Mk6 JWRC fiesta cosworth
#3923
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Finally got my speedo working on my race tech dash today after a proper head banging few days and turned out to need a 3k resistor between 5v and signal as the life racing speed sensor only show 0.22 - 0.74 volts high low swing,
Simple fix for most but taken me 3 days as electrics and all that is beyond me, but learning a lot as I go with this project lol
Simple fix for most but taken me 3 days as electrics and all that is beyond me, but learning a lot as I go with this project lol
#3927
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Bet your buzzin good luck mate
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#3928
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Will be good to see what power it makes.
#3929
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It was only a bit of road mapping today but came to an abrupt stop when it popped a driveshaft luckily at low speed so no damage done,
Also the gearbox is not happy at all and that was before we started, needs a rebuild so today was a test day for an hour but has highlighted already the shaft and boc issues that need sorting before we go back
Don't want to do any cutting just yet for the skyline box so going to rebuild the mt75 to standard and map the car to 1bar with that for now
Also the gearbox is not happy at all and that was before we started, needs a rebuild so today was a test day for an hour but has highlighted already the shaft and boc issues that need sorting before we go back
Don't want to do any cutting just yet for the skyline box so going to rebuild the mt75 to standard and map the car to 1bar with that for now
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zetaboostboy522bhp (10-06-2015)
#3930
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I know how it feels....headaches. Just need to keep lugging on knowing it will be worth it in the end
#3931
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Just teething trouble to be expected
#3932
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It was only a bit of road mapping today but came to an abrupt stop when it popped a driveshaft luckily at low speed so no damage done,
Also the gearbox is not happy at all and that was before we started, needs a rebuild so today was a test day for an hour but has highlighted already the shaft and boc issues that need sorting before we go back
Don't want to do any cutting just yet for the skyline box so going to rebuild the mt75 to standard and map the car to 1bar with that for now
Also the gearbox is not happy at all and that was before we started, needs a rebuild so today was a test day for an hour but has highlighted already the shaft and boc issues that need sorting before we go back
Don't want to do any cutting just yet for the skyline box so going to rebuild the mt75 to standard and map the car to 1bar with that for now
Hope you sort it soon mate
Cheers Paul
#3937
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Well before I order up extended shafts on Monday I am going to check plunge etc
But before that I picked up a working standard mt75 gearbox just to throw in the car and get me going for now, it has a small piece of the case missing where a front prop has hit it at some point and broke it off but for what I want it's not worth the time repairing it so I'm going seal up the hole to stop dirt getting in and get it back in the car tomorrow,
Box out
![Name: 548A61B5-308B-4134-A4BD-6D26D3082169_zps12n1zd5v.jpg
Views: 385
Size: 354.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32870d1501291495-mk6-jwrc-fiesta-cosworth-548a61b5-308b-4134-a4bd-6d26d3082169_zps12n1zd5v.jpg)
Secondhand box with broken case that's going in for a couple of weeks
![Name: CDFF4081-F1CB-425B-91BA-F022E5ABC4BB_zpsktdsru4b.jpg
Views: 381
Size: 161.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32871d1501291495-mk6-jwrc-fiesta-cosworth-cdff4081-f1cb-425b-91ba-f022e5abc4bb_zpsktdsru4b.jpg)
Also today the reason why I'm not going to spend time or decent money on another mt75 box is because I picked up the rest of an r32 box to test fit in the car,
After seeing it all in 1 piece I wrote the idea off due to size but while my box was out I offered it up under the fiesta and of course I need to enlarge the transfer case part of the tunnel but it doesn't actually look too bad to fit,
Both cases are going to MK next week to weld up then I can get them back and get a box built up
Anyway a rough test fit
![Name: 187BD0DC-9D30-4A23-B4C6-432DE379C394_zpsjwpqpjot.jpg
Views: 366
Size: 554.2 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32872d1501291495-mk6-jwrc-fiesta-cosworth-187bd0dc-9d30-4a23-b4c6-432de379c394_zpsjwpqpjot.jpg)
![Name: 46472D07-63B4-4318-8786-699B4BFEA763_zpsw98lxuzn.jpg
Views: 415
Size: 376.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32873d1501291495-mk6-jwrc-fiesta-cosworth-46472d07-63b4-4318-8786-699b4bfea763_zpsw98lxuzn.jpg)
