There's loads still to do of course, the exhaust & throttle bodies need to be properly fitted & all the electrics need to be connected up, fuel & cooling systems, starter etc BUT, it's a major step along the road, there are naturally a couple of issues, which if this were one of the car modification / restoration shows would be a MAJOR problem causing untold cost / time over-runs & at least two hissy-fits. For example the air filter is 2mm from the new brake reservoir - way too close. I'll deal with it, it just needs a little thinking about. My plan to replace the air filter with an airbox & remote filter may be about to happen "now", rather than "in the fullness of time"
Wednesday, 19 January 2022
On the up-side I've picked up the seat cushions from the upholsterer & fitted them to the seats & fitted the seats back in the car & I have to say they look pretty splended.
When I bought the car, I thought the seats were too modern for the look I wanted, but even cheap seats were expensive & the diamond quilting in these inserts makes them look more retro.
They need sitting in to press the creases in properly, but I'm pretty pleased with the result.
Thursday, 13 January 2022
That implies the front brakes are on & yes after my brother machined the brackets, the calipers are on, torqued up & the pipes & hoses are fitted.
The car's really close to having the engine put back in now.
Friday, 7 January 2022
|With the cam belt fitted|
|With the camshaft lock fitted.|
But presumably it's been like that for a while as it's a Gates belt not a Motorcraft one, so it has been changed.
Then (drum roll) the bell housing arrived, it needed a mod or two - no disrespect to RWD Motorsport, it was sold as a "Sierra replacement bell housing" & indeed it is, but the Stylus has a Mondeo concentric clutch slave cylinder, so I had to remove a little metal overhanging the central bore & make up a blanking plate for the big square hole where the clutch fork goes. But that's all done & it's on the gearbox, so it can get bled through (when the reservoir is fitted) & the engine can go back in - HOORAH!
Tuesday, 4 January 2022
Yes the engine's more or less done, it needs a few bits taken off so it fits in through the hole in the car & I'm STILL waiting for the vacuum hoses. It'll have to sit there for a while yet as the bellhousing won't arrive for a week or two.
Of course it's untested, so might be all pants when I try to start it, but it's a Zetec & they're almost impossible to kill, so fingers crossed.
As I'd hoped the throttle bodies & exhaust hide a lot of the orange on the engine block, so it's an orange hi-light, rather that "WOW - ORANGE"
Moving the coil pack under the throttle bodies & removing all the plastic helps with the vintage look, so it should look right at home in the late '60s styled car.
Friday, 31 December 2021
There’s been a lot of garage action over the festive period, but not a lot worth photographing I’m afraid, here’s a sort of list:-
Chassis – all the cleaning, de-greasing & painting is done (bulkhead forward).
Fuel System – cleaned, re-configured, shelf re-engineered & re-installed.
Front Suspension – cleaned, de-greased, painted & re-installed. I have a query in with the shock manufacturers as there’s no lock rings on the lower spring pans which doesn’t seem right.
Brakes – Cleaned ready for reinstallation, but with the smaller discs & the spacers under the callipers removed the pads overhang the discs by about 5mm so I need to get the mounting brackets machined, I have a plan for this!
Brake lines – Re-installed, now with bolted P-clips, not riveted. Flexi lines replaced.
Electrical looms – Re-installed, now with bolted P-clips, not riveted. Battery & cage re-fitted.
Brake reservoirs – The three reservoir pots (front brakes, rear brakes & clutch) & their bracket have gone, there will be a combined brake reservoir - crucially with a low level warning - & a separate clutch reservoir. I’ve drawn up the new bracket & a sheet of 1.5mm aluminium sheet is on its’ way. The final design may get "rationalised" (not be that posh).
Fuel lines – The two original ones remaining on the car are cracking & need to be replaced.
Throttle Bodies – The vacuum lines weren’t great so there’s new silicone hoses in the post. Also the trumpets / ram pipes / velocity stacks were parallel for most of their length with a flare at the end – which was just inside the air filter inner surface. I want to replace the air filter with an airbox & remote filter / intake, but for now I’ve drawn up shorter trumpets with a nice parabolic entry & the first pair is on the 3D printer as I type.
So the car is very much being re-built ready for the engine to go in when the aluminium bell housing arrives, hopefully mid January, there’s some fiddly bits like the brake calliper brackets & reservoir mount, but mostly it’s just putting stuff back & making sure it works.
Monday, 20 December 2021
After what seemed like a week of scrapeing & cleaning - but was probably seven days, all
the rust & paint was finally stripped & after de-grease & metal prep, a couple of coats of grey have been
splashed across it. It doesn't look brilliant, but it was never going to, being a 20 year old chassis & looking good was never the point.
I've added a fastner into the pedal box at the top because the whole tray was more or less attached in a single plane & although a stiffener had been rivetted on to support the swirl pot, it had been placed vertically so wasn't doing much, I've lowered the swirl pot & placed the stiffener horizontally & the swirl pot no longer sways about.
I just need to get the off side cleaned stripped & painted & I can start re-building! HURRAH!!