Puma Cosworth restoration/bodge job fix!

[OldDan]

Warren - I don't think it will the ISCV plunger will completely block the ISCV will it? Needs to be only slightly for it to idle?

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[warrenpenalver]

Originally Posted by DanCossie

Warren.....Do you want to sell me this as it is ??? Genuine Question Mate

erm no sorry!! shes definitely NOT for sale!! I'll sell my house and my pension before this car goes

Originally Posted by OldDan

Warren - I don't think it will the ISCV plunger will completely block the ISCV will it?

Needs to be only slightly for it to idle?

Harvey Gibbs has had a look at it and said hes not seen one like it before but it seems to work so why fix it if it aint broke??

Been doing some wiring work on the car. I decided to strip the engine wiring loom a bit so i can replace the fan wiring loom also so i can remove the large spare multiplug behind the drivers side headlight as its redundant on my car. Im not cutting it off just relocating it up by the fuse box so when i decide to "lightweight" the wiring loom its readily placed for easy removal.

First of all i pulled the coolant tank out the way and extracted the wiring loom on the passenger wing then removed its plastic protective cover:


Quite dirty really!! Then the loom was quite clearly exposed:


so much for protection!!! no wonder old fords generate loads of wiring problems!!!! I shall be protecting it a bit better later on!!!

I then proceeded to strip apart the Battery junction box. I used loom plug connector extractor tools to separate the relay connectors from the relay plugs so ive got access to hack and maim as required!!!


I need to rewire the supplys and relay triggers for the two relay system i am fitting (my car was fitted with a non aircon single relay cooling fan system). Im choosing two relays for back up and also bridging the power supplys and trigger wires so that a single point failure on either relay AND the fan switch will mean the fans still have full functionality. There is also a switch linking into a spare switch in the cabin to override and manually run the fans.



I have also checked the strut to chassis join and all seems good. No significant movement can be seen beyond the very narrow paint crack which is to be expected (spot welds are below that).

Im still looking to add some metal tube bracing at the front of the car but that can wait until ive learnt to weld!!!

Also i got bored of waiting for suspension, so have bought some 10000 mile GAZ coilovers!!! Tidyied them up a bit and adjusted them for the right strut length to keep roughly same ride height (will need proper corner weighting later).



Note how the threads have been taped after being greased so they dont seize up!!!

Rebuilt them with brand new strut top cups, bearings and bolts:


Should get a chance to fit them later this week and get the car back on its wheels ready for an MoT next week.

[dlatch]

my fave thing on this thread is the wiring diagrams
i have a feeling this will also be one of those on going projects that will last for many years and evolve
lets hope that means faster and faster

[warrenpenalver]

Power is limited by what the gearbox can handle at present! and being a poor student i may not be able to afford a mullit or similar box upgrade for a long time!!!

Who done the rude tag!!!?????

ace, air, bodge, carbontec, comb, compressor, cosworth, diagram, extra, fine, fix, hard, nibble, puma, rubber, tooth, variable, warren does bottom burps, wiring

[lanfire]

good idea on taping the threads, REALLY wish i had thought of that when i fitted mine. Hows the ST clocks comming along?

[warrenpenalver]

will do it once the cars running.

[warrenpenalver]

just finished off my fan wiring loom!

got my connectors here which i need to thread through into the battery junction box ready to put the relay plastic casings on:


Once they are in position they clip into these relay holders:


The joys of ford modular fuse box construction!!!!

Also all the loom has been taped up properly as well as being protected with convoluted tubing where its exposed:


Just bits and bobs now to keep things ticking over!!!

[Glenn.]

Top work.I hate anything to do with wiring.

[warrenpenalver]

wirings not so bad to be fair. just time consuming and fiddly at times. making wiring diagrams from scratch is a pain though.

[orionmojo]

Originally Posted by warrenpenalver

wirings not so bad to be fair. just time consuming and fiddly at times. making wiring diagrams from scratch is a pain though.

you think your getting the hang of wiring in a car, then when testing something you've been messing with you get "that smell", your stomach drops, you run round to the battery, disconnect it again and then rip it all out again to see what you did wrong

[DHMC]

wow you're amazing.. and a student? how old are you btw? how did you learn all this about the looms and stuff?

I'll be needing that knowledge in the near future!

