Mk6 JWRC fiesta cosworth
17-05-2013, 01:59 PM
#2925
Time for another little update
Thought I would have a look at sorting the accelerator cable set up as I have nothing for the pedal end to hold the cable as you do on a standard car with a bulkhead mount etc,
I bought the tilton linkage add on for my Tilton pedal box as an extra for about Ł100 it allows fine adjustment for throttle, but still no way to connect up a cable!
I got an old throttle body cable part that has the lump on it the cable end sits on, cut it down and fitted it to the above part, no photos though I'm afraid,
Anyway, the tb end needing tweaking as the Hart inlet manifold comes with a bracket but it sits a bit off angle so not a smooth motion on the cable, got that sorted but again forgot photos,
Then was the pedal box end,
I wanted something that takes a pretty much standard cosworth cable I can buy from anywhere, also I did not want to have brackets etc bolted to the shell or have to weld now the shells painted so had to have a think.
Decided it was best to mount a bracket somehow direct to the pedal box that can somehow hold the cable, it had to be made heavy duty or it may flex when used,
I found 2 engine lifting eyes that are about 6mm thick with an 8mm hole in 1 end and thought as I never used them they would be perfect to mod so bolted them the the box to see what I'd do next
Next up I needed another piece to go across in line with the throttle linkage part, I had some 16mm solid square bar but that was pretty heavy so got 1 meter of 16mm box tube with 1mm wall from B&Q for Ł5.87, gave it a clean up and cut to size
Needs to mount like this
So next up was how do I hold the cable end itself! Then thought of an idea and come up with this
I cut off the excess plastic on the end of the throttle cable with a dremel, so although its modded slightly its still a standard cosworth cable to start so very easy to replace although a bit dear I think lol
The bar stock turned into this
It's a tight fit internally for the plastic round end of the cable and then a smaller hole to stop it pulling through completely, also I slit it down 1 side so the cable can be passed through,
Lined this up with the linkage and welded it to the end of the bar
Then with much care for the fitted brake lines etc I tack welded the bar to the engine lifting eyes I previously bolted to the pedal box via the cylinder bolts
Once I had checked a few things I welded it up properly
and cut off the top of the lifting eyes to leave a neater piece
Re fitted it and checked it lines up again
Thought I do a little vid clip to show it working
http://smg.photobucket.com/user/CHIC...d6de3.mp4.html
And showing it getting WOT (it doesn't close fully in vid as the cable is not pushed right into holder as its tight and i didn't want to wedge it in just yet, will close fine when pushed home fully)
http://smg.photobucket.com/user/CHIC...c9c31.mp4.html
And yes the phone did fall off the side
Works spot on
Gave it a lick of paint but may need re doing as paint was old and come out a bit crap lol
Other than paint finish I'm well chuffed with how it's come out & works, may powder coat it when I have other bits to do as it's not worth going down the coaters for 1 bit
Thanks
Marc
Thought I would have a look at sorting the accelerator cable set up as I have nothing for the pedal end to hold the cable as you do on a standard car with a bulkhead mount etc,
I bought the tilton linkage add on for my Tilton pedal box as an extra for about Ł100 it allows fine adjustment for throttle, but still no way to connect up a cable!
I got an old throttle body cable part that has the lump on it the cable end sits on, cut it down and fitted it to the above part, no photos though I'm afraid,
Anyway, the tb end needing tweaking as the Hart inlet manifold comes with a bracket but it sits a bit off angle so not a smooth motion on the cable, got that sorted but again forgot photos,
Then was the pedal box end,
I wanted something that takes a pretty much standard cosworth cable I can buy from anywhere, also I did not want to have brackets etc bolted to the shell or have to weld now the shells painted so had to have a think.
