Zook

Weekendly updates, superb!

What are 'air injectors', not massively clued up on the cossie engine personally

M K

iTrader: (9)

I wanted to start sorting the boost and water hoses for the car now as i need these in place along with the alternator and belt etc before i can work out where my laminova can be mounted and where the 2 remaining -10 oil lines can be run,

First up was the turbo compressor housing to intercooler hose, i noticed when looking at hose prices that the normal cossie style hose which is "?" shaped may well fit but is just over £90 delivered from most places and that seems a bit excessive to me so tohught if i could get a 90 bend put on the housing then i could just use a straight hose from compressor housing to intercooler instead?

So off with the housing



And out with the grinder which leaves me with this



Made a call to cr turbos and ordered up a cast 90 degree elbow but it needed to be shorter to line up properly so got the grinder on that too



Quick mock up of where it needed to be



Now being alloy there was now way i could weld it as i do not have the equipment for that so had to hold it in place so i could take it to be welded by my good friend/fabricator Karl, so used some black electrical tape and wrapped it round just leaving a small gap big enough to weld a good tack which will hold it while the rest of the tape is removed and then it can be welded properly



So with that done i got it to Karl's and told him what i needed doing but also told him i wanted the weld built up around the edge so you can't see the big step in size, no problem he said and got it done and it turned out a lot better than i hoped as at one point after i had cut the compressor housing then got the bend i thought it was going to be a total abortion as the bend was not exactly the same size due to me cutting back the compressor end beyond the round hose end piece

All done





Well happy with it

But.............. nothing is ever without it's bloody issues and neither was this it seems!

When i attempted to re fit it back to the turbo it appears that the heat has distorted the shape by a very minor amount! but it seems luckily that it has not distorted the flat face as when put on a piece of glass (which is about the flattest thing you will find most likely) it made full contact but somehow the machined hole was off! so it must of been where i asked him to build the weld up to make it look better it took too much heat and that caused it so next time a big piece of brass will be used to weld on to soak up the heat along with shorter weld periods. Anyway after a bit of very careful rubbing with paper and a few million trial fits it is all good and seats good again thank god

So after that long winded story, more pics

Got some hoses from viper performance hoses which is all i could get short notice to test fit this weekend to work out sizes i need to get a custom 1 piece hose made instead of the 2 hoses and metal joiner in the pics, but i will be changing them to roose items as i like there logo better lol, also with get a slightly longer hose from tb to cooler from roose as well then sell these ones

Here's is the test fit up







Nice neat and simple which is what i like lol



Next up as you may of noticed in the pics was mounting the alternator,

I am using a 2wd set up as i have done away with the power steering and didn't want the big heavy escos style bracket but i also did not want the twin belt 2wd set up so i have gone with a 2wd bracket set up with a 4wd poly v belt that is just routed around the alternator pulley, water pump pulley and crank pulley, i know this leaves less belt to pulley contact on the crank but Martin Hadland runs a set up like this and has never seen any issue's so that is proof enough for me that it will be fine,

So to mount the alt to the block i sold my wrc bracket set up due to the cost and aggro of sourcing a wrc alt and went for a 2wd billet bracket with a drop bracket all machined into 1 from Anembo Engineering, i spoke to mk motorsport about 1 first as i always use him but he was very busy and did not have 1 available on the shelf so sent me in there direction,



Going to swap the bolts for plated ones as im a bufty at heart lol

Also you can see the stainless rose jointed belt tensioner i made instead of using the standard type,



with with all that fitted i used a dummy knackered alternator to check things lined up ok which they did but the only thing i noticed is my red anodised pulley is very faded compared to my others and they were all bought at the same time and were all the same dark red so im guessing that maybe mine was mixed up at fms and i ended up with this one but no drama's as i will either get a new 1 or re anodise this one,

Here is the alternator dummy fit pics





So now i know all that fits, i have measured the length of belt needed so will order a belt and new alternator (90amp) along with a long 130mm M8 bolt to go through the bracket as i do not have 1, and get it fitted properly,

Then it will be time to buy some water hoses and make a start on that side of things

shaun_focus4x4

Pro alloy did mine for me

M K

iTrader: (9)

I am looking into the wiggins clamps like you have,

How much we're they I you don't mind me asking?

Thanks
Marc

XRT_si

iTrader: (2)

Really nice as ever and properly coming together now!

Wiggins clamps would so suit your engine bay Marc, but fuck me they're expensive!

M K

iTrader: (9)

Yeah the wiggins would be awesome but your
Probably talking another £1500 to do the boost and water lines

Hoses for now and maybe wiggins as an upgrade a few years down the line ay

XRT_si

iTrader: (2)

Exactly! I'd love them but just too much money when a jubilee clip does pretty much the same job lol

shaun_focus4x4

Yeah think it was about 950 odd for all the wiggins.... Rad/turbo/inlet/intercooler

frayz

Wiggins clamps are a pain in the ass to faf about fittin too. Very quick to get off but overly fussy fitting. Not to mention if you have any kind of prang the they have no give whatsoever. A silicone hose will bend/collapse or tear.
Look pretty and hold monsterous boost but that's about it. Lol.

Lookin good Marc, I also welded an elbow on my turbo, much better for space and keeping the pipe runs clean.