Where the transfer case fouls as expected
![Name: FF2A64C7-2225-493E-AE73-8885ADEF36EE_zpsy0zphu4i.jpg
Views: 366
Size: 312.0 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32874d1501291495-mk6-jwrc-fiesta-cosworth-ff2a64c7-2225-493e-ae73-8885adef36ee_zpsy0zphu4i.jpg)
Once I have the front bellhousing modded by MK and back I can then accurately mark up and cut out what's needed to get it in there
Here is the difference between a standard skyline bellhousing on the left and the modified cosworth conversion 1 on the right, the modded 1 is approx 10mm taller due to the skyline input shaft being longer
![Name: 37E64650-C2A4-40A5-A000-92805F933890_zps6wta0mli.jpg
Views: 380
Size: 208.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32875d1501291495-mk6-jwrc-fiesta-cosworth-37e64650-c2a4-40a5-a000-92805f933890_zps6wta0mli.jpg)
But before that I picked up a working standard mt75 gearbox just to throw in the car and get me going for now, it has a small piece of the case missing where a front prop has hit it at some point and broke it off but for what I want it's not worth the time repairing it so I'm going seal up the hole to stop dirt getting in and get it back in the car tomorrow,
Box out
![Name: 548A61B5-308B-4134-A4BD-6D26D3082169_zps12n1zd5v.jpg
Views: 385
Size: 354.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32870d1501291495-mk6-jwrc-fiesta-cosworth-548a61b5-308b-4134-a4bd-6d26d3082169_zps12n1zd5v.jpg)
Secondhand box with broken case that's going in for a couple of weeks
![Name: CDFF4081-F1CB-425B-91BA-F022E5ABC4BB_zpsktdsru4b.jpg
Views: 381
Size: 161.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32871d1501291495-mk6-jwrc-fiesta-cosworth-cdff4081-f1cb-425b-91ba-f022e5abc4bb_zpsktdsru4b.jpg)
Also today the reason why I'm not going to spend time or decent money on another mt75 box is because I picked up the rest of an r32 box to test fit in the car,
After seeing it all in 1 piece I wrote the idea off due to size but while my box was out I offered it up under the fiesta and of course I need to enlarge the transfer case part of the tunnel but it doesn't actually look too bad to fit,
Both cases are going to MK next week to weld up then I can get them back and get a box built up
Anyway a rough test fit
![Name: 187BD0DC-9D30-4A23-B4C6-432DE379C394_zpsjwpqpjot.jpg
Views: 366
Size: 554.2 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32872d1501291495-mk6-jwrc-fiesta-cosworth-187bd0dc-9d30-4a23-b4c6-432de379c394_zpsjwpqpjot.jpg)
![Name: 46472D07-63B4-4318-8786-699B4BFEA763_zpsw98lxuzn.jpg
Views: 415
Size: 376.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32873d1501291495-mk6-jwrc-fiesta-cosworth-46472d07-63b4-4318-8786-699b4bfea763_zpsw98lxuzn.jpg)
Where the transfer case fouls as expected
![Name: FF2A64C7-2225-493E-AE73-8885ADEF36EE_zpsy0zphu4i.jpg
Views: 366
Size: 312.0 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32874d1501291495-mk6-jwrc-fiesta-cosworth-ff2a64c7-2225-493e-ae73-8885adef36ee_zpsy0zphu4i.jpg)
Once I have the front bellhousing modded by MK and back I can then accurately mark up and cut out what's needed to get it in there
Here is the difference between a standard skyline bellhousing on the left and the modified cosworth conversion 1 on the right, the modded 1 is approx 10mm taller due to the skyline input shaft being longer
![Name: 37E64650-C2A4-40A5-A000-92805F933890_zps6wta0mli.jpg
Views: 380
Size: 208.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32875d1501291495-mk6-jwrc-fiesta-cosworth-37e64650-c2a4-40a5-a000-92805f933890_zps6wta0mli.jpg)
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Last edited by M K; 12-06-2015 at 07:53 PM.
#3938
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It's the best mod you will ever do to your car putting the skyline box in i love my setup in my focos the only problem is i keep driving it in 2wd as it's so much fun lol but in 4x4 you can not beet it I just have to watch how much 4x4 i us as if i lock it 50/50 and turn the car very slow I can dip the clutch and the car will stop as the front and rear wheel are fighting each uver . I will one day get the black box that Toby has got for his 205 pug cossy it controls the gearbox by a geo sensor so when you boot it it puts it's into 4x4 and as you rolling it backs the 4x4 off and into 2wd and so on a very nice bit of kit . Any help just drop me a line and i will help you ware I can
Last edited by COLEYST200; 13-06-2015 at 06:26 AM.
#3939
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Yes, I think the ETS pro is going to be a good controller, a lot of the skyline track day boys and racers upgrade the old r32 and r33 cars from factory to the new box of tricks and report faster lap times....the instructions say that on Manual with the control know all the way round it will stall the engine at low speeds by looking up the diff so tight.
