The Flying Fridge !-gctid105

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Ex_Member

The Flying Fridge !-gctid3239

Post by Ex_Member » Tue May 11, 2010 11:48 am

Aaaragh!



I found a thread on a forum which said something like "of course the Retro Ford Zetec mounts space the engine 1" forward" WHY?? &, WHY DOESN'T IT MAKE THAT CLEAR ON THE WEB SITE??



Also making me angry this week is the fact that I'm struggling to find a clutch release bearing in spite of having the part number, the application & a picture. One should now be in the post fingers crossed, but until it arrives it's not worth thrying to make the engine & gearbox fit together.



& the third thing on my >:( list is the intake plenum. I had intended using the Ford one, but the servo's in the way, I don't want to do without it as I want my wife to be able to drive the car, & it wouldn't fit any better with a Sierra one a'la Burgundy Barn. I was going to get one made up but that's £££ & the guy's starting to not call me back, so I think he's lost interest, so now I'm thinking short DCOE to Zetec manifold, bolt a home made air-box to it & bolt the throttle body to that. OK the flow won't be brilliant, but I can fit trumpets to the DCOE manifold inside the air-box / plenum. Anyone any idea why this might not work? Can't think of any myself.

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Simon_Admin
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The Flying Fridge !-gctid3246

Post by Simon_Admin » Wed May 12, 2010 6:32 pm

Tony,



Try Dave Sewell at FibreForm in Barton upon Humber (01469 535060).

He used to build chassis and suspension for Ginetta and SSC, he also made a Zetec Plenum for Ginetta which had really long inlet runners, he made a short one for my dad's Zetec Spartan, a simple log type manifold that takes the Zetec throttle body, injector rail and sensors.



It's even got a corner missing off the "log" to clear the servo.









Ex_Member

The Flying Fridge !-gctid3253

Post by Ex_Member » Mon May 17, 2010 11:09 am

Well, on Friday the engine came out, the gearbox came out, the front X-Member came out, then the "new" X-member went in (after a little "persuasion") with new track control arms, then the engine (Escort V) was mated to the clutch (Mondeo), & the gearbox (Sierra) was fitted with a new clutch release bearing (Cortina III) & the whole ensemble matched together with the lower half of the seirra closure plate (modified) & the top of the Escort V one (because I lost the top of the Sierra one after chopping it off).



The whole was then gently lowered into the engine bay & joy of joys the prop is long enough (just) there is room for the radiator, the thermostat housing clears the bulkhead & it LOOKs like I can just turn the seirra gearbox X-member round & bolt it in - time will tell. So far so good. The clutch is all hooked up & feels smooth & light. so fingers crossed!



T

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The Flying Fridge !-gctid3260

Post by Ex_Member » Mon May 17, 2010 8:03 pm

Everything going according to plan now, Tony. Satisfying moments.

Do I understand correctly that if the Sierra gearbox cross member is half inch offset, turning it round gives you back the inch 'lost' on the engine mounts? Or is it more complicated than that.

JJ

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The Flying Fridge !-gctid3267

Post by Simon_Admin » Mon May 17, 2010 8:19 pm

If Not the gearbox mounts are easily offset...







Just make sure the fuel line is well out of the way when you put them back !

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The Flying Fridge !-gctid3274

Post by Ex_Member » Tue May 18, 2010 11:32 am

60046045444F592A0 wrote: Everything going according to plan now, Tony. Satisfying moments.

Do I understand correctly that if the Sierra gearbox cross member is half inch offset, turning it round gives you back the inch 'lost' on the engine mounts? Or is it more complicated than that.

JJ




I've yet to prove it, but yes the gerbox X-member is "swept" & has moved about an 1-and-a-bit inches forward, so one hole is in the centre ov the bracket, the other misses the bracket al together. I need to try turning the X-member round, I expext I'll need to slot the holes, but it looks as if it'll line up better. A job for tomorrow I think.



T

Ex_Member

The Flying Fridge !-gctid3281

Post by Ex_Member » Thu May 20, 2010 11:17 am

More progress, I've turned the X-member round & swapped the mountings side to side & all the holes line up - I have a small issue with the speedo cable not haveing anywhere to go, & there is a "tilt" on the X-member which is now wrong, so I may well change it back & do it another way, but for now it's in & located so I've been running the wiring round the engine bay & looking into plumbing.



T

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The Flying Fridge !-gctid3288

Post by Ex_Member » Mon May 24, 2010 11:21 am

This weekend's progress includes fitting a Rover 214 expansion tank, & the Escort V air filter box. Also cut the passenger foot well a little to allow the Zetec cooling pipes to pass as that's a lot cheaper than a water rail. On Sunday I made a start on - & to my surprise nearly finished a little mod which will make the Fridge stand out from the crowd. I'm saying no more at this stage, but it's another of those "you can't do that" mods ;).



Oh I'm such a tease.



T

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The Flying Fridge !-gctid3295

Post by Ex_Member » Wed May 26, 2010 10:58 am

Just ordered all the parts for the plumbing - £230 :-?



That is all the water, fuel & induction hoses, all the bits to join them up, size converters, clips etc though.



T

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The Flying Fridge !-gctid3302

Post by Ex_Member » Thu May 27, 2010 11:06 am

Last night it moved under it's own power!



OK, only an inch or two on the starter motor, but it proved the clutch works & the starter fits the flywheel. I've no oil pressure, so I guess the oil ran out while I was changing the pick-up pipe & being a twit I didn't think to pack the oil pump with vaseline. :-[



All is not lost though, I have a remote oil pressure sensor on a hose off a spigot on the side of the engine, so I'm going to try to back-fill the pump froom that. It's got to be a better first move than pulling the engine.

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