Mk6 JWRC fiesta cosworth
27-02-2013, 05:48 PM
#2761
I have seen a few annoying failures and silly problems relating to 4x4 gearbox gear lever cradles,
Stripped threads, loose bolts leading to stripped threads and once in the car it's a paint to sort as your have to drop the box etc,
So i drilled out the socket cap heads for the gear lever cradle and drilled 2 small holes, 1 either side of each side alloy bush
These will be used to lockwire the bolts in place once tightened,
Sides lockwired
2 top bolts lockwired to each other
So job done, i know you could easily thread lock them but then they can be a pain to remove so i prefer this way, i did the sides a little wrong so re did the lockwire as it wasn't wired correctly in the pics below
So gearbox is ready to go in other than the concentric clutch slave set up
Stripped threads, loose bolts leading to stripped threads and once in the car it's a paint to sort as your have to drop the box etc,
So i drilled out the socket cap heads for the gear lever cradle and drilled 2 small holes, 1 either side of each side alloy bush
These will be used to lockwire the bolts in place once tightened,
Sides lockwired
2 top bolts lockwired to each other
So job done, i know you could easily thread lock them but then they can be a pain to remove so i prefer this way, i did the sides a little wrong so re did the lockwire as it wasn't wired correctly in the pics below
So gearbox is ready to go in other than the concentric clutch slave set up
Last edited by M K; 27-02-2013 at 05:51 PM.
28-02-2013, 03:01 PM
#2768
Yes mate GEARS have just rebuilt my front diff, not been delivered back yet but price was good and just over a weeks turnaround so happy with that,
The box I have not had worked on but think il send it to them as well when I need a build
The box I have not had worked on but think il send it to them as well when I need a build
04-03-2013, 03:22 PM
#2770
Got the front diff back from GEARS today
3.9 shot peened and finished crown wheel and pinion, 8mm studs and strengthening plate, see how that gets on for now
Ignore the bolt in the bottom cover, they put that in there to stop any oil from the build up leaking i suppose but i have an alloy bolt to fit and wire lock for that and a magnetic plug for the oil fill
Also dropped off my standard flywheel (which was re drilled etc to suit a 7.25" race clutch) to FMS to be re ground etc as although i want a lightweight billet item it will save me a couple of hundred quid at the moment which will help
Hopefully sorted a center push clutch set up as well from a member on here, just waiting to hear back from him, so at the end of this month i will have everything to put the engine box diff etc altogether properly and in the car to stay.......................
Well until i break something anyway
3.9 shot peened and finished crown wheel and pinion, 8mm studs and strengthening plate, see how that gets on for now
Ignore the bolt in the bottom cover, they put that in there to stop any oil from the build up leaking i suppose but i have an alloy bolt to fit and wire lock for that and a magnetic plug for the oil fill
Also dropped off my standard flywheel (which was re drilled etc to suit a 7.25" race clutch) to FMS to be re ground etc as although i want a lightweight billet item it will save me a couple of hundred quid at the moment which will help
Hopefully sorted a center push clutch set up as well from a member on here, just waiting to hear back from him, so at the end of this month i will have everything to put the engine box diff etc altogether properly and in the car to stay.......................
Well until i break something anyway
Last edited by M K; 04-03-2013 at 03:25 PM.
07-03-2013, 11:14 AM
#2780
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Join Date: Jan 2007
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Car is immense! Some lovely detail, especially the labels on the loom, absolutely love that.
Out of interest, where do you get the clear heat shrink for it? Guessing the label is probably from a Dymo label maker or similar.
Out of interest, where do you get the clear heat shrink for it? Guessing the label is probably from a Dymo label maker or similar.
