Well well, 500 posts with a total of 42,100 views. It's been a bit of a journey - it started with putting a Zetec in a kit car & after 500 posts over about 8 years, here I am - putting a Zetec in a kit car.
Another weekend spent mostly under the car, this time without achieving a great deal, Thursday last week saw the arrival of the new plenum from KitSpares, I'd been looking forward to this as one of the more interesting parts of the job, but as is so often the case with aftermarket car parts it was a disapointment.
At either end.
At the other (upstream) it's just as bad, studs are welded on to mount the Ford throttle body, the studs are 18mm long, the mounting flange on the throttle body is 15mm thick meaning the studs don't go far enough into the nuts to hit the nylon lock. Worse than that, fit a gasket & washers & there is no thread to engage the nut at all!
I can cut the studs down if they're too long, but too short is a disaster.
Anyway - I thinks I have a work around that may work to my advantage - more news as it breaks.
I put another terminal on the earth wire (plastic cars need an earth line) & fitted a riv-nut to bolt it to the engine cradle just inside the engine bay, the live I've left dangling until the engine is in. All that took a day as I didn't want to trust pop-rivet so had to remove most of the interior to fit bolts to attach the P-clips - a proper faff, but worth it.
Another thing to get attended to was the handbrake, The guy I bought the car from said he'd changed the handbrake cable & indeed it looks new, however, it feels awful, it's notchy & it doesn't pull the brakes on - at all - my drive really doesn't slope much, but the car will roll down it with the handbrake on. Looking underneath It's the usual kit car thing of not holding the cable outer in line with the cable run, so it twists & snags the cable inner. I simply made up an aluminium channel with a P-clips at each end to hold the cable outers togethr about an inch away from the mounting plate, now the outers have to stay aligned, the inners don't get trapped. Then I made a strap to hold the near side cable outer up, the offside one will be clipped to the fuel plate.
Little by little the car comes together.