markobcars

BIG THANKS to everyone supporting this project!! I'm glad You like it!!

I really don't know what to say about the fuel tank donation... It would be a great help to just find one and send it to me,I'll pay for everything in advance if needed!!

I will need some help in buying a lot of small plastic/rubber bits and fittings for the body because we don't have this detailed parts here in Croatia and that would be a great contribution from anyone who wants to help me finish this dream project...

Regards

Marko

markobcars

Update for today...

While I am waiting for the parts from water jet cutting I made threaded inserts for gearbox mounting and welded them on the chassis. I also reinforced the mount points with a beam that disperses the load on a grater surface area...

Gearbox mount will be slotted so correct gearbox and engine position can be adjusted.

luke89

iTrader: (1)

great project and done really well bud , hats off to you !

karl mcghee

one work quality workmanship a lot of thought going into this time and patience

Glenn_

iTrader: (1)

Good progress.

markobcars

Thanks guys!!

Today I started TIG welding the front subframe but It is not finished yet...


















Steering rack is lifted 10mm to make room for rack gaiters.

pugford55

Excellent work mate, very impressed..

studabear

Big respect for this build, really enjoyed having a read through the thread.

whizzisat114

iTrader: (2)

Have you worked out what front hubs your using yet?
sorry if youve already mentioned it.

Have you tried the gearbox in and checked for ground clearence as it look like its going to be close to the flooe with how low the mount is.

markobcars

Thanks everyone!!

markobcars

Front hubs are going to be the Mondeo ones switched from left to right with adapters for rod ends that will be adjustable/exchangeable to improve Ackerman geometry...

The standard gearbox mount used here is just a base point for a new mount... It is too low,You are correct and I'll make a new one or modify this one...

Front subframe is positioned in line with the lowest floor beams and the gearbox mount will follow that plane/line...

whizzisat114

iTrader: (2)

What steering rack are you using?
Raising the steering rack will affect your bump steer wont it?

markobcars

Steering rack is a Sierra rack with shortened Mondeo tie rods!

Mondeo steering arms on hubs are positioned much higher than sierra steering arms so I have to raise the rack and lower a tie rod mounting point on the Mondeo steering arms with aforementioned adapters.With this mod I'll get the tie rods in line with the steering rack so bump steer is minimal!

It will be a street driven car but suspension travel will be much smaller than standard mondeo suspension and that will also improve bump steer...

The Sierra rack is wider than Mondeo one so I shortened the tie rods and that is not a good thing for bump steer but on a short suspension travel it will work fine.

markobcars

Also when looking deeper into the bump steer/roll steer geometry design the Sierra rack is in fact more suitable for neutral bump steer geometry because tie rod length is closer to lower A arm length(from pivot point to ball joint) than Mondeo standard length tie rods.
That means for any suspension travel both A-arm and tie rod will make the same radius circle and toe in/out will be unchanged.

whizzisat114

iTrader: (2)

Good work and I look forward to seeing your progress
David

markobcars

Thanks!! I can't wait to get it on the road...

rwd_fiesta

Fantastic project. Very original. Your attention to detail is great.
I do have one point to make. You say you are reversing the Mondeo struts. Be careful as I believe this will adversely affect the ackermann effect because the steering arms will be angled in the wrong direction for a steering rack ahead of the front axle line. Your easiest solution maybe to simply use Sierra struts. Best of luck.

markobcars

Thanks!!

I am aware of the ackerman change with reversed Mondeo hubs and I'll correct the geometry with the adapters to get the first setup to "true" ackerman and than I'll work from there...

I'll try the Sierra hubs but I think that they are not suitable for Mondeo geometry,they induce too much negative camber when used with standard top and bottom mount points.

markobcars

I made this ackerman/angle correction adapters for drift E36 race car...

Something similar will be made for the Mondeo...



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rwd_fiesta

You are obviously on the case so I'll keep quiet. Just out of interest, if you need to pursue the Sierra route, you can use the 4x4 hubs with the
Bilstein 1.5 neg camber strut casings turned through 180 degrees to give positive camber. This could help you if you get stuck.

markobcars

Don't get me wrong! I am opened to advices but there is so much to think about and I am not in the workshop so it is difficult to know what might work... And there are so many options... I'll check again the Sierra hubs but iirc they don't fit straight in... Thank You for the info!!

markobcars

Front subframe is 99% welded and I removed all excess metal from old steering rack mount/bridge.

