PROJECT MARSHALL:- Track day / DRIFT cossie updated 18NOV`07

[Mr C]

Ive been busy saving for the bathroom refit on my house so not much done since Jan, I did finally get down to collect my engine though, a good standard 200 blocked 4x4 engine, just needs turbo and injectors to complete. It comes with a big wing baffled sump and 6 paddle clutch, should beadequate for a while it is just in the bay temporary till I get more money together to complete the install, still need aeroquip fittings for the fuel line in the bay and boot. I will just shut the door on the car for a bit, get the house more homely and my mates 2wd sapphire finished for summer. New Estimated time of completion is Winter 2007, ready for a hard drive Spring 2008

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[Mr C]

Now I dont do bling but these had to be bought, something a bit different and as a bonus its polished too spanking-6 fuel rail c/o Genesis motorsport

and this will give you a clue as to the route Im going,

the engine has to be reliable reliable reliable and to that extent dizzyless ignition had to be the way forward so I will be on the phone to Stu at MSD when I get a chance next to complete the kit.

I did get chance to remove the rubber from the gearbox mount and replace the OE ford mount with a CNC machine item (just incase)

[Tev]

Bout time u finished the car!!!!!!!!!!!!!!!

Stop polishin :gayflag: stuff n get on with it

[Mr C]

Ive not done a lot on the car since March, mostly stocking parts to fin the build but I have got the Gearbox and the 6paddle plate is in along with the prop I need the exhaust mounts for the car floor to fit the exhaust up, down pipe has been drilled and Lambda probe boss welded in then heat wrapped to clear the bay, its a good look and fancy doing more


block has been cut for the alt drop bracket


inlet has been fitted up and fuel rail plumbed in along with custom braided hosing in the bay to and from regulator rail and bulkhead supply and return, (I dont fancy a fire so oil and fuel is braided)
_

3port GGR breather has also been fitted from my road car, just need a catch tank instead of venting fumes to air this time


It was then time to fit the T34 onto the exaust manifold but checking the manifold found one of these in the bottom bend a Fucking acorn!!!??!??! time for the hoover on all open end of the engine!

[Mr C]

Drivers set was side mounted and positioned on the rails, will be secure for now but not really happy with the position


Nor am I happy with the feel or position of the bias box which has been removed and modified to cure clutch cable issues, now back in but needing a new rear .75 cylinder


Ignition amps and coil were fitted in position

Pace RS500Cooler and re cored std rad and some water hosing and swirl pot installed too, need a modification from std oil/water modine to clear the 909 engine mounts though so a cooler may be employed alongside the remote filter head


Dash has been sripped again so I can work on the wiring loom and modify the clocks so the rev counter works after fitting the MSD wasted spark conversion


All fuel routing and the boot set up completed last month comlete with 044pump and filter from FIA bag tank


and this is the engine bay as it stands at the minute

[Mr C]

Im thinking of ditching the power steering but will drive it next year with it on for a while, see how it goes. MWS engine bay wiring loom has been fitted and routed into the car now and PAS and alternator fitted up.

Next mods are the fitting of the MSD Stg3 ECU chip and driver, wiring and cable positioning in car, fuse box rewire can wait to a later date

Dont hold your breath but hoping to be running by end of year and on the road early 2008?

[Moonstone Mart]

Good reading Mark

Mart

[Mr C]

battery ha sbeen located(its only the temp item)


I swapped the TPS for a PF09 and wires 1+3round on the loom


Engine bay cables have been neatened up and tied back into position too,

all electrical connections were checked and fluids added, engine was turned with new oil ready for the engine to be turned over for the first time
leaks are checked for, 2 on the fuel only and
IT runs!!! for 10 sec ???? Hmmm well its a start, something to work on.
A couple of fuel leaks have shown up so these needed sorting too, braided lines aswell and the connections still leak tut, just a quick nip up here and there ... and the fuel pressure regulator pisses its self
time for a strip down
thats enough for one day

[Mr C]

The culprit of the leak has been found- a small crack in the already thin rubber covered membrane in the regulator


We didnt try start ups again today but turned our attention to the mass of cut wiring that needed attending to, what a shit job- been at it all day and it looks like we have done nothing.

