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Steve’s FW 2.0 Zetec build – January 2021


SteveB21

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SteveB21
On 12/04/2021 at 08:30, 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

 

Bob - I ordered these - ordered Monday and arrived this morning.

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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:

Big day Saturday - chassis off the build stands and onto axle stands. Did it with 4 helpers plus attached the engine crane at the rear just in case... All went OK, so now I need to tidy up the wiring

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Adge Cutler- Dorset AO
10 hours ago, SteveB21 said:

can someone  please confirm that for me before I go drilling holes?


I can jack mine up and measure tomorrow. Initial thought would be it could be tight! Might be deceptive though.

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SteveB21

Thanks Adge, that would be really useful as I don’t get my bodywork for another month.

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Adge Cutler- Dorset AO

@SteveB21 Fag packet sketch of my tank, chassis, boot box and fuel pump with dimensions as best I can get. Very few parts are square to each other, although boot box front face is roughly parallel with rear face of tank and chassis vert members.

 

FBB97976-F5EA-404B-9082-2763E09AA67C.thumb.jpeg.d05bc27d0eff99dc2260ad634a95a0a8.jpeg

 

Fuel pump mounting:


BF6BB97B-DBEA-45D9-89A1-6B760CDF306D.thumb.jpeg.78ef10e57b0bfb0201da02e37cccc8b2.jpeg
 

 

Approx 25mm clearance boot box to pump rubber jacket:
 

00895A6A-8DA0-48DC-8FD4-F79B415295D5.thumb.jpeg.b6c1cab84a11682a04358f4dab28e7bd.jpeg


Boot box position relative to tank and chassis:

 

D4E74FA2-9052-40D7-AB52-C4C41F47807E.thumb.jpeg.6205792837044e106e18cd5f326db157.jpeg

 

Bear in mind each build will be unique in terms of overall body position relative to chassis. I found positioning the rear tub was like trying to align a jelly. Think it would be prudent to try and give yourself plenty of clearance.

Hope that helps, shout if you want any clarification.

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SteveB21

@Adge Cutler- Dorset AOthanks for taking the time to take those pictures and get measurements - really useful & helpful and much appreciated. I think my Sytec pump bracket won't work as it will raise the pump by about 25mm and rearwards by about 10mm, which will bring it into contact with the front bottom edge of the boot box. Looks like it may be the Westfield P clip after all...

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SteveB21

As well as pondering fuel pump brackets, I fitted the propshaft today. A bit of a fiddle with the handbrake fitted, but then the handbrake is needed so the bolts can be torqued up! I also greased the UJs as the propshaft has a label saying “please ensure this unit is fully lubricated with a lithium based grease before use” – it was clear they had already been greased after a couple of pumps from the grease gun.  Before fitting the shaft I also sealed up the couple of the last remaining gaps between the transmission tunnel panels and the chassis , including those around the seat belt mountings.

IMG_5270.thumb.JPG.441f99e7f9992b8ee0cf02e961e6f1b5.JPG

 

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SteveB21

Decided to get some more drilling (and swarf) out of the way by doing the driver's side outer panel. Had to grind down the outer edges of the seat belt mounts to get the panel flush to the lower chassis tube. Will paint them before fitting the panel.

IMG_5284.thumb.JPG.1ea45180313800412bee0e6537968f40.JPG

 

Lots of drilling later...

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Can anyone tell me what the 2 holes through the upper chassis tube are for, between the 2 rivnuts for the scuttle? I can't find any reference to them in the manual.

IMG_5282.thumb.JPG.c697ae3e447a886fc72d385b9a370162.JPG

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Gary Taylor

Some of the chassis have the holes with crush tubes in for the front leg on a full cage should be both sides

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SteveB21

Drilled out the holes for the passenger side outer panel today. As with the driver's side, had to grind the outer edges of the seat belt mounts to get the panel flush.

IMG_5314.thumb.JPG.2ee2e1d9f7e33333e4459ed1f3722397.JPG

 

Fitted the tank in place so I can start fitting hoses and the fuel pump. For those also following @BobMet's diary, here is the tank outlet clearance with the foam fitted to the tank support frame.

IMG_5315.thumb.JPG.1dd1361e73eaa5cd850993558ced81d4.JPG

 

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SteveB21

Fuel return line (Cohline 2240 R9 hose) fitted today. Used 13mm P clips with M6 dome head screws and rivnuts. Easy access as I haven't fitted the rear panel yet, but I did have to unbolt the lower wishbone from the upright so I could lift it to get access to drill the holes for the P clips on the bottom chassis tube.

IMG_5324.thumb.JPG.9ae37803c50039591ed669dec7923b41.JPG

IMG_5325.thumb.JPG.afdc5daaeb355567360ca890b3e54bfc.JPG

 

 

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SteveB21

Inertia switch and fuel pump fitted today. Fitted the inertia switch with a couple of M5 dome head screws and rivnuts.

IMG_5330.thumb.JPG.a2ad488f8af0481d7371f15c4aebae6b.JPG

 

Fitted the fuel pump with a couple of 62mm P clips, M6 bolts and rivnuts:

IMG_5334.thumb.JPG.d2ad0d8a45b351f4fa4833cdb3d14d38.JPG

 

Tried a couple of hose routings and eventually landed on this one. Fitted some rubber boots over the pump terminals as well.

IMG_5336.thumb.JPG.0af49ba741e01910aa7d9c52be524d1b.JPG

 

Finished off by fitting the fuel tank fixing straps.

 

 

 

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SteveB21

Not much to report as the TR6 demanded my attention over the weekend with an intermittent electrical ignition problem - I suspect it's the the 30+ year old electronic ignition unit after a Sunday spent fault finding, so some points (remember them?) going back in this week.  Westfield progress limited to fitting the fuel tank earth lead and drilling out the tunnel top panels for the M5 dome head screws. IMG_5346.thumb.JPG.12f9765a2971c397289cc72ba1a0b231.JPG

 

Dry fitted the panels, overlaps spot on.

IMG_5365.thumb.JPG.e941066ee14443147277af9531695f48.JPG

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IMG_5367.thumb.JPG.0b9db4aef6ad96eb7840694a2d09ef0c.JPG

 

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SteveB21

Big day Saturday - chassis off the build stands and onto axle stands. Did it with 4 helpers plus attached the engine crane at the rear just in case... All went OK, so now I need to tidy up the wiring round the engine bay and then it will be time to insert the engine & gearbox.IMG_5395.thumb.JPG.8e36eb42081bd0a97d9b4466105ea04e.JPGIMG_5396.thumb.JPG.69e92fcdbc8a5419bb8331c4011eced1.JPG

IMG_5397.thumb.JPG.70508ad10e615bb4497e38ae3efc4a74.JPG

 

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