[warrenpenalver]

it says in my profile im 29, so guess im that old

well learn a fair bit about electronics at school, do practical electronics and some basic engineering in your job, strip and repair a couple of cars and bits and bobs/electrical mods over the years, make a few bits yourself and youll soon learn how to do stuff. I dont know everything about wiring!!

Cars being 12V DC are very simple in electronic terms. Its only complicated when you start meddling with computerised engine management, generic electronic modules etc and even then you just brake it down into functions and work from there.

Most fords upto 2004 or so are relatively simple with the GEM's replacing previously relay controlled circuits but the circuits themselves are still the same so its just the control thats more advanced.

[warrenpenalver]

put most the suspension back together now after playing around and doing a bit of derusting where i wont be able to reach:

oohhh look at the hole!!!!

Fitting new top mount rubbers as the old ones were way too flexible and i could flex them by hand with ease. These new ones I cant easily flex them at all and certainly not by hand!

Bit of a pain in the backside to fit but got there in the end:


I have also finally got some spare alarm modules!!


On opening it up you can see a pretty typical PCB:


My plans will be to desolder the PCB so i can use the connector blocks to link the original wiring on the alarm in car to the new 3 button remote alarm module i intend to fit.

[andy escos]

i love this car coming along nicely ,all this electrical wizardry is way over my head but good on you for having a go

[COCHYN]

Great developments, lovin the wiring diagrams and your own handy work. Respect!

[warrenpenalver]

Been doing a few more bits and bobs, removed my leaking radiator to put the new one and new fans in.

Removed the air filter for access to find yet another bodge!!!


Good job i can bend it back into shape easy!!

While i had easy access i have replaced my thermostat with a new one ive tested in a saucepan and gave the thermostat housing a bit of a clean up.


Guess i should clean the engine to match really!! that can be a mid winter project!!!

Also decided to take a photo of my strut top mounts now theyve been painted.


The bottom fell out my old in car tool bag so ive found its replacement:

Bigger than my last one and a fair bit stronger so should hold all the tools i should need!!

[Munch]

fair play!

[Karlos G]

Superb work Warren, very impressed, love the car!!!!

[Adrian]

Originally Posted by warrenpenalver

Power is limited by what the gearbox can handle at present! and being a poor student i may not be able to afford a mullit or similar box upgrade for a long time!!!

Who done the rude tag!!!?????

ace, air, bodge, carbontec, comb, compressor, cosworth, diagram, extra, fine, fix, hard, nibble, puma, rubber, tooth, variable, warren does bottom burps, wiring

I can tell you....... thrush

[frayz]

Wow just read this from the start.

Fantastic work mate and loving your attentions to get things done right. We all know there are some cowboys out there that call themselves tuners etc, but f*ck me this takes the piss.

I'll be watching this with interest, very impressed so far, well done

[mk14dr]

I knew when I saw this thread that it'd be this puma.
I did a couple of months working for Tony just after this had been featured, it was never right, never started/battery was always flat, but when its running and running well its more than a bit quick.
I remember going over to Blackpool for a FRP meet, we were in an FRP and Tony came past us on the M62 like we were stood still and hard launches down the seafront saw it going sideways spinning all 4 wheels. Does it still pull the carpet off the trans tunnel as you dip the clutch? Do those bloody Marcos wheels hold air yet?

Im glad to see that he let it go and it isn't sat rotting somewhere (its what we always said would happen to it if he didn't lower the price) and he's sold it to someone that has the skills and time to make it the car it deserves to be.

Good luck mate, I'l watch this with interest.

[graham c]

skylinebox ? thats wot am doing when mine blows !

[warrenpenalver]

Originally Posted by Adrian

I can tell you....... thrush

excellant

THRUSH!!!

Originally Posted by mk14dr

I did a couple of months working for Tony just after this had been featured

anything you can remember more about it, good or bad, then please share it here!! Tony seems to have "forgotten" too much for what was once his project!!!!

Originally Posted by mk14dr

it was never right, never started/battery was always flat, but when its running and running well its more than a bit quick.

never had problems with it going flat battery, although i have sorted out a few wiring problems

It runs shit on idle due to the crap map making it reallly rich until it comes on boost then its ok all the way. Didnt help that he was using a air bypass valve thingy to try and put more air in during idle to up the idle revs

It was really quick because he was running over 35psi of boost (my old guage only read upto 35psi).

