Mk6 JWRC fiesta cosworth
09-03-2012, 07:42 PM
#2202
Lucifer II - 666
An engine in!!! I know not a working one but still looks 
10-03-2012, 07:38 AM
#2207
It is nice too see an engine in there, just a shame it isn't fully built up ready to stay in there,
The reason being is that if i give it to Tommy @ Fms to finish i will have no money to do anything else for 3 or 4 months, but if i dummy fit what i have now and buy the turbo as the next main thing then i can make hoses/oil/fuel lines and the exhaust system and work out a few little niggles, like there being no room for the wrc cam pick up sensor, so will have to find an alternative like Coley i think did on his focos.
I did literally drop it in as i had to lift it into place by hand on my own
Built up the sump/block/arms etc the lifted into bay over the cradle onto the mounts
The gearbox is not in place at the moment but i may put the old dummy box back in later today
A few more pics
Lifted the block and sump in
Then put the manifolds on
Soon as the exhaust manifold was fitted i thought there was no way the external wastegate was going to fit but luckily it is ok, and will have enough clearance, maybe more if i find once the turbo is fitted i can mill down the manifold spacer if possible
Not a great deal of room but enough
Another front view
And back of block
Gonna spend some more time on it today and work out where il put the remote filter head and hopefully get front and rear props painted
The reason being is that if i give it to Tommy @ Fms to finish i will have no money to do anything else for 3 or 4 months, but if i dummy fit what i have now and buy the turbo as the next main thing then i can make hoses/oil/fuel lines and the exhaust system and work out a few little niggles, like there being no room for the wrc cam pick up sensor, so will have to find an alternative like Coley i think did on his focos.
I did literally drop it in as i had to lift it into place by hand on my own
Built up the sump/block/arms etc the lifted into bay over the cradle onto the mounts
The gearbox is not in place at the moment but i may put the old dummy box back in later today
A few more pics
Lifted the block and sump in
Then put the manifolds on
Soon as the exhaust manifold was fitted i thought there was no way the external wastegate was going to fit but luckily it is ok, and will have enough clearance, maybe more if i find once the turbo is fitted i can mill down the manifold spacer if possible
Not a great deal of room but enough
Another front view
And back of block
Gonna spend some more time on it today and work out where il put the remote filter head and hopefully get front and rear props painted
Last edited by M K; 10-03-2012 at 07:42 AM.
10-03-2012, 08:30 AM
#2210
It's not OCD lol i just want to do things right first time round if i can
Ozmk1cos - cheers mate
Got some of the rear end fittings through today, but they were out of -6 teflon hose so have 12m of that coming tuesday or wednesday
Can make up the -10 fuel lines though today from tank to pumps
Ozmk1cos - cheers mate
Got some of the rear end fittings through today, but they were out of -6 teflon hose so have 12m of that coming tuesday or wednesday
Can make up the -10 fuel lines though today from tank to pumps
10-03-2012, 02:28 PM
#2214
if not there should be plenty of turbulent airflow under the boot floor to be good enough for that cooling.
If you go flat floor its relatively simple to have a naca duct to feed the cooler (and you might as well as youre doing it) then exhaust out the bumper like you said.
I presume with all that exhaust pipework in the engine bay you will be spending a fair bit of effort on heat management???
10-03-2012, 04:57 PM
#2216
Cheers Gary
are you flat flooring it??
if not there should be plenty of turbulent airflow under the boot floor to be good enough for that cooling.
If you go flat floor its relatively simple to have a naca duct to feed the cooler (and you might as well as youre doing it) then exhaust out the bumper like you said.
I presume with all that exhaust pipework in the engine bay you will be spending a fair bit of effort on heat management???
if not there should be plenty of turbulent airflow under the boot floor to be good enough for that cooling.
If you go flat floor its relatively simple to have a naca duct to feed the cooler (and you might as well as youre doing it) then exhaust out the bumper like you said.
I presume with all that exhaust pipework in the engine bay you will be spending a fair bit of effort on heat management???
At a later date maybe a flat floor but not to start so should be ok,
As for heat proof etc yes, i will most likely use the adhesive backed thermo-tec stuff and cover the turbo side wing and exhaust side of transmission tunnel and a bit of bonnet underside
10-03-2012, 05:04 PM
#2217
After getting my cam cover back from my mate i soon realised that with the engine in place as it was it is actually IMPOSSIBLE to get the bloody thing on as there is no room! This is fine if you want to have the hassle of dropping the engine 35mm every time you need to remove the cover or if you never want to remove the cover while the engine is in the car, but sometimes it may be necessary so i can't leave it like this
So i had to lower the engine down on the cradle enough to get the cover on, probably dropped about 35mm before it would go on, maybe Andrew missed this or just didn't think lower the engine is a real issue, im not sure
This is how tight it is with cover on and engine in the proper position, not a chance of using the normal wrc cam position sensor set up
So things had to get serious
......................
