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Post by perthwa on Jul 12, 2020 8:30:00 GMT
Had coffee this morning. Steve's Sonic has added about 150mm height to the screen. He said he thinks it probably needs to be 5 or 6mm thick and MUST be bolted (not rivnuted) to the fibreglass panel with reasonably big washers underneath so it does not pull through. Suggested the thicker glass as the smaller gauge flexes, especially when people use it as a hand hold to get in and out of the cab.
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Post by perthwa on Jul 12, 2020 8:37:45 GMT
back to the fuel tank etc. Made a cardboard cut out for the fuel filler unit. took some brave pills and cut a hole in the side pod. Here is a look inside with tank housing removed. Just a few welds and roll the end of the pipe and gets some connectors and... eventually I will have fuel.. Here is a better photo. still with a bolt missing.
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Post by perthwa on Jul 12, 2020 8:50:15 GMT
Extended the shifter cables... When I purchased my secondhand Locost build, it came with lots of bits and bobs... One thing was the fuel cap unit above and a spare set of shifter cables was another. I decided that I could cut two ends off, TIG weld the cables together, add a shaft to keep them straight, and separated and joined; so I did. Now I have two longer cables that fit the Focus shifter and the Duratec fittings. I had to get smart and I used a metal sleeve that I threaded the inside of and threaded the end of the shaft and the 'click on' fitting end. voila... a new cable that fits. The only down side is that I have a 20 cm length that MUST be kept straight that is about 3 cm in diameter. You can see the fatter section in the following photo. Both have two solid shafts holding the welded cable ends in place. The inner one is around 1 cm in diameter and the outer closer to 3 cm. The outer was a carbon fibre High jump bar that was surplus to requirements and damaged. I sliced a 2mm cut down the shaft and slid them over the cable housings. Then I taped the whole unit together. I was going to use hose clamps on the ends but the friction fit to the unit was plenty strong enough.. Luckily they both sit happily in the side pods and should cause no issues. Here is the gearbox side of the configuration. I used the hollow shaft of a bicycle axle, that is why there are threads on the outside, if you look closely. That allowed a sleeve to be threaded and the cable end and shaft to be mated. The other fitting clips onto a threaded shaft, so I threaded the end and fitted it together. At this stage I have used the original shifter housing out of someone else's donor to make up the retaining brackets, but I have yet to get them cleaned up and fixed in place. They are rusty and not yet fixed in this snap... And yes, I know it's not the prettiest thing on the planet, but it seems to work, cost nothing and uses more of the Donor car... and that was my brief...
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Post by wishful4444 on Jul 13, 2020 13:31:26 GMT
Good day perthwa
Many thanks for the screen information.
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Post by perthwa on Jul 16, 2020 2:47:44 GMT
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Post by perthwa on Jul 17, 2020 1:31:50 GMT
Rear Brakes and Handbrake. Now that I have had a bit of time to think about the tear down from 2 years ago, I realised that the Focus MarkII brakes were trailing, behind the axle. So, when I read the issues in the build manual about reversing the brackets for the handbrake cable attachments, I actually have to reverse the actual brake callipers. So now that I have the RH brake 'leading' on the LH side and vice-versa it seems to make more sense. I think also that there will be NO bleeding issue as they are in the same orientation... well sort of. I have yet to clean up any of the bits and there is an absolute array of bolts passing through the bush holes! The brake cables now have a reasonably smooth transition although, I am yet to finalise the actual pathway through the side-pod holes.
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Post by perthwa on Jul 17, 2020 11:05:22 GMT
Modified the handbrake bracket: when I hung the rear brakes, I then connected up the cables for the handbrake. I must have made the bracket without the brakes being attached because the slider for the cable puller is now too high and the cables will pull at an angle that will be problematic. So I had to adjust the rear cable entry section by reducing it by 1cm. Now the pull is more in line as originally designed. from above Also found the grommet for the shifter cables and these might just get used between the seats and the side pod. Then I decided to make a bracket for the radiator overflow bottle. I used two ex-Focus brackets and have yet to finish clean and support the completed set up. At this stage it just supports the bottle and I will add to rubber grommets to hold the base sections together. I think a little bit of flexibility may be useful for this bottle. Just have to check clearance with the engine cover. and then check hose fitments.. I am looking at a slight re-routing of the overflow hose as it is setup for the other side of the engine with a T piece so I will make it a straight pipe at that side and move the T piece to the left side of the engine. GeneraL QUESTIONS: How well will the heater work if I send the hoses all the way down to the front of the car? Do they have enough pressure from the water pump? Has anyone have any stuff in a page in this site about a heater?
