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Steve’s FW 2.0 Zetec build – January 2021


SteveB21
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Stuck Dynamat to the driver's side tunnel panels today, ready for fitting:

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Planning to make a start on the front suspension next - can I just doublecheck that the wishbones are fitted with the thicker bar to the front (top in this photo). It is definitely one of the less well described items in the manual!

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In the wishbone photo above, the front of the car should be towards the bottom of the photo, the rear of the car to the top.

 

The idea is that with upper and lower wishbones in place on the car, the ends connecting to the uprights should have up the upper wishbone end, behind the lower wishbone end, so that the upright is tilted towards the back of the car, to give the right castor.

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It’s not always clear in photos, depending on the angle they were taken.

 

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Made a start on the front suspension, but first I fitted the clutch stop cover from @Benrobson2999 - thanks Ben!

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Lower wishbones fitted easily, but upper wishbones were tight on the outside edge of the mounts and needed a bit of persuasion.  All 4 mounting points have about a washer's thickness of space on their inner edge (not yet torqued up) - does this need a packing washer or does the mount just deform to the bush when torqued up?

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Dampers went on OK, although I did have to go back and turn them so the adjusting knobs faced in rather than out.  There is quite a lot of space either side of the bushes when in the mounts - do I pack this with washers or, as with the wishbone mounts, does it just get taken up by the mounts deforming when torqued up?

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Remembered to fit the IVA covers for the top ball joint locking nuts. Hubs next.

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1 hour ago, SteveB21 said:

Dampers went on OK, although I did have to go back and turn them so the adjusting knobs faced in rather than out.  There is quite a lot of space either side of the bushes when in the mounts - do I pack this with washers or, as with the wishbone mounts, does it just get taken up by the mounts deforming when torqued up?

Pretty sure you'll need a washer each side.

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With wishbone eyelets, if using Westfield supplied bushes, be it Metalastic, Nylon or Poly, you shouldn’t need to pack them out with washers, they clamp up on the crush tubes.

 

Dampers on the other had are different; it depends on the brand and model used, Gaz usually need a couple of packer washers, Protech may need one, sometimes none are need though, just use what’s necessary to fill the gap!

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1 hour ago, Dave Eastwood (Gadgetman) - Club Secretary said:

With wishbone eyelets, if using Westfield supplied bushes, be it Metalastic, Nylon or Poly, you shouldn’t need to pack them out with washers, they clamp up on the crush tubes.

 

Dampers on the other had are different; it depends on the brand and model used, Gaz usually need a couple of packer washers, Protech may need one, sometimes none are need though, just use what’s necessary to fill the gap!

With my trained eye that looks like a 2 washer gap😁

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Thanks guys. I actually checked and I have 8 “spare” washers in the front suspension bag of bits, so looks like they’re not really spare! Will fit them to the damper mountings between the structure and the mounting wings. As @Rich201060says, I have a 2 washer gap. 

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Ian at WSC also confirmed the need to fit washers between the dampers and the mounts, so went back and fitted those today - looks much better. I'm using white Lithium grease on the bolts for the bushes. 

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Set the collars at 70mm and used some threadlock on the collar lock screws to ensure they stay put.

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Fitted the uprights as well - guess what colour the car is! 

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Fitted the 4mm thick black safety washer to the top ball joint mounting, instead of the BZP washer that comes tie-wrapped to the upright, as per the Sport 250 manual. Not much thread showing on the top ball joint once fitted, but I guess that will improve once fully torqued up. 

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Finally, the tool to extract the pins from the Delphi main harness to engine harness connector arrived ad did the job - I now just need a new pin, but at least I know I can progress with fitting the rest of the harness now.

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Can I say that I would not have thread locked the collar screw. As you will need to set up the ride height once the car is finished with it weight on the ground.

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Ditto, I’d strongly advise cleaning the threadlock off. The grub screws can be a devil for sticking and rounding off at the best of time, without threadlock making it worse.

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49 minutes ago, SteveB21 said:

 

Fitted the uprights as well - guess what colour the car is! 

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The best colour for a westfield is orange so great choice.

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