So i had to lower the engine down on the cradle enough to get the cover on, probably dropped about 35mm before it would go on, maybe Andrew missed this or just didn't think lower the engine is a real issue, im not sure
This is how tight it is with cover on and engine in the proper position, not a chance of using the normal wrc cam position sensor set up
So things had to get serious
......................
Last edited by M K; 10-03-2012 at 05:05 PM.
10-03-2012, 05:15 PM
#2218
PassionFord Post Troll
the reason we left the engine high was so the car could be low without drive shaft angle issues
its easy to space it down a bit but impossible to lift it,
its easy to space it down a bit but impossible to lift it,
10-03-2012, 05:40 PM
#2221
I have cut a section of the bulkhead underside so the cover fits easily now and the engine will not need to be lowered so shaft angles are kept good
10-03-2012, 05:45 PM
#2222
Sliced the panel and cut a small section out then folded it back up together and for now have bonded it together with tiger seal, i will tack weld it in place and fill in the gaps at the side and paint over to tidy up later when engine is back out
Last edited by M K; 10-03-2012 at 05:47 PM.
10-03-2012, 09:29 PM
#2229
Well spotted
I didn't even think of that
I line the engine up so it was level and obviously the box tilts it back alot more,
Well with any luck the wrc cam sensor will be ok now I have cut the extra piece off which means I won't have to buy or fit another set up as even tho it sits alot lower with the box I don't think there would of been enough room
Problem solved
Thanks for pointing that out
I didn't even think of that
I line the engine up so it was level and obviously the box tilts it back alot more,
Well with any luck the wrc cam sensor will be ok now I have cut the extra piece off which means I won't have to buy or fit another set up as even tho it sits alot lower with the box I don't think there would of been enough room
Problem solved
Thanks for pointing that out
Last edited by M K; 10-03-2012 at 09:30 PM.
11-03-2012, 06:04 AM
#2236
Yeah box will go on next time I'm in the garage to see exactly where we are,
Think the wastegate should be ok but it will be close,
STU - I wanted to avoid using the ST dizzy phase sensor set up as its big and chunky
Will update again when box gets put on
Think the wastegate should be ok but it will be close,
STU - I wanted to avoid using the ST dizzy phase sensor set up as its big and chunky
Will update again when box gets put on
11-03-2012, 08:48 AM
#2237
Spanner monkey
Mark, If you are tight for room on the rear end of the cover, Why not run a trigger off the cam pully as we do when doing a cossie management conversion on the cvh's? Only requires the disc behind the pully and a small bracket off of the cam cover, A fair bit cheaper too?
Gadge.
Gadge.
11-03-2012, 08:53 AM
#2238
Spanner monkey
18-03-2012, 01:22 AM
#2239
on the cossie head Gary there is no room for a disc behind the pulley as the cams run literally a couple of mm away from the head,
Someone sent me a pm with another option of a small wrc type sensor that goes where the dizzy used to but is a lot smaller than the ST set up, i think i will go on ebay and order a galaxy sensor and see how that is as it may just fit
The normal wrc 1 is not going to fit, even if i cut out the entire skin underneath the plug will be tight i think
Someone sent me a pm with another option of a small wrc type sensor that goes where the dizzy used to but is a lot smaller than the ST set up, i think i will go on ebay and order a galaxy sensor and see how that is as it may just fit
The normal wrc 1 is not going to fit, even if i cut out the entire skin underneath the plug will be tight i think
Last edited by M K; 18-03-2012 at 01:26 AM.
18-03-2012, 02:17 AM
#2240
Anyway, i got the box and old diff casing bolted up so the engine is exactly where it wants to be
Now that the dummy box is on and the engine is in its correct position, there is a few issues i need to sort,
The external wastegate now touches the engine bay cross bars of the cage, no major issue, i will just cut off the wastegate pipe, shorten it a tiny amount then re angle so it fits and clears then weld it back on,
Here is how it is now
I then fitted the cams to the head so i could bolt up the quaife peg drive verniers to see the clearance and they are hitting the bonnet reinforcing skin,
I will see how much clearance it creates by cutting away the reinforcing skin around the pulley area as i do not want to lower the engine if i don't have to, but i will have to if needs be but it's not the end of the world.
Now that the dummy box is on and the engine is in its correct position, there is a few issues i need to sort,
The external wastegate now touches the engine bay cross bars of the cage, no major issue, i will just cut off the wastegate pipe, shorten it a tiny amount then re angle so it fits and clears then weld it back on,
Here is how it is now
I then fitted the cams to the head so i could bolt up the quaife peg drive verniers to see the clearance and they are hitting the bonnet reinforcing skin,
I will see how much clearance it creates by cutting away the reinforcing skin around the pulley area as i do not want to lower the engine if i don't have to, but i will have to if needs be but it's not the end of the world.