Jay "TEV" looking like he knows what he is doing


and we also started to dress the front end, lights and indicators went on and wired up and power sent to them, when I flash my lights the wipers move and when I put the wipers on the headlights work WTF?!?!? has nothing been done right on this car
looks like we did a bit now


On a good note though my new ECU has turned up with a little something more than I need... ALS and launch control c/o MSD... my box just crapped itself

[Stavros]

Why you running an inlet restrictor? Or are you gonna remove it?

And dont run without PAS, will be horrid.

[Mr C]

The turbo has a restrictor because thats how it was designed for rallying regulations- restricted. I own this one as it has the Mar-M shaft needed for ALS... and also is restricted but I havent had a sleeve made or found one yet to fit a std intake pipe on.
Im guessing the steering will be crap and barge like- slow and heavy to say the least without the PAS (that was a last resort) but I will turn my attention to the steering lock at a later date

[Tev]

Oi u cheeky fooker, that photo makes me look simple

[Mr C]

Originally Posted by Moonstone Mart

Good reading Mark

Mart

Cheers Martin, good to meet you

Jay- "look simple"?? right place right time mate. Thanks again for your time pal, would take me weeks to get any of that lot sorted

Your on with the sunday lunch... as soon as K is free of a weekend

[Tev]

Originally Posted by Mr C

Cheers Martin, good to meet you

Jay- "look simple"?? right place right time mate. Thanks again for your time pal, would take me weeks to get any of that lot sorted

Your on with the sunday lunch... as soon as K is free of a weekend

yer tis true u got me there i just look simple all the time,

sweet well let me know when ur good ladys off work next, i will cook the mother of all sundy lunches

[RichardPON]

Cheeky coont! Wiring works fine You probably had the connectors on the wrong way round. No idea why it should have done that, as the loom was straight out of my saff as is.....

Good to see it finally coming together though.....

As far as the seat rails are concerned, you weld the cross bars in where you want the seat. I found one position that worked well, but with slight modifcation to the seat mounts. The rally driver who used the car was a short arse, which is why the bars are quite a way forward.....

I did tell you when you bought it too check everything over, as I hadn't had a chance to test anything out, and that includes the wiring, so don't start bitching

Now get it finished!

[purplemonster]

sorrry to hi-jack your thread but i saw you swapped throttle sensors?

why did you do that ?
reason i ask i have just built a cossie powered puma and at the moment its flat no power at all ,and i have no idea what throttle i have fitted ? could this be part of my problem ?


i know i have both types as the car came with spares and how do i know which one i need to fit according to my wiring loom ?

hope that makes sense

thanks

[Stavros]

I know why it WAS restricted, I meant I hope you not leaving it restricted, as it will give you lots of losses and no gains.

And you dont need more lock straight away, just run normal Sierra/Granada PAS rack, even non-PAS quick racks have more lock to lock than PAS ones, and thats more useful than taxi-spec steering lock

[Tev]

Originally Posted by purplemonster

sorrry to hi-jack your thread but i saw you swapped throttle sensors?

why did you do that ?
reason i ask i have just built a cossie powered puma and at the moment its flat no power at all ,and i have no idea what throttle i have fitted ? could this be part of my problem ?


i know i have both types as the car came with spares and how do i know which one i need to fit according to my wiring loom ?

hope that makes sense

thanks

Hello fella Mr c has swaped the Throttle p senser over because he has changed from a 2wd ecu (l6) over to a 4wd ecu(l8)

all hes done is used a 4wd throttle p senser

[Mr C]

Originally Posted by purplemonster

sorrry to hi-jack your thread but i saw you swapped throttle sensors?

why did you do that ?
reason i ask i have just built a cossie powered puma and at the moment its flat no power at all ,and i have no idea what throttle i have fitted ? could this be part of my problem ?


i know i have both types as the car came with spares and how do i know which one i need to fit according to my wiring loom ?

hope that makes sense

thanks

as above I have a 4x4 engine and L8 ECU and PF09 TPS but still running a 2wd engine bay loom hence the wire swap to make it still work

Stavros-
I will sort a straight through adapter as soon as- you got one? otherwise this one will have to stay for now.
what quick rack are you recommending I use? I was already using full lock too often on my STD cossie road item so will want more to play with soon. Granada rack swap is an option with mods of course (due to width differences on Granny model PAS racks.)