The subframes are fitted and also the engine,differential and gearbox so I can reconstruct the gearbox tunnel,prop shaft bearing mount and adjust engine and differential angles.

Prop shaft will need to be lengthened 110mm.



I will make a completely new gearbox mount...







Possible sway bar position...

Glenn_

iTrader: (1)

Cool progress mate.Top work.

dojj

iTrader: (3)

get a prop from a granada as the front bit is longer and that way you can shorten it rather than lengthen the sierra one

markobcars

I was looking for a granada prop shaft for 3 days on local scrapyards but those cars are hard to find these days so today I made a new prop shaft with seamless tubing.

I have to say that Ford original prop shafts are not that good... They are made from thin seamed tubing and they have a run out of aprox 2mm from end to end... I tested 2 prop shafts...

Mine has a run out of 0.05mm!! I welded it with TIG on a lathe so it didn't pull anywhere when welding...

Mk4 Rick

That's pure skillage

markobcars

Thanks

dojj

iTrader: (3)

and you are obviously going to have it balanced yes

not that you won't, but just making sure you will, because theres nothing else that says "can i have some new ankles please" than a broken prop

markobcars

Yes I'll get it balanced after I fill it with polyurethane foam for noise reduction... I have to send it 270km away in another town for balancing!!

I've shit my pants once my prop shaft broke!! luckily it was at 60km/h... It left 30mm deep scratch marks in the pavement before it broke away completely!!

den_band

Hi Marko,

nice project and professional build!

I have a Mondeo Cosworth RWD as well, and use it for Rallycross trackdays.
It's a Mondeo body on a Sierra floor, so entire Cosworth suspension fits rather easy.

Since the rear wheels had to much camber, I made camber and toe adjustable at the rear axle (front side made fully adjustable as well).
Together with the shell, I have the moulds to produce fibreglass bodypanels. They come from the MKII successor of the Karcher Mondeo MkI which was posted earlier in this topic by Mondi-DZK.

Some pics:
https://skydrive.live.com/redir?resi...=folder%2c.JPG

Success with your project!

pugford55

Sorry to butt in.. Will these f/glass panels fit a Mondeo Eurocar mk2 as the shp kits
Thanks

den_band

@pugford55: I'm not sure. My panels fit the standard Mondeo MkII shell. Only front and rear wheelarches are wider...

markobcars

Hi!! Thank You!! I like your project very much!! I wish I could build a race car... My nearest race track is 300+ km away so building one is out of the question...

I'll have to make the rear beam fully adjustable if I get into camber/toe problems...

Please send me a PM if you can produce the fiberglass panels or you are interested in selling the moulds!!

Cheers!

markobcars

I wasn't happy with how the welds came out on the prop shaft... also when I positioned the prop shaft bearing it could be some 15mm longer so I made another one...



Pulse TIG welded to control heat input.

fury556

Awesome build!

And that's some serious welding porn!

mentalasanything

I think you need re-testing

Seriously enjoyed reading the thread and that fab work is amazing.

I am intrigued by the fact you've made your own ECU. It's something I've often pondered with the cheap PIC's you can buy these days. Look forward to seeing that.

Keep up the good work!

Lee

markobcars

Thanks everybody!!

I have a BIG problem finding the plugs for silvertop/blacktop zetec TURBO engines!!

I would like to have a heat grade 6 or grade 7 NGK plugs like PLTR6A-10G but these are hard to get here in Croatia...

Does anyone have some suggestion on the plug selection from manufacturers other than NGK??

fury556

I'm not sure what they used, but can you get standard Focus RS plugs? I assume they were Motocraft made or something! If not, I guess V*uxhall turbo plugs should do as well?

clairendave

I had the plug seat modified in my head to run different plugs. i seem to remember they were escort cosworth, but it was too long ago to be sure.

Mk4 Rick

You can use focus rs plugs there is also a thread some where a zetec spark plug holes were modified to take cossy plugs