M K

iTrader: (9)

Got an alternator and belt sorted so will have the ready to fit at the weekend,

Also got my 1 piece hose coming from Roose Motorsport with another reducer for the cooler to tb hose so they match,

Going to drop this lot off tomorrow to be anodized red like the other little bits on the car, if i am lucky i may get it back for friday but will have to wait and see

JonnyBravo

Nearly there Marc

M K

iTrader: (9)

It's getting close mate,

Dropped off the stuff this morn to the anodizers and just got the call to say its all done,

Couldn't do the handbrake though as I forgot to press out the steel inserts so going to get that done next week as they said were charge you a set amount and just drop the handbrake in soon as I've presse the metal bits out and he'll get it done for nothing

Pics once I've picked the bits up

Miller 3

iTrader: (4)

Who dose the anodising bud and where are they?

M K

iTrader: (9)

Action electro plating in basildon mate

Didn't finish work in time to get down there to collect the bits tonight so picking stuff
Up in the morning and I've now removed the steel insert from the handbrake lever so there gonna do that for me tomorrow day

M K

iTrader: (9)

All done easy to re fit

Miller 3

iTrader: (4)

How much that cost me old mucca?

Miller 3

iTrader: (4)

I see you placed it all in the same order as the other pic lol

M K

iTrader: (9)

That's how much of a geek I am

Cost me £20 mate as I get a mates rate as I've used them for quite a while now

andy escos

iTrader: (1)

now thats dedicated OCD lol

looking good marc

M K

iTrader: (9)

As I'm so eager I got all the bits re fitted straight after work lol

Steering wheel spacer


Handbrake parts




Just need some new rubber heat shrink to re cover the handle,


Alternator heat shield got a lick of vht, it came with the 90a ford visteon alternator I just bought second hand in minty mint condition



Alt pulley and the plated parts fitted I had done ages ago

Sticky.

iTrader: (4)

Love the attention to detail.

stevenebm

iTrader: (6)

Takes balls to cut the turbo like that.amazing detail throughout the car.

nthorpey

the heat shrink will go sticky eventually in my old car i used a thin mountain bike grip was ace.

M K

iTrader: (9)

Thanks guys, appreciate the nice comments

Cheers for the mountain bike grip tip, may just use that,

Thanks
Marc

M K

iTrader: (9)

Toying with the idea today of re designing the cooling package,

Would mean selling my brand new pro alloy rs500 cooler and getting then to make a custom fit escort/focus wrc style cooler, slanting the radiator and putting a large air filter behind the ford grille in direct airflow as per Ronnie Amis time attack sierra,

Here it is as it is now with the rs500 cooler, absolutely no room for air filter pipe work anywhere!



Bumper removed


Angled the radiator to make it work better and give me more room around it and above it behind the ford grille for an air filter











More on this when I've made some calls to get a price for a new cooler and see what interest I get in mine as there £432 new so was thinking about £360 for mine as it is like new still

Thanks
Marc

whizzisat114

iTrader: (2)

What about a filter housing on top of the radiator like Charlie shaws focus?
It works for his 800bhp monster

dingla rs

iTrader: (2)

Yer I'd talk to Andy sure he made the filter set up him self
Was on bench been made when I was up there

M K

iTrader: (9)

Hi mate

That's what I will do if I slant the radiator, I I leave the rad and cooler as it is then there is no room for it, no way shape or form

Fudgey

iTrader: (4)

Are you going to use the car on the road marc?

If not then remove the headlight and make up some black meshed thing and stick the filter there

Or get quad lamps and remove one lamp with a duct to the filter..

Looking as awesome as ever tho bud

Cossy Mike

iTrader: (4)

I might be interested in the cooler Mark exactly what I'm after. Was looking to buy one around Xmas time anyway

M K

iTrader: (9)

Hi mate,

No it's not really a road car but I don't want to remove a headlight or use the quad lamps as I don't like the look, appreciate the ideas though


Hi Mike, if you want I can let you know once I've decided what I'm going to do, probably in a week or 2

Cossy Mike

iTrader: (4)

Ok Marc, sounds good to me, I'm out of the UK today for 2 weeks anyway

M K

iTrader: (9)

Ok mate, by the time you come back I should know what I'm going to do

steven mc kay

Hi Marc on my fiesta on the turbo side inner guard we have a cut out to let the pipe Work in for the air filter' there is a place made away from dirt and water in front of drivers front wheel for air filter to sit the air flow is fed from the front bumper area

Thanks steven

M K

iTrader: (9)

Wellens7 - you have too many pm's mate and I can not reply to you until you delete some!!!

wellens7

sorted

M K

iTrader: (9)

Due to cost and extra hassle im not going to go the slanted radiator route so im keeping the existing rad with a new cooler so ive now worked out the new cooler size etc,

Going to put double thick foam strip all around the radiator and run an identicle sized intercooler in front of it with 90degree outlets at the top,

Here is the cardboard mock up show the gap between the two which will be sealed by the foam,



You can see the circles where the inlet an outlet will be,
I have also moved the whole lot forward by approx 40mm and will go from a 50mm intercooler core to a 65mm core,

By lowering a new cooler the same size as the radiator it creates a big gap above it


This should allow me to make a smaller version of this type set up


The new cooler being a bit wider will also fill the bumper mouth better as shown


I actually made the mock up too short so the real thing will be lower and sit level with the splitter so there is no gap underneath for air to flow under it, then il make ducting for top bottom and sides so it all has to go through the cooler and in turn the radiator

Moving it all forward by 40mm also gives me a bit more room to mount the heat exchanger somewhere around here



Just waiting for a call back from pro alloy for a price on the intercooler

DanCossie

iTrader: (1)

Stunning attention to detail Mark!!!

RichieST

iTrader: (2)

Outstanding work as usual, reading the whole topic really makes me a retard like me understand what does what.

Just don't do a fudgey and prang it on it's first outing

M K

iTrader: (9)

RichieST -don't bloody jinx me mate