RichardPON- easy now just nothing has been easy or straight forward on the wiring- after the fuel leaks I just wanted an easy day to repay J- "TEV" but it wasnt to be.
Not bitching, and we are on it- not long now I hope, cant wait for the first run in the new year

[RichardPON]

The problem was that the entire loom was cut and extended, so I never got a chance to fault test it......

I want a passenger ride in it when its done

[Mr C]

I cant get a replacement fuel reg part this side of 2008 for the Ł150+ Aeromotive item so Saturday I payed Chris and Andy a visit at GGR up the road from me, took a look through their new range or Fuelab gear and found this beauty-Ł100 all in


Spent sunday building it up and fitting it, spot on guys, looks the parts, fuel relay bipassed and pressure set- no leaks and all is good. Quick swap of the ISCV, "TEV" had my good one for his 2wd and I fitted the lightly modded one for my ALS


Time for a turn over so wired up and was pretty certain the engine was a bad one as liquid spewed out the turbo, Cyl2 and exhaust as I turned it over . turns out it was fuel and cylinders had been filled last week as the Fuel reg had let go and unleaded was pumped through the vacuum pipe.

Engine then started up and idled beatifully DONE IT!!

did a bit more wiring and grounded my ALS switch big grins as I have no exhaust on and 2x pops was enough to deafen me sat half in the cabin. Im so happy now, engine needs an oil change already after the bore wash so more oil is on order thanks to Matt Lewis

While I was impressed ADi seemed less so- reckon I have 2x cylinders missing compared to the proper engine in his Skyline behind him LOL


Short list of things to do;


BIG BIG thankyou to John and Adi for the company on the last few weekends
and Im going to drop my car off for the day and visit somewhere outside of Blackpool next time I visit MSD, TOP work from Will Kenny and Stu- we took Johns "TEV" up for a set up, an 18 hour day for me but bloody worth it as I got to drive the car last night and the thing is o smooth now and SHIFTS

[magic randy]

easy mr c, long time no speak !!

you still need a granny rack ??

pm me sometime mate, will have to catch up

dev

[RichardPON]

Engine runs? Excellent work already - really getting a shift on!

[Tev]

Easy fella i think its bout time u posted some photos or updates or i will spill the beans

[Mr C]

The brakes are now filled and bled though they feel really spongy, gradually got a harder feel as I bled them all more. I Cleared the car out as its been a mobile shed since the build began, the intention last weekend was to get it driving under its own power so have given it an oil change to lose the manky fuel thinned oil have filled the diff and box and checked oil and water, started the motor up but couldnt get a gear with either the engine running or off

Jay and I checked everything, cable pull, ratchet function and gear shift but all was working great, so figured it must be a stuck clutchplate so we jacked it up onto axle stands and managed to get through the gears all the way to middle 5th- anchors on and it stalled, I started it in every gear to try to shift it but nothing so the box came off again and we were greeted by this

a rusty flywheel,


and a clutch plate rusted to the cover, gutted it must have gotten damp before purchase and I never checked it before dropping the engine in complete as it was "a new clutch" but I should have though

We refitted the box and now cleaned clutch dropped it on the deck and finall got it off the drive big grins all round though I had no brakes as they disappeared , no PAS and no mirrors so did a 3point turn with my head out the window. So now I can start on the crappy steering lock

[magic randy]

SHIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIITE

[James-W]

Good read, keep up the good work pal.
James

[Mr C]

I got started on the steering this Saturday in an attempt to increase the shite lock on the std cossie rack, after a swap of rack and a couple of mods to the front subframe I have 3" wider track and 35mm more lateral movement on the new rack, I also swapped the ARB for compression struts and fitted a pair of Adj TCAs

lock before


and now afterwards

a decent increase Im sure you will agree

The limiting factor now is the wheels catching on the Compression struts I just fitted so may resort to ARB if more lock is ever needed but Im certain this will last me a couple of years practice

I got the toe setup roughly and the steering centred enough to get to someplace to set it up.
Jay was hard at work on the wiring with Adi all afternoon saturday in an attempt to get the lights and indicators working along with the dash lights etc but it beat them this week, eventually lost them all, so maybe some melted wires at worst or plug swaps and wire adding at best
Next up will be the exhaust and gearbox mounts and space the wheels so no rubbing occurs for the MOT, untill I can swap rack for the final daddy spec I plan to work on- not really necessary but Im finding different ways round problems and enjoying some of it

[olek]

what kind of rack are you using?

i had a std sierra rack without PAS on mine a time, gave me more steering to play with, but the lock-to-lock ratio on the steering was just under 4 turns, compared to the cossie with 2.5 ca. needless to say it was a hell on tricky track-parts with a lot of turns after eachother.

i've modified the cossie-rack and after that it was much more stable and easy to deal with. gonna modify the rack even more this winter

good project!

