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Post by Johnsto on Feb 1, 2015 12:47:23 GMT
Hi All,
I have taken the plunge and bought a Sonic kit. It is not a new kit but an incomplete build. The guy I bought it from has had a change in circumstance and is unable to complete the build. Unfortunately, before spotting the bargain of a kit, I had already purchased a donor, 1999 2.0 Focus Ghia.
I have begun to strip the donor, I will only be using the following parts :- Engine, Cluster, maybe a few switches and possibly the front calipers. I will attempt to sell the rest but I don't hold out much hope of shifting a lot.
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Post by Johnsto on Feb 1, 2015 13:00:53 GMT
Ok, here is a few pics of me collecting the kit.
Not me in the pic, just a helper, Mr Bridgewater
Build originally started late 2011, it has been sat for a while and has rust bubbles starting to show through the powercoat  . I will be undoing all the work completed by the previous builder as I want to build this car to my standard, not saying the previous builder's work isn't good, but I'm sure you all know what I mean.
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Post by Johnsto on Feb 1, 2015 13:07:51 GMT
The donor engine has now left it's home for the last 16 years and is in the garage for a complete overhaul.
Hooked up to the lift.
and out !
Relatively uneventful removal, no forgotten wires etc. Only minor set back was the exhaust joint behind the sump, nothing an angle grinder and cutting disc couldn't handle  |
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Post by Johnsto on Feb 1, 2015 13:22:33 GMT
Engine in the garage ready for dismantling
And stripped ready for servicing
Wont be stripping the crankshaft out due to me having zero mechanical experience! I have been following the bible (Haynes).
Complete gasket kit on order along with seals etc. In the mean time, paint!
just need to clean up some overspray but not a bad job I think. I cleaned the block using a wire wheel, just to scuff for good adhesion, also cleaned back to bare metal in the spots showing signs of corrosion. I used Halfords Engine paint, good coverage from 1 can.
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Post by mawdo81 on Feb 1, 2015 13:26:56 GMT
Welcome,
How are you planning on using the front brakes? It's normal to use the rear set up if discs but i thought most went for the hissed fronts as the focus units didn't fit?
Are you using the mtx75 gearbox? What are your plans for shifter?
Thanks
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Post by Johnsto on Feb 1, 2015 13:36:16 GMT
I have also started a costing spreadsheet so I can monitor my incomings and outgoings. I have included any tools I have bought to aid in the build, some not really necessary but nice to have to play with  Here is a link for those who are interested. |
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Post by Johnsto on Feb 1, 2015 13:44:12 GMT
I have some wilwood 4 pots for the front (came with the kit) and thought the front focus calipers fitted the rear. I have both gearboxes, an MTX 75 (from Donor) and an IB5 (with kit). As for the shifter I have a joker shifter (with kit). Not 100% sure which box I will go with yet. I believe the weight difference between the two isn't that big. IB5 is easier to fit and the MTX75 being a stronger box, choices, choices.
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Post by mawdo81 on Feb 1, 2015 13:53:53 GMT
Got you, it's the rear calipers from the donor for the rear of the sonic.
Sent from my GT-I8190N using proboards
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Post by Johnsto on Feb 1, 2015 14:10:31 GMT
Oh right I see. I take it that's so you can use the handbrake set up aswell then. It would be nice to have access to the build guide  |
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Post by mawdo81 on Feb 1, 2015 14:19:48 GMT
Email Mr mills with your chassis number and he'll drop you the password. Do you have access to the technical section yet?
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Post by Johnsto on Feb 1, 2015 14:22:38 GMT
Yes I can access the Tech section. I will email him this evening. Thanks mawdo81
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Post by nigel on Feb 1, 2015 15:35:16 GMT
Great to see another Sonic builder on the forum will be following your build thread with great interest John.  nigel |
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Post by Johnsto on Feb 1, 2015 17:11:32 GMT
I did see the sonic build threads are thinner than the threads in my jeans! I will endeavour to keep it up to date. Looking at 18 months to build, ready for next summer, all things allowing. |
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Post by martinw on Feb 1, 2015 18:45:27 GMT
It would be nice to have access to the build guide Hi John If you've already got access to the Tech stuff, the Build Guides will be available in there. Don't be alarmed if they look a bit on the skimpy side......there's plenty of assistance available on here too . When I was building mine I had a very well-thumbed and oily printed version to refer to - and I used Nigel's website as well (the link is in his footer). Afraid I never got around to doing a build thread; mind you, it is a few years ago now, and there are many more on the forum these days. Anyway, Sonics are just so much more exclusive, that's another reason for few build threads Martin |
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Post by Johnsto on Feb 1, 2015 20:55:49 GMT
Whilst waiting for my gasket set etc (arrives tomorrow) I decided to strip out the wiring loom and ECU, I have the cluster out and 75% of the wiring disconnected and labelled but poor light stopped play. In to the garage I went to start pulling apart the half built Sonic.
This is what I started with
Note the steering joint bit (track rod ends?) does not have any thread showing through the nut ! If I tighten it, it still doesn't show through. Also I cant turn the wheel more than half lock due the wings being in the way 
All the rubbers covering the pistons on the pedal box have perished and are falling to pieces, I assume I can get spares from somewhere.
And this is where i'm at until tomorrow. My new sand blasting cab should arrive tomorrow aswell, blast some engine parts and make um shiny and then reassemble the engine
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. I will be undoing all the work completed by the previous builder as I want to build this car to my standard, not saying the previous builder's work isn't good, but I'm sure you all know what I mean.
Here is a 
