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Steve’s FW 2.0 Zetec build – January 2021


SteveB21
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7 hours ago, Steve (sdh2903) said:

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

Now you've given me a dilemma @Steve (sdh2903)as I reckon I will also need new M8 bolts with those spread washers as the 50mm ones supplied only show 1 - 2 threads as fitted. Will ponder while I work on the fuel bits - definitely one to do before the tank goes in...

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Amazing where these things come from. First time I have heard mention, though I do remember stories of driveshaft bolts coming loose.

 

I was just paranoid about making sure they were properly Loctited but I have no spreader washers.😐🤔🤔

 

When I eventually get on the road I intend to go round all my critical fasteners after a few miles and see if I have a problem.

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Theres probably loads of people running without them but everytime you see stories of these bolts loosening off it seems the spreader washers aren't fitted. 

 

Ford must've fitted them for a reason I guess. 

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I’ve not got them fitted to mine, but it something I think I’m going to fit.

I’ve had mine come loose twice now but they have been ok since the last time I did them.

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@SteveB21 I fitted the spreader plates (half moon washers) on the upright sides of the driveshaft only, so the bolts threads were no where near the inside of the upright. I have 6 spreader plates and bolts if you want them. This only applies if the stub shaft to driveshaft mating flange is 100mm in diameter on the upright end.

 

CE1ADEE5-8DD7-4E8F-B14F-4185F017AE5A.thumb.jpeg.96ec3c8676713b9ddad47ba2b57207f4.jpeg

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14 minutes ago, Steve (sdh2903) said:

Am intreagued @Yorkshire_Pudding why would you only fit them at one end? 


1st reason being that when I bought my diff second hand with stub shafts and driveshafts they were only on one end.

 

2nd reason being unless I’m mistaken, there is no need for them on the diff side as there is nothing for the bolts to collide on. However, in the upright side, you can’t see how close the ends of the bolts are to the inside of the upright. So the spreader plates just bring the end of the bolt in line with the end of the stub shaft. This means that unless the stub shaft to driveshaft mating flange rubs against the upright there is no chance of them rubbing/touching.

 

could be / most likely wrong tho! 😂

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Thanks for the offer @Yorkshire_Puddingbut I’ve just pressed the button on an order for a set. Decided it was one of those jobs to do now while access is easy. Not much else to report - spent the day pondering the fuel system layout at the rear. Decided to use rivnuts to mount the pump & filter. Plus ordered some R9 spec fuel hose as a bit of future proofing - another one of those “do it now while access is easy” jobs. 

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When I’ve bought them as sets, they’ve always come with enough for both CVH joints on both drive shafts.

 

My old Ford workshop manual for the Sierra showed them on all ends, too.

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21 minutes ago, Dave Eastwood (Gadgetman) - Club Secretary said:

When I’ve bought them as sets, they’ve always come with enough for both CVH joints on both drive shafts.

 

My old Ford workshop manual for the Sierra showed them on all ends, too.

 

Yep they always seem to come in sets of 12. I've always used them both ends. 

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Waiting for some bits for the fuel system and the spreader washers, so spent some time in the warmth of the kitchen applying sound deadening mat to the rear bulkhead panel and the fuel tank.

 

Before:

IMG_5241.thumb.JPG.e6ad02d2e465e1ac1bc8790037869044.JPG

 

After:

IMG_5242.thumb.JPG.885d190bd76cadc40d78967b3db64fd5.JPG

 

Fuel tank:

IMG_5243.thumb.JPG.b538ff16fef129bc5cac06b2c83bafb9.JPG

 

Also fitted the outlet & return spigots:

IMG_5245.thumb.JPG.a07bdc9b1ea29e926573002a0ebf112c.JPG

IMG_5244.thumb.JPG.5ea359e150c807d1f2575b1396799766.JPG

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I have a question - treated myself to a Sytec fuel pump bracket as I wanted a neater solution than the aluminium P-clip. Looking at various diaries I'm pretty sure it will be clear of the bottom of the FW boot box in this position, but can someone  please confirm that for me before I go drilling holes?  The top of the bracket hinge is about 310mm below the top of the fuel tank & about 350mm below the top of the upper chassis frame for the bulkhead. Thanks in advance!

IMG_5247.thumb.JPG.3079fcbadfe028d408feba3a7a89a47d.JPG

IMG_5246.thumb.JPG.4bf066b8d967cce218e77190d2c5c3b2.JPG

 

The inertia switch will go on the the chassis tube above & to the right of the pump.

 

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Ideally the inertia switch wants to be somewhere it can be easily accessed in the event it does trip out. The pros and cons of fitting one are another matter. I went back & forth on it on my recent project but in the end, put one in, mainly because the donor loom already had the wiring for it.

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Fuel filter fitted today, plus spreader washers on the CV joints.  Fuel filter fitted using rivnuts and M6 bolts with spring washers and threadlock. Doing some future-proofing by using Cohline 2240 R9 fuel hose and found it has the added advantage of being more flexible than the R6 hose supplied in the kit, which will be a great help when I have to run the 12mm hose from the tank to the fuel pump. 

IMG_5259.thumb.JPG.f1d40d09ac78008cd901b54352e59305.JPG

 

Fitted the spreader washers to the drive shaft CV joints using M8 55mm 12.9 bolts.  I checked the clearance behind the flange on the uprights by sticking a screwdriver through and there was another 10mm beyond the bolt length, so all good. The spreader washers are 2.4mm thick.

IMG_5261.thumb.JPG.156192e0524bf2a6d5a5dad377b4dfd3.JPG

 

About 5mm of thread on the diff flanges:

IMG_5254.thumb.JPG.21ec54a25190cd6d23f2a4131be78c34.JPG

 

As fitted:

IMG_5255.thumb.JPG.b16616ba3808d53a9c49b7ebdcdbd607.JPGIMG_5256.thumb.JPG.b277af064576c25fc09f529139e05648.JPG

 

Anyone need 24 x M8 50mm 12.9 bolts? One careful owner, only used once...

IMG_5262.thumb.JPG.ab74f94f7cacc4a84b1dbff36d770d95.JPG

 

 

 

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Steve, do you have a part number and suggested supplier for the driveshaft spreader washers?

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