Norwegian gpa focus

[COCHYN]

Cool!

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[BIG.GEOFF.H]

looks cool in silver

[Mark_1]

Originally Posted by wrctony

mark have u seen the focus cosworth on piston heads,

I've sent you an email =)

[Mark_1]

Finally ive got the clutchrelease in place.
Well almost, need to get 3 screws for it to fit it to the gearbox, but thats no issue.



So thats one litle step closer to having the engine and gearbox in place.
Now all that is missing is a bearing and a radial gasket for the crosshaft on the sump.
Which hopefully is sorted within this week.
If anyone have assembled a sump with the new type r&d x-shaft (where the flange and shaft is one unit) let me know, as i have some questions about how to fit it properly.

Also i found this litle neat expansion tank.



Which fits perfect between the dampertower and the pas tank, its a bit small and with no window to see the coolant level, but i'll see if i can find a clewer solution with this.

[Mark_1]

It hasnt happened too much the last week unfortunatly, have started to work again and it has taken some time to have some smal parts sorted.
The package from r&d arrived with a awesome gearlever carrier!


Also i bought some grease today as this is needed for the damper tops in the front, and there is also a grease nipple on the damperbodies in front.


So i started pumping the grease in but there was no resistance, so i figured something was wrong and went in to look at the papers that came along with the dampers, but no info was written there so i called Dynamic to speak with them
There i got in touch with a guy that had actually been working with the works team group a escorts and later wrc escorts, and he told me that the grease nipple was a modification done to the dampers that they used under the safary rally, as the conditions was though they had to pump grease in the dampers to prolong life on the service stops during the rally.
But the downside was that the grease heated up and went down to the oil and preasure rose and blew some gaskets, so it was not recommended putting fat in there.
And since i did stop before having much grease in he reconned it would be no problem.

So a bit of interresting history there.

also the parts needed for the sump is in place, but the front diff is currently at a machine shop as a thread for the sealer ring towards the sump needs to be made.

Next week i will be traveling to a guy that owns a 02 wrc focus.
So im looking forward to this!!

[Norwegian Wolf]

Looks awsome!!

[andrewg]

Originally Posted by Mark_1

Found this neat thing on ebay.

Owner claimed it was a proper wrc item, has anyone seen a focus wrc oil catchtank?
Anyways need some cutting in the shell, and some brackets welded for it to fit.

wrc from what i remember were on the other side and went further down the pillar but very similar.. plus the welding is too big which would make think it was made from thicker ally than wrc one

[andrewg]

Originally Posted by andrewg

wrc from what i remember were on the other side and went further down the pillar but very similar.. plus the welding is too big which would make think it was made from thicker ally than wrc one

i think that the edges on the too halfs were rolled in and welded like a clam shell

[andrewg]

looking at it now i think you have it the wrong way round and it is for the other side!

[andrewg]

Originally Posted by andrewg

looking at it now i think you have it the wrong way round and it is for the other side!

so it is a copy of wrc one

[Mark_1]

Originally Posted by andrewg

so it is a copy of wrc one

Ok thanks, i'll get a throughout look at the wrc focus next week, and see how it is done with the oilcatch tank on that car.
I do believe i have it on the right side, because there is a bulge on the side towards the inner wing that you dont see on the picture that looks like is ment to go inside the frame on top, ehhh bit hard to explain.
Ill get some pictures up to show later today.

Your car ready for gatebil in september?

[AquariousRS]

Some super cool rare parts being used here. Very cool indeed. Good luck with the rest of the build

[Mark_1]

Originally Posted by AquariousRS

Some super cool rare parts being used here. Very cool indeed. Good luck with the rest of the build

Thanks.
Trying my best to have it ready for some autoslalom events and trackdays this year, so i can see what the car (well driver actually) is good for.

[Mark_1]

some more pictures of the catchtank.

[andrewg]

it would just seem like the breather pipe with no thread should be on top


plus it would need a drain right on the bottom or oil would always lie in it..

[Mark_1]

Originally Posted by andrewg

plus it would need a drain right on the bottom or oil would always lie in it..