It has yaw sensor and g sensor to control the auto map plus hand brake and brake de lock if you want it, I have put mine on a switch so I can just bung it in to 2wd if I want.
http://www.full-race.com/store/r14-a...ne-gt-r-1.html
It has yaw sensor and g sensor to control the auto map plus hand brake and brake de lock if you want it, I have put mine on a switch so I can just bung it in to 2wd if I want.
http://www.full-race.com/store/r14-a...ne-gt-r-1.html
#3941
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could you not fab up a nice box to put the original Atessa pump and reservoir in side, i am sure you could do it, your work on this car so far is second to none.
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#3943
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Based on the high pressure at up to 500psi I think you need the attesa. It isn't huge, I mounted mine under the car on anti vibration mounts.
#3949
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#3950
I've found that life I needed.. It's HERE!!
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Not very noisey, mine just hums and vibrates a bit. Nothing like the electric accumulator on the abs or like a fuel pump.
Mine is the R32 pump too.
Mine is the R32 pump too.
Last edited by Caddyshack; 16-06-2015 at 08:47 PM.
#3953
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As mentioned before I had a front driveshaft pop out when mapping which called a stop to the day straight away, well once home and looked at the problem was far worse than I thought and we were lucky to get away with no damage
Here is how the shafts were when I removed the boots
Full droop
![Name: A8AE0979-A65C-459B-8E7A-8B83E770586E_zpsr22pzd66.jpg
Views: 369
Size: 505.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32573d1501290791-mk6-jwrc-fiesta-cosworth-a8ae0979-a65c-459b-8e7a-8b83e770586e_zpsr22pzd66.jpg)
Full compression
![Name: 1C5A7657-27EE-49A9-B8C4-BDDE3BC5E9FC_zpsn7lpkurz.jpg
Views: 360
Size: 341.9 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32574d1501290791-mk6-jwrc-fiesta-cosworth-1c5a7657-27ee-49a9-b8c4-bdde3bc5e9fc_zpsn7lpkurz.jpg)
Now before anyone sees that and think it's from poor workmanship let me just state.....
This error was in no way the fault of Andrew Gallacher and the guys at AG Motorsport nor was it the fault of the guys at MDV Specialist Engineering
Andrew set everything including driveshaft plunge spot on to suit my 4x4 standard hubs ect that I supplied when he built the shell for me and MDV's guys set up all suspension and obviously can't see under driveshaft boots and rightly assumed the would be one of the first things you check when building a car like this which Andrew did so they are not to blame
The problem lies with me changing mid build from the standard suspension set up to the wide track wrc set up and not realising the consequences with the driveshafts so I only have myself to blame and luckily no harm done other than lost time and 1 knackered tripoid joint
Anyway onto sorting the problem
I can not afford full custom machined 300m shafts right now so the next best thing and perfectly acceptable thing is to get 4 new shafts cut them all to set sizes so I can make 2 new shafts that only need to be joined in 1 place
So today's mock up shaft kit
![Name: EC18F555-7BBD-4A00-8A63-6FDB03B7364D_zpsiu3ybykf.jpg
Views: 349
Size: 689.1 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32575d1501290791-mk6-jwrc-fiesta-cosworth-ec18f555-7bbd-4a00-8a63-6fdb03b7364d_zpsiu3ybykf.jpg)
Secure 2 halfs of shafts to the L section and slide to desired length, mark up and tac weld and send away for new shafts to be welded to this length
So all marked up
![Name: 6B3D0201-9EE5-4505-B2BB-FEC7C747B73B_zpskovfwfri.jpg
Views: 400
Size: 203.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32576d1501290791-mk6-jwrc-fiesta-cosworth-6b3d0201-9ee5-4505-b2bb-fec7c747b73b_zpskovfwfri.jpg)
A few marks to remember what's were if I need to undo on the bench after
![Name: 859A2EA6-4961-4150-9BC3-A1BDCBD8CD6E_zpsq0ckhbk7.jpg
Views: 366
Size: 291.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32577d1501290791-mk6-jwrc-fiesta-cosworth-859a2ea6-4961-4150-9bc3-a1bdcbd8cd6e_zpsq0ckhbk7.jpg)
Bare in mind this blanks shaft is already 20mm longer than what I had in there that popped out and I've separated it 28mm so the new ones once welded need to be 48mm longer than what I had in there!