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Post by buildityourself on Jul 17, 2020 19:17:20 GMT
Pics from the last 3 posts not displaying. Sharing permission issue?
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Post by perthwa on Jul 18, 2020 6:02:25 GMT
Here is a link... not sure what this actually allows people to do... but should give access to google photos... Pain in the butt as I can see them ok.
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Post by perthwa on Jul 18, 2020 6:02:52 GMT
Build a bead roller: I saw this and then built this I used the pipe end as I could not find a nut for the bolt I used. Seems to work ok.
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Post by buildityourself on Jul 18, 2020 8:11:42 GMT
Pics working now, so you must have fixed it, can probably remove the link to the album.
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Post by perthwa on Jul 18, 2020 12:13:09 GMT
Thanks for the heads up
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Post by perthwa on Jul 19, 2020 12:02:33 GMT
Made up a list. Ran to 153 items. here are the first 50... labels are a bit arbitrary. 1. Body - Aluminium Floor panel construction and fitment 2. Body - Battery Cable and harness support to frame – P clips make and fit 3. Body - Bolt on headlights 4. Body - Boots for gear shifter and handbrake attachment to center console 5. Body - Centre console bracket 6. Body - Connect sidepods to internal passenger body rivnuts 7. Body - Cover airbag substitute with leather. 8. Body - Dash-board construction 9. Body - Decide on and purchase rear indicator and brake lights 10. Body - Decide on and purchase reverse light 11. Body - Decide on muffler location and pipes 12. Body - Engine compartment cooling cover attachment 13. Body - Engine compartment cooling cover ventilation holes 14. Body - Engine compartment cover release button location. 15. Body - Fit electrical and relay panels to frame. 16. Body - Fit seatbelt units 17. Body - Fit sidepods to frame Rivnuts 18. Body - Fit steering bearing to firewall. 19. Body - Fitment internal passenger body segments 20. Body - Fix horn and steering wheel function 21. Body - Fix up all 15 Earthing points 22. Body - Frame to sidepod bracket construction 23. Body - Front and rear Number plate fitment brackets and rivnuts 24. Body - Front fire wall panel fitment 25. Body - Front Indicators bracket 26. Body - Front Indicators fitment and wiring 27. Body - Front Indicators selection 28. Body - Front splitter fitment 29. Body - Front wheel fender fit to strut 30. Body - Front wheel fender trim. 31. Body - Fuel tank container ‘bridge’ to side pod completion 32. Body - Headlight attach to frame 33. Body - Headlight wiring 34. Body - Headlight wiring connector purchase find… 35. Body - Heat shield for battery 36. Body - Heater unit modification 37. Body - Horn relocation and bracket Body - Internal side pod walls 38. Body - Look at additional bolts for Gear shift bracket 39. Body - Make bracket and Fit rear indicator and brake lights and wiring 40. Body - Make bracket and Fit reverse light and wiring 41. Body - Paint brackets for fuel tank 42. Body - Paint seat belt runners 43. Body - Passenger seat belt stalk construction 44. Body - Passenger side rear quarter panel completion for fuel tank 45. Body - Rear wheel fender fit to strut 46. Body - Seat belt bracket integration to side pod. 47. Body - Side pod hole clean up 48. Body - Weld seatbelt retractor brackets to frame 49. Body - Windscreen fitment 50. Body - Wire headlights
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Post by perthwa on Jul 19, 2020 12:02:57 GMT
and here is todays work. 93. Fuel - Bead roll - fuel pipe filler and tank filler ends. 100. Fuel - Cover extra hole in fuel tank. 102. Fuel - Finish containment tank inspection plates with rubber seals 111. Fuel - Weld filler pipe to fuel cap Done 112. Fuel – Paint containment cell brackets 31. Body - Fuel tank container ‘bridge’ to side pod completion only 147 to go.
