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Two7

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35 In Build

About Two7

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    Learner Driver

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    Abingdon

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  1. Two7

    FW SE Zetec Build 2018

    Thanks for the detailed advice, I got the impression the wipers and the fillet was a long and painful journey, I just wanted to make sure I was doing the first steps right.
  2. Two7

    FW SE Zetec Build 2018

    Wipers Step 3. Bend the drive tubes to shape ( remembering to do this with the drive core inside). The tubes are a lot less tough than those brake and fuel pipes so not to difficult. When tubes are the right shape push the drive core through both the wheelbox's, satisfying to see the cogs go round. Then position and bolt on the wiper motor. Things not to forget 1) install the rubber pad under the motor, 2) use big penny washers next to GRP, 3) Make sure the wiper motor fits within the scuttle, in particular it must not touch the panel above passengers feet or the hinged shelf holding ECU ( as you can see it can get very close). All done now till the dreaded filet. However once the switchgear is all wired up I will test the wiper motor to make sure it parks on the drivers side, fingers crossed.
  3. Two7

    FW SE Zetec Build 2018

    Thought I would bite the bullet and do a detailed summary of work on the wipers. I know it ain't done till the fillet is done, but I thought I would share my steps along the way. Please shout if you spot a school boy error. First I had a chat with Ian at the Factory. He confirmed Wheelbox clamps should be at the bottom ( not the top as per some of the manual diagrams). The Wipers must park on drivers side, i.e. they must point to the right. He also confirmed that it will be 50:50 they park on the correct side only way to check is a test. If they park on wrong side you have to take apart the wiper gear motor (Chris Brading has a good set of pictures on that). Step 1. Confirm distance between wheelbox's , i.e. locate tube B in each wheelbox. I had 320 mm between outer edge of tapered rubbers. Work out distance between center of both wiper shafts 290 mm for me. Mark up using moulded depressions on scuttle as datum and drill 3mm pilot hole in centre of moulded depressions on scuttle , I drilled at an angle equivalent to the tapered rubbers. Note this part of the exercise is not using mm accuracy, it appears the rubbers are hand crafted so they are of different lengths and the angle of cut is different and the diameters look slightly different. Probably obvious but just in case, the wiper shaft must point forwards, i.e. away from the windscreen, Step 2. I used a cone drill to bore out a bigger hole. I used the pilot hole and tried to maintain the same angle with the bigger drill. I opened the hole out to about 14mm. Disassemble the wiper shaft ( I found circlip pliers essential). Keep the bigger tapered rubber on the inside of the scuttle and feed through the hole to the outside of the scuttle then pop on the smaller tapered rubber and screw on ferrule nut with circlip pliers. The holes are larger than shaft so there is a fair bit of play left right / back and forth, however it may not be enough for the fillet fitting so I have worked on logic it is easier to take off less rather than recover from a hole that is too big As a result I may have to fettle those holes later in the build. Just for confidence building I balanced the fillet on the shafts and it all looks roughly in the right place. Next step is bending pipes and installing the actuator core.
  4. Two7

    FW SE Zetec Build 2018

    tunnel top in place, cant delay any more starting on the wipers. Just to check what is the IVA position on washer jets. The kit has two twin jet washers, the manual says install a single twin jet washer. What do the IVA people like 1 or 2, 1 sounds easier.
  5. Two7

    FW SE Zetec Build 2018

    Thanks, that reassuring. So it looks like 3 blocks on one side and 4 on the other is the norm, I wonder why, perhaps a ghost in the machine.
  6. Two7

    FW SE Zetec Build 2018

    Thanks for the feedback, it does look like you have to get a number of the panels almost attached then once the bonnet is in place you can align and screw down everything else. Having mentioned the blocks, I notice that on my new sans number plate dent FW rear end I only have 1 block on RHS, is this something to be concerned about or is this the new normal ?
  7. Two7

    FW SE Zetec Build 2018

    made the first attempt at steering mouse hole and the cut out for engine management loom. Finally getting a bit of colour on the chassis. With respect to the mouse hole I I have cut enough to get it all level, but I am reluctant to carve away any more till I know where the scuttle will finally sit ( I assume that is when I get the bonnet on. With respect to scuttle rivserts, Does it look like need to cut a bit away around the dash rail or does it look Ok to you folks, I assume the rivsert needs to be covered completely by the scuttle return.
  8. Two7

    FW SE Zetec Build 2018

    Quick question re scuttle prep. Should I tackle heater first then windscreen wipers or vice versa.
  9. Two7

    FW SE Zetec Build 2018

    Reassurance when the lights work. Scuttle next, going to get heater in, expansion tank installed, then the rev counter and gauges then a test of the engine, can't wait to hear the mighty ford splutter in to life. As the engine has been static since this time last year I was going to take out spark plugs and turn by hand a few dozen times to get oil moving. Any suggestions on how best to do a manual turn over ( clockwise I assume).
  10. Two7

    FW SE Zetec Build 2018

    Thanks AdgeC. Thanks for the advice as you can see I have slotted the bottom mounting hole and added nuts to keep the lamp at an angle so it is now a bit more vertical, hopefully good enough for an IVA. 9v battery test proves everything is working.
  11. Two7

    FW SE Zetec Build 2018

    Thanks AdgeC, so it sounds like shaving a little of the tub away is the answer.
  12. Two7

    FW SE Zetec Build 2018

    So damn cold in the garage I have managed to negotiate building space indoors . Followed Bugmans blog on doing the lights, with a few tweaks. Made cardboard template for the 3 holes and drilled the reflector ring holes. Attached with self tapping screws and some M4 nuts as spacers, that way they should be removable. I have trial fitted the fog lamp and reversing lamp, and just like everybody else they appear to be pointing up at 20 degs compared to other lights. Spacers are not helping as it looks like metal plate and GRP contoured light holes are not perfectly aligned. I think I need to shave some of the GRP away on the bottom of the holes to allow the light to be at 90 degs to road. Has anybody else had to do similar GRP surgery , is there a less risky route to getting these lamps pointing horizontal ? I assume the lamps don't need to stick out more than the contour, again let me know if that is a duff assumption.
  13. Two7

    FW SE Zetec Build 2018

    Thanks for the advice
  14. Two7

    FW SE Zetec Build 2018

    Thanks folks, some helpful advice. I will do a picture once completed. ADGEC are those 4 popers I can see on the underside of the tail lip for the half hood ? If so did you fit them before fitting the rear tub to the chassis or can you do them easily later when all finished ?
  15. Two7

    FW SE Zetec Build 2018

    Starting to fit the rear lights. I have the new FW rear end without the number plate indent, so should I follow the manual guidance with respect to number plate light position or should it be fitted differently, the factory said the Tea tray is no longer required. Has anybody else got the new back end through IVA yet ? What are the key location points for the number plate light to pass IVA, there is a mention of 55mm. I have read about issues re Fog Light angle, is there some guidance on this people would recommend ? With respect to the reflectors and indicators the manual says "Bond the reflector in place with a suitable mastic-­‐glue such as MS Polymer – anything with “Nails” in the title will do. ". Could I use the sika stuff I have been using between chassis and alu panels or should I use something more appropriate ? Any guidance appreciated as I am not very confident when it comes to GRP.
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