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Paul T

1999 SEiW 1800 Q Zetec - Rebuild & Update

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Howsafe Workwear and Safety Equipment

Nice job - hope the brollie does you proud 😎

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Paul T

This week my main aim was to prepare the car for my first outing at Curborough by changing the gearbox and diff oil...

 

Draining the MT75 ‘box is straightforward, there is a drain plug at the rear which has a taper seal (no washer) and comes out with a 10mm hex key. The diff however is more complicated as it only has a single fill point so I had to syringe the old oil out - not the quickest as I only have a 60ml syringe!..but did the job.

 

I bought replacement fluids from ECP, MT75 Specific Oil for the ‘box and regular EP90 for the diff...annoyingly both only come in 1 litre or 5 litre containers and I needed 1.2 and 1.25 litres respectively 🤦🏻‍♂️

 

Refilling the diff is simple but the gearbox is obviously buried in the trans tunnel so I needed a solution to pump the fluid in ideally without buying a pump as I don’t plan on doing this regularly.

 

so I improvised with a pop bottle, bike inner tube and screen washer tubing...

 

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basically cut the valve out of the tube, stuck it inside with a dab of sealant and used a bike pump to pressurise the bottle and push the fluid out. Again not the quickest method but allowed me to fill the box from one bottle fill in about 5 mins 👍🏻

 

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I also finally got around to fitting the small form factor LED number plate light I bought from CBS some time ago, I cut the back down by 5mm so that the lens is level with the edge of the plate and used double sided foam to attach it, it’s tiny and super lightweight so should be fine.

 

Top tip when soldering, use a strand of copper cable to wrap the two wires together before soldering, no need for clamps and gives an additional mechanical grip for a stronger soldered joint...

 

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Another job this week was to get a can of tyre weld and mount on top of the fuel tank with cable ties, hopefully I’ll never need it but without a spare it’s good to have a backup

 

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As in the above pic I have fitted a dip-type fuel sender which is a huge improvement on the float type, the reading is rock steady even in the twistys and much, much easier to install with the welded flange (although I did need to make a cutout in the rear tub to allow easy install/removal) - I did also find out that the dip type sender uses a different range gauge to the float type so I had to grab one of these from Merlin also - because of the variable resistance of these type senders (available in different lengths) there is a little zero-adjustment potentiometer on the side of the gauge which you need to calibrate when you first install. 

 

Looking forward for Curborough now, hopefully will get some good footage/pics to share next week :black-westy:

 

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Quinten

I would be tempted to stick the tyre weld into a bicycle bottle holder...

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Paul T

Curborough was great, started out as a soggy ride over with a couple of the local guys, but the rain stopped around 10 and the first few of us went out onto a very slippery track for a few laps to get a feel for it. The first thing I noticed was 20psi is too high for a damp track so dropped to 15 which made things a little easier.

The track dried of by 11:30 and by that time pretty much everyone had arrived and  the lap times came down significantly. We mixed it up after lunch with different track layouts which really made it interesting and had a few laps out in some very nice cars. Nobody had any major issues...other than a few grass cutting incidents and a new member found out his battery was only held on by double sided tape (not any more!). Overall I was really happy with the car, there are a few things I’d like to tweak and added to the longer term jobs list:

 

- Fuelling wasn’t great when hot, hesitating slightly coming out of corners and when blipping through down shifts.

- Suspension is too soft especially at the rear - having been out in other’s they were more composed and predictable on corner entry and exit.

- Need to sort out the rear tyres rubbing on arches, either change wheel offset, or try adding a degree or so of camber and trimming the arch lip.

- Fit an LSD! 😊 really difficult to get a decent pull out of the corners, inside tyre always spinning up.

 

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I’ve got another track day in June at Bedford so will probably look at the rear arch clash and possibly an LSD before then.

 

A clip from the afternoon session:

 

I also took my DSLR and got some pics

of the other guys if anyone is interested:

 

Curborough May 2019

 

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Greenstreak-Andy D

Great first run!

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AdamR

Good to see you enjoying the car :t-up:

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Paul T

A few more jobs done over the long weekend....

 

As mentioned earlier in the thread, unfortunately as nice as the Intatrim seats are, they were were made with ill-fitting grommets, disappointingly they didn’t disclose this when I collected them so when I went to fit them I was gutted to find the grommets were ~18mm too long for the thickness of the seat(!). I got in touch and they claimed they were trying to source alternatives, but after a couple of months eventually admitted they were unable to source any replacement.

 

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I couldn’t live with them not fitting so decided to modify them myself by removing the two halves (had to break the clips to do this), shortening one side and bonding them back together with polyurethane adhesive.

 

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To ensure a nice tight fit I made up some clamps from threaded bar and some wood and left 24hrs to cure.

 

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Although I’m not happy with having to modify seats that I paid good money for in good faith, I’m pleased with the final result and only had the car out of action for the weekend so a relatively positive result.

 

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I still need to wire in the heaters but as it’s getting warmer now I’m not in a rush, but have started to fabricate a centre panel to house the 2 x heater switches and 12v USB socket which I’ll trim up and start wiring over the next few weeks.

 

2B3B5432-C098-4ADD-96A3-6DCC69F7C451.thumb.jpeg.56de369b5d855f02b70e35be269e8f69.jpeg

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Paul T

I went to Shelsey Walsh last weekend for the first time and had a fantastic day, what a great place, will definitely be back.