But at the new length under full droop
![Name: 2C48A234-D20B-4EF9-83B6-779459675220_zps4bgqov5i.jpg
Views: 365
Size: 231.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32578d1501290791-mk6-jwrc-fiesta-cosworth-2c48a234-d20b-4ef9-83b6-779459675220_zps4bgqov5i.jpg)
Nice engagement in the cup
And full compression
![Name: 2FCC51DB-5FC7-4D7E-90BD-E4B7AD363B0D_zps4gmvl1w3.jpg
Views: 364
Size: 238.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32579d1501290791-mk6-jwrc-fiesta-cosworth-2fcc51db-5fc7-4d7e-90bd-e4b7ad363b0d_zps4gmvl1w3.jpg)
No chance of them popping out ever again,
That will be sent off to CPS Drivelink to be friction welded and I should have them back in about a week
Here is how the shafts were when I removed the boots
Full droop
![Name: A8AE0979-A65C-459B-8E7A-8B83E770586E_zpsr22pzd66.jpg
Views: 369
Size: 505.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32573d1501290791-mk6-jwrc-fiesta-cosworth-a8ae0979-a65c-459b-8e7a-8b83e770586e_zpsr22pzd66.jpg)
Full compression
![Name: 1C5A7657-27EE-49A9-B8C4-BDDE3BC5E9FC_zpsn7lpkurz.jpg
Views: 360
Size: 341.9 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32574d1501290791-mk6-jwrc-fiesta-cosworth-1c5a7657-27ee-49a9-b8c4-bdde3bc5e9fc_zpsn7lpkurz.jpg)
Now before anyone sees that and think it's from poor workmanship let me just state.....
This error was in no way the fault of Andrew Gallacher and the guys at AG Motorsport nor was it the fault of the guys at MDV Specialist Engineering
Andrew set everything including driveshaft plunge spot on to suit my 4x4 standard hubs ect that I supplied when he built the shell for me and MDV's guys set up all suspension and obviously can't see under driveshaft boots and rightly assumed the would be one of the first things you check when building a car like this which Andrew did so they are not to blame
The problem lies with me changing mid build from the standard suspension set up to the wide track wrc set up and not realising the consequences with the driveshafts so I only have myself to blame and luckily no harm done other than lost time and 1 knackered tripoid joint
Anyway onto sorting the problem
I can not afford full custom machined 300m shafts right now so the next best thing and perfectly acceptable thing is to get 4 new shafts cut them all to set sizes so I can make 2 new shafts that only need to be joined in 1 place
So today's mock up shaft kit
![Name: EC18F555-7BBD-4A00-8A63-6FDB03B7364D_zpsiu3ybykf.jpg
Views: 349
Size: 689.1 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32575d1501290791-mk6-jwrc-fiesta-cosworth-ec18f555-7bbd-4a00-8a63-6fdb03b7364d_zpsiu3ybykf.jpg)
Secure 2 halfs of shafts to the L section and slide to desired length, mark up and tac weld and send away for new shafts to be welded to this length
So all marked up
![Name: 6B3D0201-9EE5-4505-B2BB-FEC7C747B73B_zpskovfwfri.jpg
Views: 400
Size: 203.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32576d1501290791-mk6-jwrc-fiesta-cosworth-6b3d0201-9ee5-4505-b2bb-fec7c747b73b_zpskovfwfri.jpg)
A few marks to remember what's were if I need to undo on the bench after
![Name: 859A2EA6-4961-4150-9BC3-A1BDCBD8CD6E_zpsq0ckhbk7.jpg
Views: 366
Size: 291.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32577d1501290791-mk6-jwrc-fiesta-cosworth-859a2ea6-4961-4150-9bc3-a1bdcbd8cd6e_zpsq0ckhbk7.jpg)
Bare in mind this blanks shaft is already 20mm longer than what I had in there that popped out and I've separated it 28mm so the new ones once welded need to be 48mm longer than what I had in there!
But at the new length under full droop
![Name: 2C48A234-D20B-4EF9-83B6-779459675220_zps4bgqov5i.jpg
Views: 365
Size: 231.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32578d1501290791-mk6-jwrc-fiesta-cosworth-2c48a234-d20b-4ef9-83b6-779459675220_zps4bgqov5i.jpg)
Nice engagement in the cup
And full compression
![Name: 2FCC51DB-5FC7-4D7E-90BD-E4B7AD363B0D_zps4gmvl1w3.jpg
Views: 364
Size: 238.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/32579d1501290791-mk6-jwrc-fiesta-cosworth-2fcc51db-5fc7-4d7e-90bd-e4b7ad363b0d_zps4gmvl1w3.jpg)
No chance of them popping out ever again,
That will be sent off to CPS Drivelink to be friction welded and I should have them back in about a week
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#3954
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I would add 2 jubilee clips each side or they will spin on full boost lol
No wonder they popped before. Nice job fixing it though, as always
No wonder they popped before. Nice job fixing it though, as always
#3957
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