Jump to content

Steve’s FW 2.0 Zetec build – January 2021


SteveB21
 Share

Recommended Posts

I know that feeling. Sometimes I spend more time walking around the garage in circles and then come in again!

Link to comment
Share on other sites

Mixed progress today. Spent some time working out where all the coolant pipes and hoses go, then ordered some black silicone hoses to replace the mixed selection that came with the kit.  

 

Then spent some time adjusting the handbrake on the rear calipers - definitely a job that should have been done before fitting the handbrake cables (as they block access to the inboard adjustment nut) and before fitting the propshaft, but done now.

IMG_5711.thumb.JPG.a85bf6fa2c9a5178959059ef0bae2c69.JPG

IMG_5714.thumb.JPG.8638dcca27ef027692b2008ae8013295.JPG

 

Finally, decided to fit the brake hoses - only to find that I should have fitted the connection to the brake pipe through the chassis plate before I fitted the fuel tank, as they are now virtually impossible to access. Hopefully a set of stubby spanners from Halfords tomorrow will sort the problem - I really don't want to lift the fuel tank at this stage...  I had previously decided to fit shakeproof washers on this connection, so those are now on in anticipation of being able to tighten the nut onto them!

IMG_5715.thumb.JPG.d4c722c5bc724a78ebec73fcbea26797.JPG

IMG_5716.thumb.JPG.46afa8620315acc8b8aca23c73c26961.JPG

 

 

  • Like 1
Link to comment
Share on other sites

Phew - a 17mm stubby spanner did the trick - although it would have also helped if I was double-jointed...

IMG_5721.thumb.JPG.4dab5513e77f3236db77dffc30df4ba5.JPG

 

All brake hoses now connected, with a 10mm shakeproof washer under the nut at each chassis connection.  

IMG_5723.thumb.JPG.54752778140b9cad9ebd88db230bafb6.JPG

 

Also put a covers on the connections at the starter - not the neatest solution, but does the job.

IMG_5726.thumb.JPG.be57c0a402814dbda037549fef532dc7.JPG

 

Was looking at the engine mounting bracket in front of the starter and think I'll drill a drain hole in it::

IMG_5727.thumb.JPG.54b70c7a2a199ce143bcce7dcd4dd9f4.JPG

  • Like 3
Link to comment
Share on other sites

Decided to make a start on the dash today. As others have noted, will need to drill a 7mm hole for the speedo function button - will put this to the bottom right of the speedo.

IMG_5741.thumb.JPG.a2bfb069e5b65fc8f3dc1ba1e2e6c123.JPG

 

Oddly, the hole for the heated windscreen warning light is too small - which led me to think that the warning light would be better next to the heated windscreen button anyway. I can't see any reason not to do this (checked the IVA manual), other than extending the loom wires for the light, which is easily done.

IMG_5742.thumb.JPG.2b576d9aa2b7166ee19b630513b9242d.JPG

 

Link to comment
Share on other sites

Are you drilling the dash mounting holes today also? That one of my next jobs I keep putting off 😂 

Link to comment
Share on other sites

Productive afternoon building the dash. Not got to the dash mounting holes yet Ben as I don't have a scuttle yet. Fitted the speedo function button bottom right of the speedo an fitted the heated windscreen waning light next to the heated windscreen button. Drilled these holes by slowly drilling a 2mm pilot hole to avoid pulling the foam, cutting the foam and vinyl around the pilot hole and then using a step drill to make the hole for the function button and a 1/2" sheet metal punch for the warning light. 

 

The 3 small gauges were a  very tight fit and I had to remove the stickers that say "removal cancels warranty"!  I was very glad I got all 3 gauges straight first time.

IMG_5743.thumb.JPG.ef0818a0f50e587ef71dac8e8d8fddfc.JPG

IMG_5744.thumb.JPG.3b1ad6d9e6d6b935aac60c6f01187794.JPG

 

Had to slit the vinyl corners to fit all the rocker switches, but the cuts are covered by the switch bezels.

 

The large gauges were a much easier fit.

IMG_5746.thumb.JPG.605336171c813bf65f2454c63065addf.JPG

 

Better give the kitchen table back now!

 

  • Like 7
Link to comment
Share on other sites

Bodywork and seats collected today - forgot to take the obligatory loaded van photo, so instead here is a picture of it all thrown into the garage so I could return the van on time. Will sort it all out tomorrow.

IMG_5808.thumb.JPG.bb3936ef8bbb77c3b79ba82531c2f993.JPG

 

All very straightforward - apart from one of the van's rear tyres giving way at 70mph on the M40 - don't want to repeat that again in a hurry! Luckily got to the the hard shoulder in one piece and the AA arrived and got it changed within 30 minutes.