Originally Posted by mk14dr

I remember going over to Blackpool for a FRP meet, we were in an FRP and Tony came past us on the M62 like we were stood still and hard launches down the seafront saw it going sideways spinning all 4 wheels.

Its a bit of an animal when it works!

Originally Posted by mk14dr

Does it still pull the carpet off the trans tunnel as you dip the clutch?

nah i modified the carpet, ie attached it properly to bulkhead!!

Originally Posted by mk14dr

Do those bloody Marcos wheels hold air yet?

yes, the rears were leaking air from the valves which is sorted now and the fronts i had a big nail buried in the tyre

Originally Posted by mk14dr

Im glad to see that he let it go and it isn't sat rotting somewhere (its what we always said would happen to it if he didn't lower the price) and he's sold it to someone that has the skills and time to make it the car it deserves to be.

yeah 2 years ago he had it up at like Ł25k

Luckily its stayed in his garage so not doing badly in rust terms!!! He hadnt put much underseal/paint on the underside so good job it was in garage really!! been sorting paint underneath it lots.

Originally Posted by graham c

skylinebox ? thats wot am doing when mine blows !

maybe. depends on how this oppliger box turns out as thats a cheap option and where i ultimately want to end up power wise.

[warrenpenalver]

Quick update....

Finished spraying the inside of the turret tops so later in the winter i can do rest of arch safe that the tops been done!


Was doing some more of my MoT checks and found another problem, this time with the front antiroll bar bush!! I wasnt happy that the ARB to TCA bolt only just covered the ARB stud:


Compared to other cars which sit proud by a few mm's


So obviously something was wrong!! A bit more closer inspection showed the rear of the TCA outer bush didnt look right:

On closer inspection i found this:

2 washers!!!! nothing major in the big scheme of things just a bit of extra hassle as its a bit awkward pulling the TCA off and putting it back on, but we like a challenge!!

finished prepping my fusebox for the new fan loom:


All the original fuse holders have been separated and removed so i can fit the new ones once i have threaded the wires into the fuse box. Should be simple case of then inserting the "click" in connectors to the relay holder and putting in the relay.

Another issue i want to solve long term is the intercooler to inlet pipe which as you can see is quite badly bent down:

What i want long term is one of those end fed log type plenums as i can get a simple straight feed from intercooler to inlet, plus with the kind of powers those inlets can flow, then i should never have to upgrade unless i go totally power insane.

I was also thinking about my carbon footprint:

[focus 4x4]

What a minging trotter you have.....


Just as the well the puma is decent!! lol

[warrenpenalver]

feet aint meant to be pretty!!

[CRAIG HAYTER]

Warren that looks mentaliam not really into Pumas but i like yours

[warrenpenalver]

Well finally it lives!!!!!!!!!

got struts sorted and fitted:


I then tapped up my threads but will probably have to redo it when i adjust the hieght!!


Ive also refitted my radiator and fans. I thought my wires were a bit close but its at least 2" between wires and anything moving, i may tie them back later.


While down there im also trying to work out which sensor is which!


I wired in my new fans with twin relays into the original fusebox so it looks factory almost! Its the dark green and black relay. Still to wire switch in car!


I intend to replace fuel filter which is grotty:



and clean up some of the rusty bits under chassis:





and my custom cut up washer bottle!! its tiny!! It shall be replaced in the future!


And here it is back on wheels!! A bit high at moment but i wil let it settle on a test drive then adjust ride hieght accordingly.

[marky_g]

thats very cool mate looks like it been put together just to get running, only lil bits nice to do them properly

[warrenpenalver]

it annoys me some of the bodges! Like the handbrake cable, yes with 3 clamps its secure and safe as a normal cable but why do that when for the sake of Ł20 he could have bought a proper adjustable cable connector!

[cossiejsy]

Hi warren the sensors in your picture ringed pink is the crankshaft position sensor and the one ringed green is phase sensor which is in the dizzy
Hope that helps mate

You have done yourself proud mate and one hell of a project

[Glenn.]

Dont forget when ever you disconnect the phase sensor make sure you know which way it came off cause the plug can go on both ways.If its on the wrong way round the engine wont start.


Top progress mate keep up the good work.

[andy escos]

Originally Posted by Glenny Boy

Dont forget when ever you disconnect the phase sensor make sure you know which way it came off cause the plug can go on both ways.If its on the wrong way round the engine wont start.