Decided it was best to mount a bracket somehow direct to the pedal box that can somehow hold the cable, it had to be made heavy duty or it may flex when used,
I found 2 engine lifting eyes that are about 6mm thick with an 8mm hole in 1 end and thought as I never used them they would be perfect to mod so bolted them the the box to see what I'd do next
Next up I needed another piece to go across in line with the throttle linkage part, I had some 16mm solid square bar but that was pretty heavy so got 1 meter of 16mm box tube with 1mm wall from B&Q for Ł5.87, gave it a clean up and cut to size
Needs to mount like this
So next up was how do I hold the cable end itself! Then thought of an idea and come up with this
I cut off the excess plastic on the end of the throttle cable with a dremel, so although its modded slightly its still a standard cosworth cable to start so very easy to replace although a bit dear I think lol
The bar stock turned into this
It's a tight fit internally for the plastic round end of the cable and then a smaller hole to stop it pulling through completely, also I slit it down 1 side so the cable can be passed through,
Lined this up with the linkage and welded it to the end of the bar
Then with much care for the fitted brake lines etc I tack welded the bar to the engine lifting eyes I previously bolted to the pedal box via the cylinder bolts
Once I had checked a few things I welded it up properly
and cut off the top of the lifting eyes to leave a neater piece
Re fitted it and checked it lines up again
Thought I do a little vid clip to show it working
http://smg.photobucket.com/user/CHIC...d6de3.mp4.html
And showing it getting WOT (it doesn't close fully in vid as the cable is not pushed right into holder as its tight and i didn't want to wedge it in just yet, will close fine when pushed home fully)
http://smg.photobucket.com/user/CHIC...c9c31.mp4.html
And yes the phone did fall off the side
Works spot on
Gave it a lick of paint but may need re doing as paint was old and come out a bit crap lol
Other than paint finish I'm well chuffed with how it's come out & works, may powder coat it when I have other bits to do as it's not worth going down the coaters for 1 bit
Thanks
Marc
Last edited by M K; 18-05-2013 at 05:15 AM.
20-05-2013, 06:01 PM
#2929
Bracket paint was crap so I bare metal'd it again and re primered and painted satin black and got it fitted properly
Cable clipped up out the way with all other lines etc
I hadn't yet run the clutch line from pedal box to gearbox with the dry break so I bolted it up to the master cylinder and drilled through the tunnel and fitted a grommet to keep it neat and stop it chaffing the line
Clipped up the lines to the gearbox, the bleed fitting will stay there for now but I will extend the line to mount it somewhere more convenient so the car does not need Jacking up to bleed
Love the look with the dash out, looks so raw
Cable clipped up out the way with all other lines etc
I hadn't yet run the clutch line from pedal box to gearbox with the dry break so I bolted it up to the master cylinder and drilled through the tunnel and fitted a grommet to keep it neat and stop it chaffing the line
Clipped up the lines to the gearbox, the bleed fitting will stay there for now but I will extend the line to mount it somewhere more convenient so the car does not need Jacking up to bleed
Love the look with the dash out, looks so raw
Last edited by M K; 20-05-2013 at 06:04 PM.
23-05-2013, 03:46 PM
#2935
Slowly but surely guys
Next time i get a chance to spend a bit of time on the car I think this lot will keep me busy for a few hours
That the last to do the fuel lines in the bay, the turbo oil feed and filter line, all the wastegate lines, map sensor and fuel pressure reg lines and 1 of the oil lines to the remote filter housing,
Won't be able to do the rest of the oil lines until I have the laminova heat exchanger and know where it will be positioned but hopefully have that within the next week
Next time i get a chance to spend a bit of time on the car I think this lot will keep me busy for a few hours
That the last to do the fuel lines in the bay, the turbo oil feed and filter line, all the wastegate lines, map sensor and fuel pressure reg lines and 1 of the oil lines to the remote filter housing,
Won't be able to do the rest of the oil lines until I have the laminova heat exchanger and know where it will be positioned but hopefully have that within the next week
28-05-2013, 04:39 PM
#2936
Have done most of the hoses now apart from the waste gate air lines, looking a bit like spaghetti junction now but there's not a lot i can do about that lol