Thank you Andy.
That line there get me starting to think.
so i took of the left wing and VOILA!



Now im glad the welding had to be postponed, or else it would've been mounted all wrong.

[carlo]

Nice one mate glad you got it sorted in the end

[Mark_1]

some more work carried out at the machine shop today.
Front diff have been o-ringed


And now i have all the parts needed to fit the sump.
Just need to clean it a bit before its ready.



Also made some brakets for the oilcatch tank to be welded on the innerwing, and the steering wheel extension boss is now ready with new threads.

[COCHYN]

Quality build!

[Mark_1]

Big things happening these days.
Car is at at my friends workshop, where we have proper tools.


The plan now is to fit the engine and drivetrain, and also weld the oilcatch tank brackets.

As always there are unforseen problems....
The rnd carrier did not fit the linkage rod, so i had to use the old carrier.
Also the gearlever with the white nylon knob had a thinner bottom end where the reverse lock is, so i have to use the other lever.
WHY DO R&D CREATE SAME PARTS IN DIFFERENT SIZES??!?!!

Anyways, gearbox is ready to be fitted.


After a bit fiddeling the xshaft came in place..
As im using an r&d front diff, the xshaft is fitted in a whole other way, but a big hammer got it in place.
Also burton gated sump plate.


And finally the engine.
It was a huge change of plans, as i was to buy tommy fields old engine, unfortunatly it took too long time to get hold of it, and now i have to buy a house.. so i had to find a cheaper solution as of yet.
Enter this beauty


Its a "clubman" gpa engine, mapped by Harvey.
I know really litle about it, but it got original internals.
Mahle pistons which looks new, so maybe theres a different comp.
Anyways, p8 ecu and antilag, so should be sufficient to start with at least.

If not something comes up, engine and gearbox is going in tomorrow

[Mark_1]

Got to do alot of things today.
Support pillars for the rear beam had cracked so needed welding


The left one proved to be hit pretty hard with rust, so we needed to make up a plate to weld it proper.


Also the brakets for the oilcatchtank was welded.
Pretty cool this picture i think.


And the final result


Fitted the sump and the engine mounts to the engine.


But there was a problem i was afraid would show up, cause some people say you have to skim off 12mm where you fit the engine mount on the right side, this turned out to be true.
Since its difficult to do this when the engine is complete, and also i did not want to do this to a 200 block, we modified the engine mount instead.
Also it turned out to be tricky to get the engine in with the enginemounts fitted, so we fitted the engine mount to the chassi, lifted in the engine and then fitted it to the engine mount...
Acording to my friend they had to do this to an wrc escort aswell..
thought the gpa stuff meant it should be easy to fit...

anyways.. pictures
Enginemount cutted.


And finaly engine is in


So looking forward to fit the gearbox and rear diff tomorrow.

[Mark_1]

Also i bought oils for the transmission today.
If anyone have any opinions on this please let me know.

For the front r&d diff i bought castrol Hypoy LS 90
Rear quaife diff: castrol Taf-x 75w-90
r&d gearbox: castrol Saf-xj 75w-140
Viscous: castrol Transmax Z

[Mark_1]

Some more work carried out yesterday.
Welded engine mount and rd diff fitted.


padleclutch removed and ap 2plate clutch fitted with heavier 4wd flywheel.


Gearbox going in



Also fitted the rear diff, but as there had been a 9inch diff fitted there before, the left driveshaft was to long to fit the 7.5inch diff.
So i need to come up with something smart here, maybe i'll use a standard driveshaft as for now.
The ones currently fitted are hollow wrc ones, so i would really like to use them.

Also put the car out in the sun for some tan

[jummpingjim]

Love it. Do you have any ideas for the final colour or you going to stick with the silver and black?

[Dicko&Sarah]

awesome thread and stunning car with all the proper parts

[Zzz...Zzz]

Befriende å se noe annet enn en sierra eller escort bli bygget - morro å følge med på tråden din.

Har ikke lyst å invitere på garasjebesøk da?

