GavinR's Mk2 Stage Car - DVY

[wildo105e]

Re: GavinR's Mk2 Stage Car - DVY

Nice work Gavin, Interestingly I spent on the engine mounts (hindsight says i should have gone chassis mount but it's in now) and skimped on the alternator mount making that myself but i don't have a dry sump pump to fight with. I am awaiting my exhasut and manifold from ashley now but my engine is in the standard position on the engine mounts now so hopefully it will fit.

Out of curiosity how much was the crank keyway work (thinking ahead for more power).

[alladdin]

Re: GavinR's Mk2 Stage Car - DVY

keep it coming gavin , nice to have a home build to read lately

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

Nice work Gavin, Interestingly I spent on the engine mounts (hindsight says i should have gone chassis mount but it's in now) and skimped on the alternator mount making that myself but i don't have a dry sump pump to fight with. I am awaiting my exhasut and manifold from ashley now but my engine is in the standard position on the engine mounts now so hopefully it will fit.

Out of curiosity how much was the crank keyway work (thinking ahead for more power).

I think I've ended up with the engine lower than most as the Ashley manifold outlet was below the chassis rails and also hit the compression strut mount
The Retroford manifold is also a little bit lower than it needs to be but should be ok once the sump guard is fitted. It was also touching the steering column and the chassis gusset, so I moved the engine 5mm to the drivers side and added a scallop to the gusset so it should fit ok now

The work done by Dunnell was keyway in the crank (£40), 5 mm key (£8), enlarge keyway in the Retroford pulley as it only had a 3mm keyway, (£29.50) and they also supplied a new crank sprocket (£87.50) as mine was worn, all plus VAT and delivery
I could have got a machine shop to do the work, but decided it was better to go to someone who builds engines for a living!

[dodgydoughnut]

Re: GavinR's Mk2 Stage Car - DVY

Nice work gavin. Always good to see. Might end up with a nice duratec in my Mk1 someday soon.

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

Some more pics

The ST oil filter plate would normally have an oil / water cooler on top so has a port down into the filter
A union was welded on and the other port welded up. The 60 degree union just fits underneath the starter motor and points nicely to the 120 degree union from the dry sump pump, and the -10 pipe is above the engine mount



Rear water elbow and bypass pipe



I think this will work for the alternator after removing a web below the FWD engine mount. If there's too long a length, I can add another idler near the alternator pulley as I've seen other people do



Idler pulley threaded into the ally block



Clutch reservoir and gusset scallop. Clutch pipe is coming out the side of the bulkhead which should miss the water elbow and meet up with the bellhousing without too many problems



Cosworth radiator was modified by Chris DrDub

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

As well as selling the engine, I also sold the Quaife Pro to Oddy as I wanted to fit a Tracsport box with the Duratec

I'd picked up a suitable donor box last September for £183 - I think no one wanted it as it was a Diesel box so had a long input shaft and also an electronic speedo tailhousing, but ideal for fitting a gear kit
It had also been "reconditioned" according to the seller and the insides looked good when I finally got it apart. I'm not sure who had rebuilt it though as there were no gaskets used, tons of grease everywhere and the 5th gear nut was done up to about 200lb ft instead of 100lb ft !

Complete box



A few hours later



I'd gone for Tracsport's semi-helical kit with heavy duty main shaft, 2.29 first gear and 0.82 5th gear
Excellent service from SP Components - I phoned them on a Tuesday, agreed what I wanted and it arrived on the Friday



New gears built up on the new main shaft



Their kits also come with a proper bearing at the front of the laygear cluster
This can be used either with a sleeve on the layshaft, or you can fit a laygear stub shaft to the front of the casing
I thought it was worth doing this while everything is apart, and the Duratec bellhousing is designed for the extra plate
A 1" hole was carefully drilled in the front of the casing (enlarged from the 3/4" layshaft hole about 1/32" at a time)



Stub shaft fitted



And input shaft sleeve cut off (for the hydraulic clutch) and the bottom trimmed



The box is back together now but still on the bench
I decided it would be easier to fit the engine on it's own as it's a bit tight !



Still plenty to do before it's running but no rush as I don't think much will be happening before the summer

[Sidways93]

Re: GavinR's Mk2 Stage Car - DVY

Hi Gavin, nice progress. Any particular reason you went the Duratec route?

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

Hi Gavin, nice progress. Any particular reason you went the Duratec route?

Only because the Cosworth is very expensive when it breaks as everything is modified, where a Duratec uses more standard components to get similar power

[mexicotait]

Re: GavinR's Mk2 Stage Car - DVY

I thought that might be the case. Are cosworth bits, blocks heads etc getting harder to find?

How about the weight of the duratec is it much lighter?

[wildo105e]

Re: GavinR's Mk2 Stage Car - DVY

How about the weight of the duratec is it much lighter?

very much lighter.

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

very much lighter.

Alloy block is standard on the Duratec as well as a lot of modern engines
An alloy block for a Pinto / Cosworth is £4,680 from Burtons but saves 22kg over an original cast iron block, so I assume a Duratec will be similarly lighter than the Cosworth

[GavinR]

Re: GavinR's Mk2 Stage Car - DVY

I got the Duratec running the other weekend, it started quite easily, then stalled when I got out to check everything as the idle was too low.
Turned up the idle and restarted it, it was idling quite smoothly, I had a good look round and noticed fluid coming out of the exhaust.

So I turned it off and pulled the plugs out to find no 2 plug was completely clean and smelt of petrol and the other 3 were sooty. Thinking the worst, that the head gasket had gone, I went to do a compression test but the tester wouldn't fit into the recessed spark plug hole.
A couple of days later, a new compression tester was delivered and this fitted fine, and the engine checked out ok with around 230psi in each cylinder.

Next I unbolted the exhaust manifold and moved it away from the head so I could see what was happening / where the fluid was coming from, and went to start the engine.
Only it wouldn't turn over very well - it would do nearly a complete revolution then stop as if it had a tight spot. I could move it past this with a socket on the crank bolt, then it would do another revolution and stop in the same place. The starter is old and rusty but turned the engine over fine for the compression test (with all the plugs out), so I removed the no 2 spark plug to see if that would help.

It definitely helped and this time fluid shot out of the spark plug hole
A quick sniff test established it was petrol and this was caused by a duff injector which was permanently open, so as soon as the fuel pump was on, it was filling the cylinder with petrol!

Another week and I got some new Bosch "Green" injectors, and a new starter, and it's all running better now - I had a little drive around the yard this afternoon



It definitely needs a rolling road session so that's the next thing to do before I enter any events

[wildo105e]

Re: GavinR's Mk2 Stage Car - DVY

great news and good find on that. I assume it was sort of hydrolocking on fuel. Don't duratecs look right at home in an escort bay.

[mexicotait]

Re: GavinR's Mk2 Stage Car - DVY

That looks really smart Gavin

Look forward to seeing it being used

[notenoughtime]

Re: GavinR's Mk2 Stage Car - DVY

Looks great, as i was reading your post I though injector is stuck open