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Steve’s FW 2.0 Zetec build – January 2021


SteveB21

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Benrobson2999
On 29/03/2021 at 11:25, SteveB21 said:

Couple of small jobs over the weekend - torqued up the ball joints on the front uprights and track rod ends to steering arms. Left 1 - 2 threads spare on the steering racks at the TREs for future adjustment.

Used a crows foot to torque up the bottom ball joint on the uprights and found this useful site to calculate the adjustment required on the wrench setting - only about 12% reduction as it turned out.

 

https://www.tekton.com/how-to-accurately-use-a-torque-wrench-with-a-crowfoot-wrench

 

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Only just over one thread showing on top ball joint after torqueing up, but looking at the Sport 250 manual photos this seems to be as expected.

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Fitted the speed sensor on its bracket. Fitted the bracket first and then realised I needed to take it off again to get access to tighten the 2 sensor nuts, but ended up with just over 1mm gap when all re-assembled, so hopefully that's it.🤞IMG_5060.thumb.JPG.85fcd1511cf8891f4a04450664ab67c1.JPG

 

Will fit some convoluted sleeving, run the wire up and along the upper rear wishbone arm and fit a 3 way Econoseal connector to connect to the harness.

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Front end view:

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Steve now your catching up you can help me 😆 did you find the correct wiring for the econoseal? I earlier today asked the question on my build thread with pics

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No going back now - stock check day tomorrow and then the fun really starts!  Bodywork and seats are for collection at a later date.

Both floor panels on today:

Did a bit of research and found out that the 4-way connector is a Delphi "Weather Pack" connector (20A rating). WSC are getting some new pins from the harness manufacturer for me - apparently bent pin

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SteveB21

Hi Ben - replied on your thread - hope it helps.

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SteveB21

Rear upper wishbones and tank frame fitted today. Had to use a 1/2" UNF tap as per the manual on the rose joint threads.

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Wishbones and frame fitted OK, although fitting the 2 spacer washers between the rear frame mount and wishbone mounting required a bit of leverage with a screwdriver.

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Rose joints & lock nuts fitted with Copper grease: 

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Foam strips fitted to the frame:

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SteveB21

Finished off the rest of the rear suspension today - lower wishbones, uprights and dampers all fitted. Had to use the 1/2" UNF tap on the lower wishbones as with the upper ones. One of the 9-1/2" x 7/16" rods needed fettling with emery paper in order to accept a reducing sleeve for the rose joint and one reducing sleeve need similar on its' outer surface due to poor finish, but other than that it was all straightforward, although a third  hand would have been useful at times. Damper collar set at 85mm as per manual.  Drive shafts next, then fuel tank, pump, etc.

 

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All assembled:

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Realised I was using a very appropriate coffee mug...

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SteveB21

It occurs to me that I am getting close to being able to drop the car (no longer a chassis!) onto axle stands - I'm assuming it's a 4 man lift to do it safely? 

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jonjh1964
4 minutes ago, SteveB21 said:

It occurs to me that I am getting close to being able to drop the car (no longer a chassis!) onto axle stands - I'm assuming it's a 4 man lift to do it safely? 

4 people or an engine hoist and 2 people - we tried with 3 and it was a struggle and I wouldn't do it with less than 4 or a hoist again.

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Benrobson2999

Yes I did the same at that stage and had 5 people. Two at each and and me to shuffle the axle stands where I wanted them. Once it was down on one end it was panic over! 

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Adge Cutler- Dorset AO

If you haven’t threaded the handbrake cables through yet, you may wish to consider doing so after fitting the drive shafts and before fitting the fuel tank, makes access much easier IMHO.

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My vote is to leave it up there until you have finished but I have an independent streak with an aversion to bending down!

 

🤣

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45 minutes ago, Adge Cutler- Dorset AO said:

If you haven’t threaded the handbrake cables through yet, you may wish to consider doing so after fitting the drive shafts and before fitting the fuel tank, makes access much easier IMHO.

Thanks @Adge Cutler- Dorset AO - will do.

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SteveB21

Driveshafts and handbrake cables yesterday. Both driveshafts dropped in OK and I found my adjustable wrench was a good fit on the wheel studs to hold the hub while I torqued the driveshaft bolts.

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The handbrake cables were a bit more fiddly. Ran the cables as per the FW manual, but had to spend some time filing out the gap in the ferrule pockets on both callipers to get the nylon coated cable through and then had to unbolt the calliper from the upright so I could get the cable ferrule into place.

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Could not find a nut & bolt anywhere to connect the cable to the calliper - will take another look today.

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Torqued both calliper bolts back to 47Nm. Good news was that there was no need to drill the compensator to take the cable nipples. Will fit some sleeving where the cables touch the chassis and upper wishbones. 

 

Finally, I received some new pins from Westfield to replace the bent pin on my main harness connector (see page 10, 25th March post), replaced the bent pin and connected the engine harness to the main harness.

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corsechris

Re the cable, should ideally be a clevis pin, or at the very least, a plain shank bolt. No idea what WF supply now though, it’s 30 years since I bought our kit :)

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SteveB21

Yes - I initially went looking for a couple of clevis pins, but then saw the manual showed a nut & bolt arrangement, as do a couple of pictures I have of other rear calliper setups. Having said that, the clevis bracket is a machined item, not a bent piece of steel, so a bolt/machine screw with nyloc nut would probably work OK.

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Steve. There was no clevis pins in my kit so I just used a machine screw and Nyloc nut out of my drawer. Seems fine.

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Steve (sdh2903)

Regarding the driveshaft bolts. I know Westfield don't provide these in the new kits, but they should be fitted with the half moon washer plates. I reckon if they weren't needed that Ford would have saved the cost and not bothered either.  Like these 

 

https://www.ebay.co.uk/itm/Ford-Sierra-Escort-4x4-Cosworth-Rear-Drive-Shaft-Spreader-Plate-Washer-New-/265104342531?_trksid=p2349624.m46890.l49286

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