Arizona Sonic Build

[snowbird1]

The Replicar has gone so I need something to keep me busy. This time it will be another MEV design – a Sonic 7.
I usually start my builds in the UK, where I have a reasonably well equipped workshop, I was thinking of a new kit from Equilibrium so that I could complete most of the chassis work in the UK, but found an ‘old’ new kit available in the US.
Using the US kit means I don’t have to deal with shipping and import with only a 2300 mile RT to collect it, but I will have to do all the construction here in AZ in a 2 car garage with a few Harbor Freight tools!
The donor is a rust free SoCal SVT – 136K on the odometer, looks OK and drives well, no engine rattles or smoke and no DTCs recorded. Has a salvage title due to being hit in the back. When I registered it at the local MVD office the clerk said ‘what are you going to build with this one’, I’m afraid they are getting to know me there!


I’ve dismantled the donor, probably stripped out more stuff than I need, I like to keep all the emission equipment intact but this car is a PZEV with a quite complex EVAPS system, not sure if I will be able to incorporate it all into the Sonic.

Test fit of the body panels, seem to have come through their travels well - a few scuffs that will buff out and one chip that looks like it was a void under the gel coat, does anyone know the colour code for 'Tangerine Orange'?


Trying to figure out how much of the OE wiring I can use - always the fun part!

[snowbird1]

Stripped out the wiring I'll use, OBDII connector, rear lighting harness, steering column harnesses, front lighting and cooling fans harness plus underhood fuse and relay box.

Also traced and identified the 30 odd connections between the engine harness and body harnesses.



With a bit of trimming I got a reasonable fit between the dash and side panels.



Looks like it will need 6 mm fillers either side of the grill to get the bonnet/hood to fit, also the RH body side sits slightly forward compared to the LH side - a bit of trimming needed there.



Now I need to find somewhere to store the body panels while I work on the chassis.

[snowbird1]

Some progress in the last month - mainly figuring out what I need and how it will fit.
Test fit of the engine:

All seems to line up OK.

I'd like to use the stock exhaust - the SVT guys obviously did a lot of work on this.

But obviously going to need some work!

Whittled a steering column connector from a length of 19 mm bar:

And made a mounting bracket:


Realised that the Wilwood bits are SAE and all my stuff here is SI - need to buy a few more tools!

[kiwicanfly]

That's a nice bit of whittling on that shaft, Swiss Army Knife?

[snowbird1]

Slow progress report:
Got the chassis mounted so I can work on all sides:


Made a start on the plumbing:


Check ride height:


For the record, chassis to ground clearance - Full bump = Front 100 Rear 150, Full droop = Front 260, Rear 290 (all dimensions in millimeters).
Suspension travel = Front 160 (6 5/16") Rear 140 (5 1/2").

[Stiggy]

a rotisserie, how posh are you ! Coming on nicely John.

[skyquake]

Stiggy are those steering rack brackets in the correct place?  They look to be much higher up than on my chassis.

[Stiggy]

They are higher than the ones MEV made, we left them low so that spacers could be added to dial out bump steer which can occur if castor is increased with differing bones thus rotating the steering arms. Adding height is easier than trying to cut it down. Hopefully John will check for bump steer and find this position is fine.

[snowbird1]

Progress report:
Relocated the FEAD belt tensioner:

Used the original P/S bracket, seems pretty rigid.

The belt is speced for a '97 - '02 2.0 Escort with A/C - Gates P/N K060507

Mounted the clutch and brake pedal switches:

Needs a bit more work on the brackets.

Found a place that could flare the cooling tubes:


Master cylinder plumbing:


Cut and marked out the floor panel:

Won't install it yet, easier to work on other stuff without it in the way.

[snowbird1]

Arizona Sonic update before I put it away for the Summer (temperatures are already getting into the 40s).
There is some progress, all the aluminum panels are cut to shape although only the front firewall is installed:


Body sides are fitted.
Wiring is all planed out – using stuff off the donor with the wiper switch for the lights and repurposing some relays and fuses in the Focus Battery Junction Box (BJB):

Just have to connect it all up!

Local fabricator has remade the SVT exhaust manifold, I’ll be able to use the OE cat:



I gave up on trying to make the SVT radiator fit, looks like VW Golf VR6 aluminium rad will do the job:


Still plenty to do when we get back in September, still haven't got the gearshift for the 6-speed Getrag figured out, I have the shifter and cables from a 5-speed and would like to find a way to connect the two sets of cables together but suspect I will end up with marine cables.

In the meantime I have another Sonic to finish off in (Sunny?) Wales! I'll get back to this one in September.

[snowbird1]

Finished work on the UK Sonic, now back in Arizona - looks like it got a bit warm during the Summer:



Temps now less than 100F (38C) need to get to work on the AZ Sonic, target is to have it ready for the Route 66 Car and Boat Show in February. Now I just have to remember where I put everything!

(As I've got older I've learned two things - forgot what the first one was but the second is to write things down!)

[martinw]

Sept 30, 2017 14:20:24 GMT snowbird1 said:

(As I've got older I've learned two things - forgot what the first one was but the second is to write things down!)

Yep, I know the feeling! Trouble is, I keep forgetting to write things down too! 

Martin

[snowbird1]

Arizona Sonic progress report, (slow – too much other stuff going on) spent some time planning the wiring - using mainly the original Focus harnesses without the passenger compartment fuse box (CJB) and the body control module (GEM), this involves relocating some relays and fuses to the under bonnet junction box (BJB) and reassigning the wiper switch as the light switch. All connected and powered up – seems to work OK.
One unexpected issue, I’m using the type of flasher unit that flashes at a constant rate regardless of load (may not be legal but keeps things simple), I connected the clicker in the turn signal switch but discovered that is supplied enough load to operate the flasher by itself, so it clicked even when the signals weren’t on – had to connect it to left and right circuits with a couple of diodes.
I’m using the Acewell 7859 digi dash – I considered using the SVT dash, looks neat complete with oil pressure and temperature gauges, until you realize there is no oil pressure or temperature sensor – the gauges are mainly decoration like most temperature gauges!
The SVT came with HID kits so I thought I’d use them, certainly a difference in colour temperature.

I think I can make the original throttle pedal and cable work:

Connected to another OE cable:

I have a 5-speed shifter and cables and was hoping to do something similar but can’t seem to make it work, guess I’ll have to give in and get a pair of custom push/pulls.

[buildityourself]

Won't the extra spring in the dual throttle cable cause a double dead spot?

[snowbird1]

Good point - I don't think the springs compress until you hit WOT, I'll check though.