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The guy I bought the box off gave me the original inner wing mount from the focus so we were able to cut that down and weld it into place.
Had a look at options for the torque limiter mount at the rear and we're thinking of cutting up the original cradle and fabbing up a front and rear mount to ensure its nice and secure.
Will also be addind a steady bar from one of the top bell housing bolts to the bulk head
Looking good mate,ive got the same setup in my mk3 escort. What you doing about hydro clutch,pedal etc?
Not had a close look at it yet but will bemaking up a bracket of some sort to mount the master cylinder and a connecting rod to the pedal.
Cable shifter again will be modified to mount to the floor!
Will be buying a racetech digi speedo and rev counter eventually too.
How you finding the conversion? I hooked up the cable shiter to the box a out of the car and it feels really nice, cant wait to get it in!
So far mines mounted in the car just need to fabricate a rear gearbox mount. Im going to use the focus mount then weld up a bracket to the car.
Ive welded up the old rod shifter hole and now have a focus rs gearstick and shifter cables fitted properly. Yea your right they do feel so much better( i used to have a frs so know what they felt like etc)
Ive got a wilwood slave cylinder through the bulkhead direct to the pedal,just need to do the pipe work
Nice one mate, still got the rear mount to do myself. Will be using the standard rear mount with a modified mounting bracket of some sort.
How you tackling the shafts? I'm prob gonna be getting mine sleeved and welded.
Been a while since I last updated, chassis leg is now seam sealed and painted, gear selector tower is installed and I've made a start on the rear gearbox mount. Had to modify the top mounting slightly to allow the engine to move back a bit so it is sitting square.
Chopped up my original gearbox cradle and have been building onto that with box section and strengthening up with 3mm steel.
Still plenty to do to the rear mount, will be extending it along the floor to allow another two fixings into the floor and then triangulate what I've made so far to that to add strength. I'll also be strengthening up where the dog bone mount slides into the bracket.
Will be doing something similar to the front of the gearbox which will bolt to the front cross member!
Added some more strength to the mount yesterday and have recycled the middle section of the original cradle to allow me to bolt to the floor pan. Should be able to fit 3 fixings to the floor hopefully!
Will see how it copes like this and if needed will add more bracing to the floor. Will be starting on the front mounting soon.
I got an xr2 trailing arm and cut that up to make a mounting for the front of the gearbox. Then chopped up a panhard rod and used it to brace the front and rear mounts together.
Will be welding a plate between these to strengthen it up.
Also made up a bracket for the clutch master cylinder and mounted it into position. Still to make a rod up to connect this to the clutch pedal but shouldn't be too tricky!
Got it all primed the other day then painted with hammerite yesterday and fitted it up tonight. Is a snug fit but seems pretty sturdy
Will focus on finishing the clutch master cylinder and source some pipework for this next along with modding selector bracket on gearbox. Once thats done I'll cut shafts, measure them then send them to Crazycage to be welded up!
Gearbox mount is fitted along with the clutch master cylinder.
Jobs still to do are -
Make connecting rod up from clutch pedal to master cylinder
Source and fit hydraulic clutch pipes
Measure up shafts and get them sleeved by Crazycage
The intermediate joint on the two piece shaft is extremely close to to the chassis so I'm having to re think the shafts.
I don't have room to move engine forward as the turbo/manifold is a cunt to get on as it is Plus it would be a nightmare adjusting the mountings.
Think I'm going to make up a one piece shaft for the drivers side much like the xr2 has originally. I think the rs 2000 might use this set up?? so will prob try to source one and have it sleeved.
Stripped the BC box this morning to remove the LSD.
Can now see why I lost drive in 5th
Conversion is looking good, I am in process of fitting the Mk1 FRS box into my S1 at the mo, a couple of tips for you while the engine is out, look at where your rear engine breather is fitted, because on mine it was directly underneath the rear starter when the started is fitted, didn't realise till I bolted the engine and box together, so I have had to block that up and open up the original breather on the front of the engine, You will have to extend the wiring to the starter from the alternator as well, nice exhaust manifold BTW, where did you get it from ? Keep up the good work.
Breather is fine mate already checked that but cheers for the heads up!
Still to re-route the starter wiring, should be easy tho as my battery is in boot so just have to re-route existing wiring and extend crank wire.
Just ordered a long shaft from a mk5 escort so hopefully have shafts sorted soon.
Milesy, the ex manifold is a Devil Developments one I got off ebay.
Studabear, yeah I've spoken to Sean. He moved his engine forward 9 mm and tilted the engine slightly which I don't have the room to do unless I was to make a removable slam panel somehow or change turbo/manifold setup.
Finally got the gearbox conversion completed on this.
Ended up having to take the box back out to have it rebuilt as the synchro's and a shift fork were shagged
All back together now and working tho.
Had a custom exhaust made the other day and it's off for MOT tomorrow!
Plan is to get some miles on it and iron out any issues then it's off to MSD on 20th September for mapping
I bought a racetech electronic Speedo and rev counter to match my other gauges.
Bought a MK3 escort set of clocks and fitted them into there.
Uses the original FRS Speedo sensor.
Yet to calibrate the speedo.
Yeah we have had it fully working on my mates test bed, using a pulse generator to mimic the signal from the gearbox sensor and a speedo removed from a set of clocks. It can be fully calibrated.
Plans are to mount the control box where the ecu would normally be on a RS turbo but speedo cable is too long, so Ive got one from a LHD fiesta that should be alright, if not will need to have one made.
The car passed its MOT on Friday. Took it for a drive and developed an electrical fault after 5 mins
After having a look tonight, a fuse had blown but after replacing the fuse I don't seem to be getting enough fuel pressure so it misfires and runs lean.
Going to try more fuel in it tomorrow incase my gauge is reading wrong but I suspect the fuel pump or regulator is fucked.
Never seem to have much luck with this fucking car
Was at MSD yesterday to have the car mapped. They encountered a few issues with fuel supply when adding boost so it had to be left at 8 psi.
Injectors only have 11 volts at them so loom needs looked at. Fuel pressure was dropping off which Stu thinks is a restriction somewhere in the line, possibly the swirl pot.
An elbow I've used on the air filter pipework is restrictive as it's smaller than the turbo inlet and the idle valve is jammed open all the time and not responding to adjustments.
So I've a few things to sort out
For now it's safe to drive and enjoy so I'm happy!
Great service at MSD and Stu was VERY informative
Ended up at 218bhp and similar torque at the flywheel which isn't too shabby. Goes well indeed!
very nice build mate, think the wheels really look well on it as well
shame about the few issues but it wouldnt be a build without a few of them haha, once sorted what sort of boost are you aiming to run?
Thanks man!
Was aiming for 21psi high boost and around 14-17 low boost.
Think I may revise the spec a bit before it returns alongside sorting out the issues.
Car looks really good and the builds a credit to you grant
Since you used Agra in Dundee to build the engine up for you,you must be in my neck of the woods mate. Curious what did they charge you to build it up?? Pm me if you’d prefer and I’ll be keeping my eyes peeled for it out and about
04-05-2014, 10:20 AM
Plus it would be a nightmare adjusting the mountings.
