Fiesta Duratec Hillclimber

[grahamb]

The rubber boots arrived from M-Sport (thanks Graeme) and tonight I assembled the near side drive shaft, and refitted the hub, having packed the inboard CV with good quality grease first. I then realised that I had a problem with the way that I'd fitted the Kustom suspension on the near side. Where the inboard heim (rod end) for the track control arm locates in the chassis leg, Karl had supplied a very neat brace assembly, that fits inside the original chassis leg box section, and runs forward to the tie bar mount. I'd not fitted the brace bar fully up inside the chassis, and there was a whitness mark on the alloy heim, which shows that when the car sits on the suspension, the heim had been resting on the uppermost section of the brace box. Still with me? My fault for not fitting it correctly. However, when I tried to push the box section further up inside the chassis leg, the brace that runs underneath the gearbox, hit the box, and the gear selector mechanism. Simples. I removed the brace and cut off the tube that runs forward. I've done exactly the same on the drivers side as my Duratec sump also hit the brace bar. So no great loss considering I'd not ran brace bars previously.

So with the Kustom box section now fully inside the chassis leg, I refitted the track control heim, and then re-assembled the front suspension. I then realised I hadn't yet torqued up the tie bar brackets, so I had to undo the fasteners for the radiator, so I could move it sideways to allow access to the top of the bolts that hold the tie bar brackets in place. Everything was then quickly torqued up, but I'd run out of time to give the brakes one last bleed, so I'll do that tomorrow evening, prior to trying out the clutch for the first time at the weekend.

[grahamb]

Brakes are done, and the fiesta is back on its rear wheels.
I tried adjusting the front toe angle but realised that the steering rack was modified to reduce the length of the threaded arms, and its not suitable for the new wider track.
So I'll select a replacement rack from the 3 spares and swap it over today.

[grahamb]

The mk2 rack that I removed from the car, is too narrow for the track I'm now running, and on closer inspection the steering rack gearbox is shot anyway, as 7 yrs of competition appears to.have taken its toll.

The 3 spare racks are all mk1 variety, and i don't have the saddle brackets required to.fit them.

Luckily on eBay I spotted a brand new genuine ford mk2 XR2 rack, and as the only bidder, I won it last night, and the seller is able to get it to me by Weds so when it arrives, I'll fit it, adjust the tracking and give the car a quick run around the estate, assuming the clutch is working.

[spd(john)]

Just took time out with a bottle of red wine to read through your thread, stunning job, keep up the good work.

Regards,

John

[grahamb]

Originally Posted by spd(john)

Just took time out with a bottle of red wine to read through your thread, stunning job, keep up the good work.

Regards,

John

Thanks for the feedback John

New rack arrived, and it is brand new, manufactured in 1987 I think from the codes on the rack and the box.
Fitted it, and the car is back on her wheels again.
Fitted the cool-it mat to the underside of the car. Sticky orrible job, but someones got to do it

[grahamb]

Silly rule, not being able to post more than 4 images, and as for the 180 seconds between postings....

[grahamb]

Fed and watered the gearbox last night with some of Halfords finest. The garage floor had some too, as I'd overfilled the box, and when I pulled the filler hose out, the excess decided to flood the floor. Just a quarter of a litre or so, but damn it made a mess.

Aligned the steering by eye, so the wheels at least look parallel. It'll do until she gets on the ramps at Northampton Motorsport.

Tonight I'll be running the engine up to operating temperature for the 1st time, setting the cooling fan on/off temp in the ECU (95C for now) and testing the bite point on the clutch.

[EMac]

Originally Posted by grahamb

. . . The garage floor had some too, as I'd overfilled the box, and when I pulled the filler hose out, the excess decided to flood the floor. Just a quarter of a litre or so, but damn it made a mess.

Yeah - doesn't it make a mess! I remember once bringing home a new company car (one of Henry's finest), and discovering the following morning that one of the gearbox seals was leaking . .

[AndyMil]

Smells wonderful too, and it's a smell that lingers

[grahamb]

Originally Posted by AndyMil

Smells wonderful too, and it's a smell that lingers

I went in the garage again this morning, and I must agree, I do like the smell of gearbox oil....

Adjusted the gear linkage last night, and attended to a few other bits and pieces. aka fettling.



The orange piece snaps in to place, once the willing assistant had wiggled the gearlever around and you're happy with the outcome (ooer!)

I'll be running it this afternoon. Next door has some housesitters in, with a 12month old in the house, so I would have been very unpopular last night if I'd have started the old girl up.

Anyone else going to FordFair on Sunday? I'm on the xrtwo.com stand.