As i could not run the turbo oil feed filter on the rocker cover as it hit the bonnet and the fact it looked crap i decided to relocate it to the rear left side of the cover so still easily accessible, the line then runs around the rear of the block and under the plenum to the remote filter housing
A few pics, please ignore the large cable ties as they are just temporarily holding things in place while everything is routed etc
Once the waste gate lines are done i will remove all the hoses, flush them through with a hose and then dry them all out with a high pressure airline making sure they are clean and dry then re fit them properly and tighten them up
As i could not run the turbo oil feed filter on the rocker cover as it hit the bonnet and the fact it looked crap i decided to relocate it to the rear left side of the cover so still easily accessible, the line then runs around the rear of the block and under the plenum to the remote filter housing
A few pics, please ignore the large cable ties as they are just temporarily holding things in place while everything is routed etc
Once the waste gate lines are done i will remove all the hoses, flush them through with a hose and then dry them all out with a high pressure airline making sure they are clean and dry then re fit them properly and tighten them up
30-05-2013, 08:50 PM
#2938
I have got a fair bit of saving to do yet Andy
Started to fit up the loom again but to run it nice i have found some of the wires to plugs to be shorter than i want so rather than use extension as i am fussy im going to give it back to Gary Barker and get them properly extended,
If anybody needs some loom extensions pm me as i have some as i bought them to use before deciding to have the loom cut and extended properly, i have a few for act,tps,als etc in various lengths all in raychem dr-25
Anyway, the loom is going to be run down between the fuel rail and cam cover for neatness, here it is sitting roughly where it will end up
Should be dropping the loom off to Gary tomorrow to be modified, ideally if the fully dressed engine had been in the car when the loom was made i would not of had this cock up as Gary would of measured it first but it was down to me to specify any lengths other than standard and i thought it would be ok but due to me having a few things different to standard it's not as neat as i want it so this is the only way.
Have also ordered new black plugs for the cops to replace the 2 grey ones
Also thanks to Jano @ oddkid creations i picked up my Laminova heat exchanger today
Lovely bit of kit, so im now ready to plumb in when i do my water hoses etc. this will then allow me to measure and make up my last 2 oil lines
Started to fit up the loom again but to run it nice i have found some of the wires to plugs to be shorter than i want so rather than use extension as i am fussy im going to give it back to Gary Barker and get them properly extended,
If anybody needs some loom extensions pm me as i have some as i bought them to use before deciding to have the loom cut and extended properly, i have a few for act,tps,als etc in various lengths all in raychem dr-25
Anyway, the loom is going to be run down between the fuel rail and cam cover for neatness, here it is sitting roughly where it will end up
Should be dropping the loom off to Gary tomorrow to be modified, ideally if the fully dressed engine had been in the car when the loom was made i would not of had this cock up as Gary would of measured it first but it was down to me to specify any lengths other than standard and i thought it would be ok but due to me having a few things different to standard it's not as neat as i want it so this is the only way.
Have also ordered new black plugs for the cops to replace the 2 grey ones
Also thanks to Jano @ oddkid creations i picked up my Laminova heat exchanger today
Lovely bit of kit, so im now ready to plumb in when i do my water hoses etc. this will then allow me to measure and make up my last 2 oil lines
Last edited by M K; 30-05-2013 at 08:53 PM.
30-05-2013, 09:40 PM
#2942
The one I have is the equivant to a 16 row oil to air cooler,
They also have the advantage of getting both water and oil up to temperature quicker as they heat and cool each other,
I'd say the reason you don't see many people use them is because they are quite a bit dearer than a normal oil to air cooler, but the fact every wrc car uses them from the original wrc escos to the current wrc fiesta's shows they are the best thing available
Last edited by M K; 30-05-2013 at 09:44 PM.