 

  • Like 3
Link to comment
Share on other sites

23 minutes ago, SteveB21 said:

Bodywork and seats collected today - forgot to take the obligatory loaded van photo, so instead here is a picture of it all thrown into the garage so I could return the van on time. Will sort it all out tomorrow.

IMG_5808.thumb.JPG.bb3936ef8bbb77c3b79ba82531c2f993.JPG

 

All very straightforward - apart from one of the van's rear tyres giving way at 70mph on the M40 - don't want to repeat that again in a hurry! Luckily got to the the hard shoulder in one piece and the AA arrived and got it changed within 30 minutes.

 

Exciting. That will be a lovely colour! Make sure you check all your panels closely for any scuffs. Hopefully yours will be ok 🤞🏼

Link to comment
Share on other sites

Spent this morning sorting and checking all the bits I picked up yesterday. The good news is that the bodywork looks great, plus I really like the diamond stitching on the seats, which I was in two minds about. The bad news is that one of the seats has a gash in the vinyl, so Westfield have agreed to replace it. There was no gash in the packaging and the seats were well packed in the van by Dan, so looks like pre-existing damage.

IMG_5811.thumb.JPG.3d42a28c30de0d259ebc9a5d5c97bd16.JPG

 

Also, the driver's side footwell carpet is too long by about 15mm and is too narrow. The passenger side carpet sits in the footwell, but is very wonky, so they will both get replaced.

IMG_5813.thumb.JPG.e2df757cf986a4cadc8299390166bdcd.JPG

IMG_5814.thumb.JPG.9ea3a56c34895878bbaaca67fcf768a7.JPG

IMG_5815.thumb.JPG.d0fde380051a83d1605d57daee7e5654.JPG

 

The carpets under the seats are also slightly wonky, but I wonder if this will be less obvious once the tunnel carpet, vinyl side panels and bulkhead carpet are all in place?

IMG_5818.thumb.JPG.0b1084af07d81bf365a0ca8be715a62d.JPG

IMG_5819.thumb.JPG.b55d71f4ee19b21782e9a352c6fe7edf.JPG

  

Link to comment
Share on other sites

I must admit I thought the carpets on mine were a bit odd shapes. Once it all came together it fitted a bit better. The only thing Iam not entirely happy with is the location of the gear stick gaitor. It feels slightly to far forwards or back, I can’t remember now without looking at it.

on a positive though you really cannot fault WSC for customer service can you. :) 

Link to comment
Share on other sites

Yes - customer service is great - the immediate response was "we'll get the seat replaced", no argument.

 

Ben - I seem to recall you found a template for the various scuttle holes, but I can't find it with a search - can you please send me a link or a copy - thanks! 

Link to comment
Share on other sites

1 hour ago, SteveB21 said:

template for the various scuttle holes,


Apologies for jumping in, this what WF supplied me 3 1/2 years ago.

My advice would be to not take it as gospel, I worked it from a centre line on the scuttle, suggest double check positioning before drilling to ensure positions look reasonable

 

49D517B7-A462-464A-8CC7-AFAF3172823A.thumb.jpeg.3f1900677041a63b5a9b640bbe178d0b.jpeg

Link to comment
Share on other sites

I also used the one above as a rough guide against my own trail and error fitting the heater in place, and looking at it scratching my head lol

Link to comment
Share on other sites

I finally stopped procrastinating and finished off the engine bay wiring today - I'm glad that's done!

 

Here's a mid-job shot. I had fitted cable-tie bases on the inside and bottom of the front chassis tube, the bottom of the driver's side tube and the inside of the rear tube under the scuttle - with hindsight I should also fitted cable-tie bases to the inside of the driver's side chassis tube to avoid having to tie cables to other cables.

IMG_5868.thumb.JPG.90f6a1b2646611a028d6e85c4ea8902b.JPG

 

Fitted some extra cable-tie clips for the lambda sensor wiring as I will have to bundle up some of the wire out of the way when the sensor is fitted:

IMG_5869.thumb.JPG.4a80868dd0f1b01661b61a2ba89f4549.JPG

 

Ran the harness wiring for the lambda sensor along the top side chassis rail and back again to use up its length:

IMG_5871.thumb.JPG.e0826deb0771a44d07c03432755307eb.JPG

 

Crankshaft position sensor cable dropped down from the top diagonal chassis rail:

IMG_5872.thumb.JPG.7ea1d2f2a42c1eb5dd7b7b5bff0eb607.JPG

 

Coolant system next now I have the scuttle.

 

Finally - picked up a bargain in Wilko yesterday - wheel nut wrench for £5 !

IMG_5864.thumb.JPG.70984e489687ebc0da926ab8644c3194.JPG

  • Like 2
Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Restore formatting

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

 Share

×
×
  • Create New...

Important Information

Please review our Terms of Use, Guidelines and Privacy Policy. We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue.