage on the Legacy instead of working in the garage.

I'm enjoying a week at home this week. Garage time every night!

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The missing threaded section turned up from Quaife, so I fitted it to the cable last night, then assembled the shaft that sits inside the gear lever housing, and assembled the gearlever back together again.




Next job was to secure the gear lever tower to the floor of the car. I used 4x M6 rivnuts in the base of the tower, and bolted it through the floor using stainless socket head screws.



The gear lever now sits on top, with the cable passing through the bulkhead in to the engine bay. I'm going to relocate the hole, so the cable avoids the exhaust manifold on the other side of the bulkhead.

[Dan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

all looking super tidy graham

and the pic links seems to be fixed now, so doing it the normal way should work

[jonboy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Nice tower you've made there

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Looks better in ally I reckon

Suspension is being shipped tomorrow from the USA. Still waiting for Raceline to call today to confirm the f/wheel and clutch costs (yes, I'll be sitting down).
Engine and box are coming again out over the next few nights.

[jonboy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Lol, my mate with that nova was round last night and there were a few comments made about the copy ha ha.

I think he now wants a match up against you, small block vs big block and all that !

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Removed the engine and box last week, and discovered a crack in the chassis rail on the drivers side where I'd modified it to clear the crank pulley (10 yrs ago).



So I took the opportunity to brace the chassis, and also add gussets to the TCA box section to add some rigidity.






Quite a scare, but spotted in time I hope. If I hadn't removed the engine and box, I'd never have spotted it.

The Titan flywheel has also turned up, only weighs 3.7KG and is the lightest flywheel I've ever held. Also gone for an AP Racing 8.5" clutch and cover, and ARP rod bolts. Fitting these at the weekend and then the engine is going back in.






The suspension has arrived at Leicester parcel force depot, so just waiting for the postcard so I can go and collect it. Took 4 days to clear customs at Heathrow.

[Tristan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

whats the idle speed likely to be , with such a light flywheel?

[Graham]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

tbh, flywheel weight doesnt have a massive effect on idle speed, most full race engines on ultra light flywheels will still idle ok at about 1000 rpm on one, more of an issue is trying to pull away without stalling or lighting the tyres up when your not "going for it"

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I've accomplished feck all this long weekend, after I discovered today that the wrong clutch has been supplied by Raceline. Its centre is too large to fit on the Fiesta gearbox input shaft.

But I did find that after discovering that fitting the gearbox, I couldn't turn the crank by hand, I needed to Dremel some ally away from inside the gearbox, because the larger diameter Titan flywheel hits the inside of the gearbox.

Then I realised that I needed to make 3 x 2mm spacers to move the starter motor out from the larger Titan flywheel to allow the starter motor pinion to engage/disengage correctly. Why on earth does the Fiesta ST have a smaller flywheel, clutch cover, and different starter motor to the Focus/Mondeo!

And I sprayed the engine bay where I'd modified it, with Red paint.

So not a complete loss of a long weekend, but I'm deeply disappointed this evening not to have the engine & box reinstalled. (The open bottle of Merlot is softening the blow)

And the new f/w is 5kg lighter than the one I removed, so its not all bad news.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Just been on the phone to Burtons, and purchased an AP CP5354-15 paddle clutch to replace the Type 9 clutch that Raceline provided me with. Burtons say that the 5354 clutch will work with the CP5905-500 cover. Delivery by the weekend.

Raceline have asked me to send the Type 9 clutch back for a refund.

So I'm sticking with the taller flywheel, but changing to a paddle clutch to avoid any slip.

And just to confirm, yes the Fiesta ST uses a 4mm shorter flywheel than the Duratec engined Focus and Mondeo. Nice!

[rwd2ltrfiesta]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

the spec of this festa is emmence.
did you eva expect it 2 b this gr8 wen u 1st started???? where do you gt some of your ideas??? trully a cleaver chap and hats of 2 u

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Thanks. Its turned in to a bit of an obsession. I'm always looking for ideas from others, and spend many many hours thinking about how to improve the car. Presently, with the new box, I hadn't anticipated having to go back to square one with the suspension again, so thats set me back a few more months. I just hope when I wring its neck, that its rewarding and fast enough to drive. If not, then I'll be going down the Turbo or Supercharger route, with a 2.3 block.

Big heavy box of suspension collected this AM from Parcel Force in Leicester. Checked the contents and there's two of everything, which is always a good sign. Pics later.

Just waiting for the clutch plate and ARP rods to appear in the post and I can crack on with the install again.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The cerametallic Paddle clutch has arrived, Burton are as good as ever in delivering on time.

Now if I'm really lucky the rod bolts will come today too, in which case I'll be burning the midnight oil over the coming nights.