07-03-2013, 05:50 PM
#2782
PassionFord Post Whore!!
iTrader: (2)
You can get clear heatshrink from polevolt and ive used dymo tapes before but just do a couple of dummy runs to make sure your tape doesnt turn completely black from the heat whilst warming up the heatshrink 
David
David
10-03-2013, 10:36 PM
#2783
Started to look at where to mount things over the weekend like air injectors, fuel pressure reg and 5 bar map sensor,
first and easiest was the air injectors, i had previously bought an mk motorsport air injector bracket but due to how close the engine is to the bonnet i could not use it which is a shame, so a simple 5 minute job on the lathe turned up a simple stand off to mount them on,
Just need a nice shiny plated socket cap head and some loctite and a clean up of the billet housings and thats that sorted,
Shit pics i know lol
Just working on making the concentric hydraulic clutch now, got the billet turning up in the week along with a release bearing and that should be made and sorted by the weekend
first and easiest was the air injectors, i had previously bought an mk motorsport air injector bracket but due to how close the engine is to the bonnet i could not use it which is a shame, so a simple 5 minute job on the lathe turned up a simple stand off to mount them on,
Just need a nice shiny plated socket cap head and some loctite and a clean up of the billet housings and thats that sorted,
Shit pics i know lol
Just working on making the concentric hydraulic clutch now, got the billet turning up in the week along with a release bearing and that should be made and sorted by the weekend
14-03-2013, 10:40 AM
#2787
Started to make my own concentric hydraulic clutch set up,
Spent a long time looking for the correct bearing and slave cylinder as there's lots of photos if different supplied kits on the net but no part numbers etc
Sorted the cylinder, sorted a proper bearing for twin plate clutches, bought some billet to make the spacer,
Bored out the spacer so its a snug fit over the gearbox nose piece
Bearing press fitted on retainer
Spacer test fit
Just need to get my flywheel back so I can bolt up the clutch pack and test fit to work out spacer height, then the spacer can be turned down, drilled and threaded for the bolt holes and an anti rotation fixing
Spent a long time looking for the correct bearing and slave cylinder as there's lots of photos if different supplied kits on the net but no part numbers etc
Sorted the cylinder, sorted a proper bearing for twin plate clutches, bought some billet to make the spacer,
Bored out the spacer so its a snug fit over the gearbox nose piece
Bearing press fitted on retainer
Spacer test fit
Just need to get my flywheel back so I can bolt up the clutch pack and test fit to work out spacer height, then the spacer can be turned down, drilled and threaded for the bolt holes and an anti rotation fixing
15-03-2013, 08:00 AM
#2792
Thanks mate, a lot of it comes down to trying to save money where I can, I also absolutely love making parts myself from Billet etc on the lathe so even if it takes me ages, rather than buy off the shelf tomorrow I save a few quid, learn more about machining and have fun doing it all at the same time,
Plus the more things you have done or know about yourself, the more chance there will be that you know how to fix it or what's causing it when you have issues rather than just taking the car somewhere and picking up the bill,
The only part I have never attempted to do is the engine itself as I'm not confident enough on such a big spec engine (big for me anyway)
Thanks mate, as said many times before, makes all the hard work worthwhile hearing comments like that
Plus the more things you have done or know about yourself, the more chance there will be that you know how to fix it or what's causing it when you have issues rather than just taking the car somewhere and picking up the bill,
The only part I have never attempted to do is the engine itself as I'm not confident enough on such a big spec engine (big for me anyway)
17-03-2013, 10:26 AM
#2794
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Has to be one of THE most thought out cars ever made!
How have you done the brake setup, has the ABS been lost and brake servo relocated or have these been done away with? I tried to find the info but so many pages now
How have you done the brake setup, has the ABS been lost and brake servo relocated or have these been done away with? I tried to find the info but so many pages now
17-03-2013, 02:41 PM
#2796
There is no abs or brake servo, nothing of the original fiesta or cosworth brake set up has been used.
I run a Tilton bias pedal box
I also have the adjustable front rear bias lever you can see on the right and this one inline to the rear brakes although this one will be left fully open as I will only use the one to the actual pedal bias
Ap cp5555 6 pot front calipers on the front with 360mm discs
Rear brakes are Ap cp5200 4 pots with 330mm discs