Top progress mate keep up the good work.

the phase sensor plug will only go on one way as there is a grove in one side just do not mix them up with crank & phase plugs on loom

[dingla rs]

Originally Posted by warrenpenalver

Well finally it lives!!!!!!!!!

got struts sorted and fitted:


I then tapped up my threads but will probably have to redo it when i adjust the hieght!!


Ive also refitted my radiator and fans. I thought my wires were a bit close but its at least 2" between wires and anything moving, i may tie them back later.


While down there im also trying to work out which sensor is which!


I wired in my new fans with twin relays into the original fusebox so it looks factory almost! Its the dark green and black relay. Still to wire switch in car!


I intend to replace fuel filter which is grotty:



and clean up some of the rusty bits under chassis:





and my custom cut up washer bottle!! its tiny!! It shall be replaced in the future!


And here it is back on wheels!! A bit high at moment but i wil let it settle on a test drive then adjust ride hieght accordingly.

seen a puma like this at motorscope procters old one ,im likein them a lot ,looks like your nearly there sorting the problems out mate ,wise i new bout car elec would be so handy,i hope ur goin do underside resto at some point tho fella

[warrenpenalver]

Originally Posted by cossiejsy

Hi warren the sensors in your picture ringed pink is the crankshaft position sensor and the one ringed green is phase sensor which is in the dizzy
Hope that helps mate

cool thats just what i needed to know!

[warrenpenalver]

Originally Posted by dingla rs

i hope ur goin do underside resto at some point tho fella

the underside of the shell isnt bad at all. the only rusty bits are on the cossie parts and thats surface rust mostly. It will be getting treated though just as and when really. like fuel tank is coming out this week coming to replace pump wiring and fit an 044 so while its off the floor will be painted. same when i do rear beam eventually etc etc.

[Glenn.]

Originally Posted by andy escos

the phase sensor plug will only go on one way as there is a grove in one side just do not mix them up with crank & phase plugs on loom

Ive read a few posts on here and people have said the phase sensor wire can go on both ways.Or well im wrong again lol.

[cossiejsy]

Originally Posted by warrenpenalver

cool thats just what i needed to know!

Your welcome mate

[warrenpenalver]

i decided today to check the cooling system by running it upto temp and proving the fans.

I knew it would take a while as its cold out, but it took 10 mins to get to normal temp and a further 20 minutes held at 3000rpm to drive the temp high enough to trigger fans

no leaks and the fans cycle fine! so thats good news and apart from the suspension strut snapping, was the other main reason the car was off the road!

[warrenpenalver]

I fitted my new land rover disco 3/range rover sport wing mirror switch. Totally cosmetic but i fancied a change.



Also a third of the price of a new one from ford!!! Strange how a range rover part which originally came from the ford parts bin retails a lot less than the original ford part!! Youd think it would be the other way round!!

Ive also started a new indicator stalk mod. This will work on all pumas. Basically i eventually plan to change my steering wheel so will need to sort horn out. So remembering mk3 fiestas had the same basic stalk design but with the horn on the light switch, i decided to get busy!!!

First i butchered a mk3 stalk:

that is the bit i want to keep!!! It is held in only by a small pin in the back of the stalk body. I just butchered the stalk to remove it then desoldered the wires from the circuit board.

I then removed the light unit from a puma/fiesta mk4 stalk unit. Ideally you would be able to just extract the retaining pin but mine wouldnt come out so i just hacked to death the light unit then butchered the remains with a drill until i could remove it!! Be careful not to damage the front of the stalk unit itself as this will be visible when its built.



then unclip the wires from the circuit board so that you can fit the new light/horn unit. You will notice an extra wire and different colour codes. I worked out using a multimeter which wire did each function and will post a table up later.

looking at the circuit board you can see the tags for the new wires and also the two horn tags:


What i will do is source the correct size connectors and fit them to the wires on the horn/light unit as they are the right length. I will also wire the horn switch in.

I will do this as a guide eventually along with variable intermittant wipe once its tested! I had a problem where it worked in my car but not jackos but i think that was because in the escort they used several different circuit boards in the stalk units and only one of them was cross compatable with the later pumas/fiesta mk 4s. So its easier to wire in the intermittant stalk into a puma stalk unit as you know it will work then rather than risk it with escort parts!!