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Post by snowbird1 on Nov 22, 2019 15:16:47 GMT
Don't know, it was the only manual shift Ford in the local dismantlers, for/aft shift opposite to the SVT one, got it with the cables and connected them to the SVT cables - seemed ideal until I discovered the wrong left/right shift. At my local dismantler in Wales, lots of Fords, all with manual shifts, surprising how many different Ford shifters there are! Found one that all the levers moved the 'right' way, (forgot which Ford it came out of): Unfortunately the cable lengths are different so won't just bolt in. I should make something like this: I've got as far as buying the Rose (heim) joints !
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Post by snowbird1 on Jan 21, 2020 14:17:08 GMT
Run out to a local car show Sunday - temperature about 8 degrees (46 F), chilly for us and a cold North wind but I noticed when the thermostat opened there was plenty of warm air coming into the cockpit. The problem will be getting the heat out from the radiator when it warms up here. I didn't want to cut holes in the front cover but I think it will be necessary, found these louvers on ebay - they don't look too bad :
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Post by snowbird1 on Apr 14, 2020 17:41:39 GMT
April Update: We have a functionating gearshift with the gears in the right places, it’s a bit of a hybrid (i.e. lash up!) using the shifter from the SVT with the push-pull functions reversed and the base from a 5-speed. I was having trouble getting 5th gear, when I took it apart I realised 5th is now in the blank position below reverse in the original role – needed to grind away some of the gate to make it usable. The car had been running well but hesitating on acceleration, I checked and there was a ‘fuel pressure sensor’ fault recorded, checked the sensor wiring and swapped out the sensor but the fault reset immediately when the engine started. Hooked the pressure guage – zero fuel pressure Figured that the gauge must be bad because the engine was running – gauge was OK. Checked the tank and the plastic pressure hose was broken! I can only assume that as the fuel level in the tank was above the end of the hose and manifold pressure was sucking the fuel through the injectors. Replaced the hose and now runs fine. Found some hood louvers on ebay for the rear engine cover – cooler air in on the left: and hot air out on the right – hopefully
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Post by snowbird1 on Apr 26, 2020 16:03:17 GMT
Fitted a rear wing: I had been looking at the one that came with the kit but the steel support brackets seemed a bit much - they weigh over 2 kilos : I saw the aluminium one on ebay, seemed cheap enough ($38) to just get it for the mounting brackets but it looked OK with the aluminium blade and it probably gives just as much down force as the 'big' wing (i.e. hardly any) with less drag. It also works as a stop for the hinged engine cover:
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Post by snowbird1 on Jul 5, 2020 0:19:28 GMT
Reading through my build story I realized I hadn’t mentioned much about the electrics, most of the wiring was from the original Focus donor, I didn’t use the GEM or the IP the GEM functions were incorporated into the BJB The SVT IP looks good but the Acewell is more compact and has a ‘real’ temperature gauge and some data logging. The location of the PCM is pretty much governed by the engine harness, I mounted mine in the side pod using the original housing: Outside view, before the side body was installed. Access from the inside panel: The fuel shutoff switch is located next to the PCM. The main EMS power, starter and fuel pump driver relays and fuses located in engine compartment.
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Post by buildityourself on Jul 5, 2020 19:25:08 GMT
How are your side pods secured on the flap in the cockpit as can't see any obvious bolts/rivets?
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Post by snowbird1 on Jul 7, 2020 15:23:56 GMT
How are your side pods secured on the flap in the cockpit as can't see any obvious bolts/rivets? The side panels are a pretty snug fit - I just have one M6 bolt at the front and rear:
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Post by buildityourself on Jul 7, 2020 19:06:11 GMT
The side panels are a pretty snug fit - I just have one M6 bolt at the front and rear: Nice, that will save some drilling! Thanks for the picture with the roll bar, I can see I would have put one at the end which while discrete would have been hard to access behind it.
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Post by snowbird1 on Sept 18, 2020 19:13:33 GMT
The other day it was a bit cooler so decided to take the Sonic for a run – pulled out of the garage and it died. Fuel pump was running but no fuel, checked the tank and the pump pickup strainer had disintegrated: There are 2 strainers, one on the outside of the swirl pot and one inside both were bad. Installed a complete new pump and external filter and it seems to run OK. Trying to figure out what happened, I’ve never seen anything like this. The pump was the original one from the 2003 Focus so probably 17 years old but I realized the last time out was to check the cooling, it was about 110°F (43°C) was able to run it over 100 MPH for a mile or so and engine temp seemed OK but a lot of heat coming over the wind shield, certainly very hot in the cockpit, not fun, I figure this is a 30°C max temperature car. However the fuel tank is right behind the radiator and must have been getting hot – possibly the cause of the strainer failure? I haven’t installed the vent on the front cover: But may have to.
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Post by snowbird1 on Dec 9, 2020 15:39:46 GMT
Just out of interest I checked the weight of the Sonic yesterday, for the record, 1,360 lbs (617 kg) with about 3/4 tank of petrol. Just about 1/2 the weight of the SVT Focus.
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Post by buildityourself on Dec 9, 2020 20:18:25 GMT
Interesting. I think we will exceed that but a good benchmark as you also have the EVAP system. The 1.6 is a alloy block so might gain some back here, but its got a lot less power :-( The side panels are a pretty snug fit - I just have one M6 bolt at the front and rear: Nice, that will save some drilling! Thanks for the picture with the roll bar, I can see I would have put one at the end which while discrete would have been hard to access behind it. I promptly forgot about this when drilling and put it behind the roll bar . Probably will need to use a hex head so a spanner can be used.
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Post by snowbird1 on Dec 22, 2021 22:13:24 GMT
The build I started in Wales, has arrived after a long and expensive trip across the Atlantic (and through the Panama Canal then North to LA) the garage is a bit crowded, I need to sell the Sonic.
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