Uansett lykke til videre, ser jo ut som du har raska til deg mye fine deler å bygge bil av så dette blir nok braaa

MVh
Joel

[andrewg]

you want to get a couple of braces onto your front diff before it breaks the sump

[COCHYN]

Bad experience one time eh Andy?

[Mark_1]

Originally Posted by andrewg

you want to get a couple of braces onto your front diff before it breaks the sump

Yes im concerned about this, but as im only running around 300hp/450nm i do belive it will be sufficient with the standard cossie brace.
I may ofcourse be wrong, as its a limited slip diff in front the forces will be alot stronger than with a standard open diff.

Joel
A guy like you is always welcome, as im sure you have some tips and tricks to tell me =)

Jim
I have a couple of litres of imperial blue paint which i was thinking of using, but alot of focuses are already blue, so as for now i will stick with this combo, as i do suspect there will be some panel beating the first months of running the car.

The car was really heavy to push, so i checked the wheel bearings and it turns out that the front left one has a 1-2mm slack soooo i guess a bit more unexpected work needs to be carried out.

[timrud]

Good luck with the rest of the project. Make sure you post some videos when it's done please!

[Mark_1]

Originally Posted by timrud

Good luck with the rest of the project. Make sure you post some videos when it's done please!

Regretfully on my last "track" car i did not have a camera running all the time, so alot of memories are lost, so i will try having a camera running inside the car everytime it is beeing run.
(sweet memories http://www.osenworks.no/filmer/15auggatebil.mpg)

Havent done much today, aparat from taking apart the front hub, ive fitted a nice dynamo drop plate.
Supposed to be a rs500 copy, so the dynamo is fitted more away from the exhaust

[Mark_1]

Today i took the front hub to pieces, and from the look of it this bearing is REALLY EXPENSIVE!!
So a bit anxious to call my local skf distributor tomorrow to get the price on a SKF441933E bearing....

Sum pictures



Some machining needs to be done to the tca to crossmember spacer


Will have this sorted within this week i guess.

Also there is some welding needed to be done to the geartunnel.

Also need a mount here for the hydraulick handbrake.

Think ive got my hands on some proper mag oz's, waiting for a confirmation mail now, those would suit the car GREAT!

[M K]

excellent project and some very good driving skills from your old footage

what is the r&d billet gear lever part about? quickshift?

marc,

[Mark_1]

Originally Posted by M K

excellent project and some very good driving skills from your old footage

what is the r&d billet gear lever part about? quickshift?

marc,

No, they all are quickshift, but its the latest design which is more rigid.

[M K]

isn't quickshift for the mt75 box a bad idea as you tend to ruin syncro's ? or is yours not a standard box,

[Mad Matt]

Mate, don't get proper group A bearings !! You can get an adaptator to fit the group A hub which allow then the use of the Ford Transit bearings which are something like 45£ !

[Mark_1]

gpa bearings was out of stock, so i will buy an adapter so the wrc gravel bearing will fit.
Which i think is a better solution than the transit bearing.
Although the bearing kosts 150£..

m k, gearbox has dog rings.

[Mark_1]

Here are some pictures of the bearing adapter.



Looks neat.
Even more neat is the Oz mag wheels i just have bought, they will arrive in norway as soon as i get hold of some rear brakes aswell.

[andrewg]

Originally Posted by Mark_1

Here are some pictures of the bearing adapter.



Looks neat.
Even more neat is the Oz mag wheels i just have bought, they will arrive in norway as soon as i get hold of some rear brakes aswell.

problem with these is that they flex causing pad knock-off so i got steel ones made and also you need to machine a wider bearing surface onto the flange then that weakens it causing it to snap off, and cause the bearing is wider the shaft doesn't go right throu the flange so the splines are driving the weak part,,thats even leaving a radius in the corner and putting a radius on the bearing,,and also you will want to take a thou of the mateing faces of the bearing to tighten them up a bit.


i went back to the original type at £300 a bearing!!

thou some aparenently never have problems with them!

[Mark_1]

Ok, thanks for the input, they are already shipped, so ill see if it snaps or not. =)

Today i discovered i had the wrong startertype and that the gearbox xmember needs to be modified.
But i think i will remedy this within this week