 

I only could only stop for a short time but managed to chat to some of the competitors in the paddock including some of WSCC Speed Series guys, and got some shots of @Marto303 and @Keith the Teeth on the hill:

 

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More pics here

 

Conveniently, @mrsntw lives just around the corner so I stopped off on the way home took his 1.8 Zetec engine off his hands (he’s recently bought the car and is going through the process of swapping to an ST170 engine...his build thread is here)

 

The reason being that as per a previous post my current bottom end is of questionable past being re-bored at some point and is currently high on leakdown and low on compression on cyl 3 and 4, so for the relatively low cost of the donor engine I can switch bottom-ends easily which together the head I’ve already re-built and a set of ARP rod bolts, should give a very solid engine for the foreseeable.

 

The engine was a new, crate engine when the car was built and Simon’s car was low mileage so I wasn’t surprised to find the bores and block deck in excellent condition with what looks to be the original head gasket fitted.

 

Next job is to get it on the stand, inspect the crank & bearings before fitting ARP bolts and prepping the windage tray for the Raceline sump, ready for the swap.

 

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In parallel to this I’ve also started on the fuel injection swap, I’ve sourced a set of GSXR1000 throttle bodies and looking at how best to install them (likely a DanST manifold)...plenty to be getting on with, plus another track day next week to keep me busy 😊

 

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mrsntw

Thanks for the shoutout @Paul T :) 

 

Exciting times ahead!

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Keith the Teeth

Good to meet you at Shelsley and glad you had a good day. Great pictures. Best of luck with the engine build.

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Paul T

Haven’t updated for a while (too busy enjoying the car!) but I’ve now stripped the engine fully and because of the condition I’m just going to clean it all up, check the clearances and then rebuild with a gasket set and of ARP rod bolts (which are en-route with my cousin from the states).

 

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With the shocking weather I also spent some time painting the front suspension as it had a little surface rust that was bothering me so that all looks much neater now.

 

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And finally fitted the dominators I pickup up recently from @WINGNUT 👍🏻, I wasn’t sure I liked them at first, but now they’ve been on a week or so I’m going to keep them on (626g weight saving😁).

 

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Chris King - Webmaster and Joint North East AO
On 04/06/2019 at 23:47, Paul T said:

GSXR1000 throttle bodies and looking at how best to install them (likely a DanST manifold

 

I can recommend the DanST manifold and other conversion parts - here’s mine

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A5CBF782-41F9-4BE4-A1DE-5B811DBFC3BC.jpeg

DF839A94-B165-434B-AD58-5CE05460476B.jpeg

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WINGNUT
2 hours ago, Paul T said:

Haven’t updated for a while (too busy enjoying the car!) but I’ve now stripped the engine fully and because of the condition I’m just going to clean it all up, check the clearances and then rebuild with a gasket set and of ARP rod bolts (which are en-route with my cousin from the states).

 

C6AE6263-C528-4D86-8C2F-2D099F035970.thumb.jpeg.da68566b8ccd3e65ce655d0ffb638ede.jpeg

 

CC1B2E25-E464-4131-BEEF-E1AD76BAA7DE.thumb.jpeg.9c5b345b69eab0d8ccc611a3f7d4b50b.jpeg

 

With the shocking weather I also spent some time painting the front suspension as it had a little surface rust that was bothering me so that all looks much neater now.

 

6F8A9423-AAA1-4E5A-BE0E-6A4F98F67ABE.thumb.jpeg.bab4f651f26baacaf07c931b1990aa83.jpeg

 

And finally fitted the dominators I pickup up recently from @WINGNUT 👍🏻, I wasn’t sure I liked them at first, but now they’ve been on a week or so I’m going to keep them on (626g weight saving😁).

 

830D4F80-EB7C-45C4-9264-B7BB3BA5ED52.thumb.jpeg.0703e3176280598602f53c6a8043cb15.jpeg

 

FF7D6EC4-3053-4972-82BF-A8DFBE5BE634.thumb.jpeg.656d7cd66531425ad9a45a580c2d18a3.jpeg

 

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Glad your happy with them Paul, just didn't look right on mine, possibly the wide track I have or the colour of car? Just couldn't settle with them, look mint on yours 👍

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Paul T

It’s a been a while since I posted, mainly due to spending lots of time driving the car and enjoying the pockets of nice weather!

 

It was MOT time this month (first time

for me), I gave the car a once over and took it to my local garage who were very interested in the car and happy for me to sit in an operate the controls etc...one thing I did notice was the CV joints starting to perish..this was on my ‘winter to do’ list but I think you can see what’s coming...

 

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Unfortunately the rear of the car was jacked back up off the ramp the NS outboard boot split open (doh!), obviously this is a fail (other than that it went through with no advisories) so this week I thought I’d get the shafts out and give them a proper clean up and new boots all around.

 

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The old shaft assemblies were pretty rusty and the metal shields which attach to the boots were very bad, so I managed to source a genuine GKN Lobro all-in-one shield and boot from ECP, they are listed as ‘Porsche 924/944 Non Turbo‘ but the dimensions are perfect for the Sierra Shaft and 100mm Lobro.

 

I saw in @Barnsley John‘s post @Steve (sdh2903) found a much cheaper alternative to the genuine GKN boots, but as I needed them quick (10 day retest) I opted to get next day from ECP.

 

With the boots ordered I stripped the CV joints and gave them a thorough clean, sanded the surface rust off the externals and re-painted satin black, and then re-assembled with plenty of moly grease on the bearing surfaces before assembly and packed in once it’s all together.

 

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Top tip for re-assembly, make sure the inner part (splined) and the outer body features are out of phase...basically the wide and narrow sections need to be opposing as in picture below, otherwise the joint won’t articulate 👍🏻

 

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Just waiting on a set of zinc plated 12.9 SHCS bolts to re-assemble to the car and get back for the re-test...hopefully arriving today so I can take the car to the Kineton Classic Meet Thursday 🤞🏻

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Paul T

Done, 25lb ft / 34Nm 👍🏻

 

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