30-05-2013, 10:15 PM
#2944
Yeah it's a pain, shame to have to cut it but its being done properly so it won't cause any issues and will look better,
Hi Rob, yes they are better for a few reasons, they do not have to be in direct airflow to work effectively like an oil to air cooler, they can be cleaned and re used after an engine failure whereas a normal oil cooler should always be thrown away, and also they are impact resistant so stones and debris or even a crash to an extent won't damage it,
The one I have is the equivant to a 16 row oil to air cooler,
They also have the advantage of getting both water and oil up to temperature quicker as they heat and cool each other,
I'd say the reason you don't see many people use them is because they are quite a bit dearer than a normal oil to air cooler, but the fact every wrc car uses them from the original wrc escos to the current wrc fiesta's shows they are the best thing available
Hi Rob, yes they are better for a few reasons, they do not have to be in direct airflow to work effectively like an oil to air cooler, they can be cleaned and re used after an engine failure whereas a normal oil cooler should always be thrown away, and also they are impact resistant so stones and debris or even a crash to an extent won't damage it,
The one I have is the equivant to a 16 row oil to air cooler,
They also have the advantage of getting both water and oil up to temperature quicker as they heat and cool each other,
I'd say the reason you don't see many people use them is because they are quite a bit dearer than a normal oil to air cooler, but the fact every wrc car uses them from the original wrc escos to the current wrc fiesta's shows they are the best thing available
31-05-2013, 07:44 PM
#2946
Cheers mate,
Got the dash 4 lines made up today, air injectors mounted on the passenger wing beside the remote filter, external wastegate lines made, even the top line the just goes to atmos has been quipped lol
A few more pics
Lines from air inj to inlet, fuel reg to inlet and map sensor to inlet, the last 1 is going to be the aeroquiped boost gauge line,
External wastegate lines
Just see the air injectors mounted in the lower right of the pic
Also dropped the loom off to be modded and extended where needed,
Will take all the quip lines off next time I'm in the garage to be washed through and then dry'd out ready to re fit for the final time
Got the dash 4 lines made up today, air injectors mounted on the passenger wing beside the remote filter, external wastegate lines made, even the top line the just goes to atmos has been quipped lol
A few more pics
Lines from air inj to inlet, fuel reg to inlet and map sensor to inlet, the last 1 is going to be the aeroquiped boost gauge line,
External wastegate lines
Just see the air injectors mounted in the lower right of the pic
Also dropped the loom off to be modded and extended where needed,
Will take all the quip lines off next time I'm in the garage to be washed through and then dry'd out ready to re fit for the final time
01-06-2013, 09:09 PM
#2949
Advanced PassionFord User
awesome as always marc 
liking your mod for the throttle cable,mine was a bitch lol but i did make my own bell crank,sod paying overŁ100+ for one...mine was around Ł10 and im glad you spoke to jano about the laminova 
liking your mod for the throttle cable,mine was a bitch lol but i did make my own bell crank,sod paying overŁ100+ for one...mine was around Ł10 and im glad you spoke to jano about the laminova
01-06-2013, 11:00 PM
#2951
Cheers guys
Spent the afternoon on it again today and removed all the aeroquip lines from the engine bay for everything except the breather and the turbo drain as these were cleaned after assembly at FMS,
Flushed them through with the hose pipe and going to take them into work Monday so I can blow them through with a high pressure air line as I don't have a compressor at home,
Drying off after flushing, first time you've seen a washing line if Aeroquip
Also while at it today I drilled a hole in a large jubilee, tightened it around the oil filter and drilled a hole in the Anti roll bar bracket and painted it after of course lol
This is something i see on all the race/rally cars the guys at FMS prep and it makes sense in my opinion as I have seen filters work loose on more than 1 occasion and this will guarantee that will not happen
Better to be safe than sorry
Spent the afternoon on it again today and removed all the aeroquip lines from the engine bay for everything except the breather and the turbo drain as these were cleaned after assembly at FMS,
Flushed them through with the hose pipe and going to take them into work Monday so I can blow them through with a high pressure air line as I don't have a compressor at home,
Drying off after flushing, first time you've seen a washing line if Aeroquip
Also while at it today I drilled a hole in a large jubilee, tightened it around the oil filter and drilled a hole in the Anti roll bar bracket and painted it after of course lol
This is something i see on all the race/rally cars the guys at FMS prep and it makes sense in my opinion as I have seen filters work loose on more than 1 occasion and this will guarantee that will not happen
Better to be safe than sorry
Last edited by M K; 01-06-2013 at 11:04 PM.
02-06-2013, 09:01 AM
#2957
Also I don't think the engine will move much at all will it?
The only thing that will allow movement is the gearbox mount I believe as that being soft or hard will allow the engine to tilt back and forward, even then I'd say only a few mm max
The only thing that will allow movement is the gearbox mount I believe as that being soft or hard will allow the engine to tilt back and forward, even then I'd say only a few mm max
