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Post by duratec1999cc on Apr 21, 2017 19:46:56 GMT
Just catching up on a bit of progress made since 2015, Focus RS handbrake modified and fitted:
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Post by duratec1999cc on Apr 21, 2017 19:55:57 GMT
Clutch line fitted, had to make up and adaptor from the ford hydraulic fitting to an AN3 fitting, so tapped out the ford fitting and screwed in an AN3 male to male, soldering it in to seal it used steel braided and covered AN3 nylon pipe:
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Post by duratec1999cc on Apr 21, 2017 20:20:50 GMT
Brake lines fitted, used copper pipes for the chassis runs as i figured it would give a firmer pedal than braided throughout. Used a 4 way connector at the bottom there so i can screw in a pressure switch for the brake light. I forgot to screw it in when i filled up the system, wondered why i had no pedal and got brake fluid everywhere! Modified the original brake fluid reservoir by screwing in 2 x 8mm tails in the holes where it used to mount to the brake servo. Clears the bonnet ok too Had some custom length hoses made up by HEL to fit the HiSpec calipers and standard brake pipe unions: Notice the washers at the top of the damper, thats to prevent ball joint lockout at full bump.
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Post by duratec1999cc on Apr 21, 2017 20:45:00 GMT
Sorted out the aux drive belt routing, without the AC and power steering pump some changes are required. managed to find the correct tensioner from a vehicle which uses same engine but has electric power steering, new tensioner top right where power steering pump used to be, AC pump used to be below that. thats not all that was needed, the back side of the belt used to do a 180 around the water pump and then go around an idler near the alternator, clearly that is not possible without the AC pump, but the belt cant go from the bottom pulley straight to the alternator because it would foul on the crank sensor. What i did was replace the old tensioner with an additional idler pulley, extra idler shown here packed out with washers to line it up: After i figured that route out i found this photo i took at the stoneleigh show in 2015: thats exactly what i have done, my only concern is that the belt is now only engaged with the water pump over about 30 - 40 degrees rather then 180 degrees so less friction, might slip at high rpm. If it's ok for that duratec engine on display maybe its fine. oh, and i checked that the water pump would still run the same direction as it did before!
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Post by duratec1999cc on Apr 21, 2017 21:29:55 GMT
Moving house delayed the build, here it is, as it was at the end of 2015, a fully rolling chassis, seats, brakes, clutch, gear linkage, handbrake, steering, suspension, all functioning. Hardly got anything done since then, once i get the engine running it's drivable, will then need to get all the boring stuff fitted to make it pass IVA such as panels, lights, speedo etc. Stuff i need to sort out to get the engine running: Cooling system (complete, just need to install the rad) Battery, wiring loom build and ECU installation (made some progress on the loom already) Fuel system (main fuel line installed onto rail, need to install tank, pump, filter, rest of pipework) Radiator goes behind the seats in front of the engine bay, fuel tank is going in between the front bulkhead and the steering rack, battery in passenger footwell in a sealed battery box against the bulkhead with a footrest in front of it Hope to get it running by end of May... I sent off some CAD drawings the other day to a laser cutting shop to have some shapes cut out of 3mm ally plate. Custom centre tunnel, fuel tank reinforcing plates, fuel pump fitting and sealing plates, passenger footrest, wheel spacers. I didn't fancy spending hours jigsawing those out!
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rena
Junior
Maybe building a Exobusa...
Posts: 22
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Post by rena on Nov 21, 2017 13:56:05 GMT
Any progress?
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