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Post by perthwa on Jul 19, 2020 13:19:28 GMT
And the rest of the jobs / decisions. 50. Body - Windscreen fitment 51. Body - Wire headlights 52. Brakes - Bend all brake lines. 53. Brakes - Brake line construction 54. Brakes - Brake line fitment to frame 55. Brakes - Brake line Front 56. Brakes - Brake line front fit to calliper on side pod 57. Brakes - Brake line rear fit to calliper on side pod 58. Brakes - Brake lines rear 59. Brakes - Brake master cylinder slave actuator. 60. Brakes - Brake reservoir bracket 61. Brakes - Brake reservoir connections 62. Brakes - Brake reservoir location 63. Brakes - Buy brake line steel. Measure length before. 64. Brakes - Clean up all disc calipers 65. Brakes - Complete Brake master cylinder 66. Brakes - Decide on power booster. 67. Brakes - Finish handbrake connection to bracket 68. Brakes - Handbrake cable routing and support brackets. 69. Brakes - Paint disc calipers 70. Brakes - Purchase Brake line fittings choices and hardware 71. Engine - Air filter bracket 72. Engine - Clutch fitment and breather? 73. Engine - Clutch line construction 74. Engine - Decide on exhaust tip etc. 75. Engine - Decide on muffler location and pipes 76. Engine - Dogbone drilling frame welding in threaded crush tubes and bolt fitment 77. Engine - ECU fire wall bracket 78. Engine - Engine mount washers selection and support bracket completion 79. Engine - Extend the sensor in catalytic converter (lower sensor) 80. Engine - Finish gearbox cable bracket 81. Engine - Finish water overflow bracket 82. Engine - Fit gearbox cables to bracket 83. Engine - Fit heat shield 84. Engine - Fit heater unit 85. Engine - Fix connector for Airbox . 86. Engine - Get engine to run 87. Engine - Heater unit pipes purchase and fitment 88. Engine - Make exhaust 89. Engine - Oil change and filter replacement. 90. Engine - Relocate ECU to fire wall 91. Engine - Weld up catalytic converter 92. Engine - Weld up exhaust manifold 93. Fuel - Add additional inspection panel if required 94. Fuel - Bead roll - fuel pipe filler and tank filler ends. 95. Fuel - Breather to fuel tank. 96. Fuel - Check fuel pump wiring and function 97. Fuel - Clamp and fit breather hose to tank and fuel cap. 98. Fuel - Clamp and fit fuel connector hose 99. Fuel - Connection breather hose for fuel tank and filler pipe 100. Fuel - Connection fuel filler hose for fuel tank and filler pipe 101. Fuel - Cover extra hole in fuel tank. 102. Fuel - Find fuel filter 103. Fuel - Finish containment tank inspection plates with rubber seals 104. Fuel - Finish fuel lines for fuel tank 105. Fuel - Fix and test fuel tank filling slider (broken) 106. Fuel - Fuel filling pipe to fuel tank 107. Fuel - Fuel line design and fitment 108. Fuel - Fuel vapour return canister fitment and lines 109. Fuel - Look at bracket for lower fuel pipe support to frame. 110. Fuel - Look at complete fuel line and returns locations 111. Fuel - Rubber internals support for fuel tank. 112. Fuel - Weld filler pipe to fuel cap 113. Fuel – Paint containment cell brackets 114. Locktite purchase and use on required bolts. 115. Radiator - Radiator boxing in construction 116. Radiator - Radiator fan purchase and or fitment 117. Radiator - Radiator fan wiring 118. Radiator - Radiator fitment 119. Radiator - Radiator pipe connector hose fitment including P-clamps and hose clamps 120. Radiator - Radiator pipe connector hose purchase 121. Radiator - Radiator pipe fitment bending etc 122. Radiator - Radiator pipe purchase 123. Suspension - Ball joints for steering rack check and install. 124. Suspension - Complete upright installation 125. Suspension - Find bolts, sleeves and washes for bush fitment. 126. Suspension - Finish welding all suspension bush brackets 127. Suspension - Finish welding of all frame parts and brackets 128. Suspension - Front Steering rack install 129. Suspension - Front wheel fender strut fitment to upright 130. Suspension - Get Bush materials from Osborne Park 131. Suspension - Make additional camber adjustment bush and bolts as needed. 132. Suspension - Make bush inserts for Butch’s mold on Greg’s lathe 133. Suspension - Make bushes. 134. Suspension - Make Rear Drive shaft bearings 135. Suspension - Measure drive shaft length 136. Suspension - Paint wishbones 137. Suspension - Rack extender check and install 138. Suspension - Rear uprights fit to bearings 139. Suspension - Rear uprights strengthening 140. Suspension - Rear wheel fender strut fitment to upright 141. Suspension - Ride height setting 142. Suspension - Tap the slag from the camber adjustment bush 143. Suspension - Acquire / make Top hats for front Cortina uprights 144. Suspension - Wheel alignment 145. Xtra - Buy more rivnuts smaller size. 146. Xtra - Electrical wiring clean up 147. Xtra - Engine debug 148. Xtra - Engineering test and sign off. 149. Xtra - Lock tight 150. Xtra - Look at pipe bender construction by modifying Aiden’s bender. 151. Xtra - Nuts and bolts purchase according to standards 152. Xtra - Tuning engine 153. Xtra – Paint Body 154. Xtra – Paint Frame 155. Xtra – clean Frame
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