Did you get my PM Will?

 

Yes mate - will reply when i've heard back

 

Leg!

 

Cor not another one lol

 

That looks awsome fella

 

Like it!

 

It looks well Will.

 

Its looking very nice i must say

 

awesome project mate

 

cant really go wrong if this chap is involved

 

Well, done a little more yesterday and today with the help of my good mate Al (spudmurphy on here).

We started to have a look at how the cooling systems were going to go together and ideally move the radiator as far forward as possible to give us more space to play with.

So, up first was the Airtec intercooler! Bearing in mind this is meant for a Mk1 Focus RS, it was never going to be a direct fit...


Major problem was hitting the back of the fog light area (even after a lot of cutting back)


However, we got it pretty close and hopefully my fabricator Russ can modify the pipework on the cooler to clear the rest!

Then it was on to the oil cooler and power steering cooler. I'd had an idea in my mind for this for a while... So, spot the difference:


And:


Lock mechanism cut out

Which meant that once a bracket had been made up for the coolers, this could happen:


I took delivery of a set of Morette headlights earlier in the week so chucked them in for this next picture...


Before stripping them to make a start on wrapping the shells. So far, its not been an easy job and i've had to rip it off and start again twice


Hopefully will get them done tomorrow...

Oh, and got my carbon doorcards remounted with some edging strip and a seal between the polycarb window and the top of the door



More as it happens

 

Hi will great looking project, I had Matt over on Thursday and pull up this thread.

We run the same ecu on mini cooper s and love it. Very user friendly.

I have a EC1 going on my cossie too.

 

You have been busy.

 

Looking really good Will, can't wait for it to be finished.

 

I'm looking forward to seeing what the ECU can do! Matt's been great to deal with so far, i'm booked in with him in early April to configure the drive by wire throttle and hopefully commission the ECU installation before a fire up!

Doesn't seem that long away now...

I'm trying to keep the progress rolling on without you love... Wanna come and help me wrap these headlight shells?

Cheers! Will try and have a run down to one of the meets once its done

 

That'd be good

 

Tidy spot for the oil cooler, same place as mine. Bags of air

 

Really taking shape... Can't wait to see it in action

 

Send them down & i'll have a go mate.

 

Well, after 3 attempts, I gave up trying to wrap the light shells

I could get the vinyl to stretch to shape but by the time i'd got all the way inside the light apertures, there wasn't enough adhesive to make it stick.

So today I thought i'd try painting them!

Scotched and primered (take note painters in the north east called Jacko! )


Painted


Checked for colour match:


Built up:


Fitted:


Chucked the seats in:


Hopefully going to get the fire extinguishers and brake stuff mounted and plumbed over the next few days

 

Looking good mate...

Might be worth spraying the bumpers if the colour match is that good.

 

PMSL @ the painting comments

The colour match is perfect

 

Decided to take full advantage of the facilities at uni today and took everything in to flow test and measure etc.

Started out by measuring everything on my cylinder head from throat diameters, valve sizes etc. through to cc'ing the inlet port on my new spec head.

Inlet port


Exhaust port (ignore the gunk on the edges - just where the grease and parafin reacted with each other!)


cc'ing the inlet port:




Then it was on to flow testing the inlet and exhaust ports through 1mm valve lift increments:



I fitted up part of the Jenvey inlet so that there was a bell mouth for the port to breathe through:





Then it was on to cc'ing the cylinder head combustion chambers:


And the piston crown:


Then once the compression ratio had been confirmed, it was time to check valve clearances at full lift etc.

Plastecine on the piston crown:


Lift at TDC simulated:


Sectioned to measure clearance:


Compression ratio has worked out slightly lower than expected - not by a lot, it's still very much a high comp motor, but I might be able to get a bit more boost in it after all

Flow test results were very good, shifting well over 300CFM at full lift and with good flow properties at low valve lift too.

Hoping to get some more work done on the new front end cradle tonight too!

 

Looks like Uni has some pretty nifty kit there eh Will.

 

Top work fella... Coming together nicely

 

How many inches of water to get 300cfm?

What lift?

 

your not hangin round with this are ya mate lol

 

brilliant thread!!! keep up the good work!!

 

looking good mate

 

hello again will.

more questions im affraid mate.lol.you know the cage picks up on the front struts..is that going to obstruct the wiper mechanism atal???only on the left side.

cheers,luke.

 

Is it done yet?

 

Yeah. Its the result of years of getting all the bits of the jigsaw together, now its time to put it all together!

From memory the test was performed at 50" test pressure. I've got a datapack to go through tomorrow with port velocity readings, swirl, tumble etc. to sit and sift through so will confirm then. 12mm lift on the inlet cam.

Can't afford to mate! Fire up is planned for early April and Time Attack first round is early May! Then the small matter of me getting my dissertation for uni done out of it by the end of May... Will give you a bell soon mate, need a quick chat with you

Cheers, I think Sticky and I did a good job between us!

Thanks!

Aye, wish i'd still got it on the ramp at yours

Hard to say mate. Mine was LHD originally being a motorsport shell so the mountings were all different on mine anyway.

No. Not quite...

Did a bit more this evening though with the assistance of Spud.

He'd managed to get some work done on the new front end cradle so we hung the intercooler:


And made a start on integrating the coolers:






Nibbling away at it slowly but surely...

 

Very interesting thread Will

 

Love it, keep up the good work, nice to see a well thought out build,

 

Hard to say mate. Mine was LHD originally being a motorsport shell so the mountings were all different on mine anyway.





And made a start on integrating the coolers:






Nibbling away at it slowly but surely... [/quote]

ahhhh i see will,thanks anyway mate.ill have to rip it apart and mock stuff up as the cage is going in.

intresting front set up youv made.im in planing stage of doing something to replace the front crash bar too.iv took insperation from the wrc set up.

 

your welcome to use it whenever you want just a bit far lol

 

Quick update - car was nearly for sale earlier this afternoon

The new Corbeau Revenge seat has distinctly wider sections to it around the shoulders and head... My rollcage has a nice 45 degree section between the roof bar and the B pillar bar as well as door bars. Fascinatingly enough, the seat hits every single part of the cage on the drivers side

So, I had to adjust the seat position to clear it, only moved a few inches forward. Initially I was really pleased as I felt I had a better position for using the gearstick, but then I tried the brakes...

Unless I chose to try and steer with my knees, there was no way I could use the brake and clutch pedals on the Tilton floor mounted pedal box. So, it looks like i'll be buying an overhung unit to allow me to run the pedals higher up!

Also, I finally caved in and bought these:


Means I can pull the car apart quicker trackside should I need to as everything will be on connectors. And they're an awful lot cheaper than the autosport ones!

Matt Lewis is on the case for the last few bits I need to build the engine up, once they land it'll be engine build and fit time!

 

Top update Will.Its getting there.

 

Did a bit more this afternoon - after yesterdays dramas with the seat, some careful adjusting, tweaking, modifying etc and this was the result!





Got the harness eyes mounted into the bosses welded into the cage:


Hydraulic handbrake mounted on rivnuts:


Fire extinguisher again mounted with high tensile bolts and rivnuts:


Spud popped up and did a little more on the front end:


More as it happens

 

quality mucka ,

will bell ya at some point for a catchy up !!!