[Tev]

Originally Posted by Mr C

The limiting factor now is the wheels catching on the Compression struts I just fitted so may resort to ARB if more lock is ever needed but Im certain this will last me a couple of years practice

Such a shame bout the compression struts, i know of a car they would work really well on if u go back 2 standard items

[Tev]

oi u puff stick some updates up or atleast stick some photos up (the 1s with my car in them)

[fezzajsy]

[Mr C]

A quick update then, the twin side exit exhaust has been fitted and the rear ARB too, the pedal box has had both cylinders swapped over for better sizes and the balence tweaked, the Hydraulic handbrake has been fittted piped in and all brakes re bled.


Jay seems to have managed to run himself over in a Brian Harvey styley, I ran to his help- obviously after photos were taken LOL


Engine is complete for now untill a few alloy pipes are sorted alongwith more ALS gubbins and a couple of other ideas in the pipeline to gain some performance and reliability, looks pretty smart;


front wheel spaces have gone on to the tune of 8mm a side so far, I may have to rethink the comp struts if it doesnt need toe in come tracking time or a decent offset of alloy, I`ve fixed the front bumper with a laguna splitter and removed the fogs, fitted No. plates F+R, and body trim like the grill lights and lower plastic etc too, so it would be rude not to see if the work was all worth it. . . so I hopped in with a jerry can and a starter pack)which I needed both before the end of my road

[Mr C]

Here is Marshall before its first drive on my private test road about to scrape the speed humps, JOY!

Once on my private road it was only proper to open her up and bloody hell, no grip on boost 1st or second, but plenty of sideways action WOW, Ive never driven with a welded diff before and along with the BHP, windows open, exhaust rattling and such a stiff shell on coilovers my senses were in overload Time for some effortless donuts:ban ana:, sweet!!!!!!
and to prove it can move from off of my drive

But still needs some work for the MOT, mirrors, lights F and R boot lid securing, exhaust banging, bodywork, fuse box, new loom etc etc etc

And back home safe and well

[Mr C]

And the Pic TEV has been waiting for, this is the best that I have mate we needed more light for better results, superb Focus RS rims,

Fancy a grudge match John??

[Mr C]

Next job is to replace the whole car wiring loom with one that works as we simply cant get the lights to work front or rear, it will be easier to do this that spend another6 weeks on the one that is in there. Gutted that I will more than likely miss tha chance to run up the strip at central day but hey it needs to be done for the MOT and alarm guy, more work instead of just finishing off. Real tears here from all involved cos we have spent litterally weeks fault finding. What a cock.

[Moonstone Mart]

Alright Mark, i totally forgot about the pics/info you wanted
Do you still need it? Send me a PM with what you need and i will sort it out.
Cars looking good, bugger about the lights though!

Mart.

[Tev]

bring it on!!!!!! Im up 4 the Grudge match!!!!!!!!!!!!!!!!

cheers 4 puttin the photo up,

im off to book my car in at stus if we r going 4 a grudge match,

[jeek]

Can i ask what changes you made to the rack to get the extra lock? I have a granada rack on mines with eccentic top mounts 20mm spacers and i have ordered Adj TCAs and compression struts!

[Mr C]

Originally Posted by jeek

Can i ask what changes you made to the rack to get the extra lock? I have a granada rack on mines with eccentic top mounts 20mm spacers and i have ordered Adj TCAs and compression struts!

same as yours but with out the eccentric strut tops, do you find your tyre catches the compression strut on full lock? or is your TCA fully wound out? or you changed the offset of wheel or? Im working on something to reduce the -4.8 degree camber on the front, how much you running and I would guess the eccentrics go a long way to removing some of that extra unwanted -ve camber?