PassionFord - Ford Focus, Escort & RS Forum Discussion
Paul V and a few others have offered tips on welding, generally this was "add more heat"
Paul V and a few others have offered tips on welding, generally this was "add more heat"
0 2022/06/04 08:13:25
These 2 show the hotter welds.
These 2 show the hotter welds.
0 2022/06/04 08:13:32
Trolley on wheels.
Trolley on wheels.
0 2022/06/04 08:13:38
This is the 1 inch oppliger spacer. It occurs to me that I can lop this corner off…may as well save the weight.
This is the 1 inch oppliger spacer. It occurs to me that I can lop this corner off…may as well save the weight.
0 2022/06/04 08:19:43
The spacer hits the tunnel even with 25mm to go up on the gearbox mount.i had to cut the tunnel out. I will be able to shave a few mm off the spacer and then make a very low profile box to seal up the tunnel. I need to buy a new slave cylinder as my one with dry break hydraulics went walkies.
The spacer hits the tunnel even with 25mm to go up on the gearbox mount.i had to cut the tunnel out. I will be able to shave a few mm off the spacer and then make a very low profile box to seal up the tunnel. I need to buy a new slave cylinder as my one with dry break hydraulics went walkies.
0 2022/06/04 08:19:51
Transfer box also hit the back of that tunnel piece….Mr plasma was out again.
Transfer box also hit the back of that tunnel piece….Mr plasma was out again.
0 2022/06/04 08:19:57
The gear selector cradle hits the tunnel before the gearbox goes all the way up on the mount.
The gear selector cradle hits the tunnel before the gearbox goes all the way up on the mount.
0 2022/06/04 08:20:02
Bolts on the transfer case hit the tunnel, still 25mm to go up yet on the mount.
Bolts on the transfer case hit the tunnel, still 25mm to go up yet on the mount.
0 2022/06/04 08:20:07
0 2022/06/04 08:20:14
I roughly cut the tunnel to allow the selector to come up through the tunnel.
I roughly cut the tunnel to allow the selector to come up through the tunnel.
0 2022/06/04 08:20:20
You can see the selector cradle hard against the tunnel. I will shave off lots of the cradle to allow more room….obviously there will be some engine and box movement.
You can see the selector cradle hard against the tunnel. I will shave off lots of the cradle to allow more room….obviously there will be some engine and box movement.
0 2022/06/04 08:20:25
0 2022/06/04 08:20:30
0 2022/06/04 08:20:35
Spacer hard against the tunnel.
Spacer hard against the tunnel.
0 2022/06/04 08:20:41
0 2022/06/05 02:50:42
I also used metal squares to check.
I also used metal squares to check.
0 2022/06/05 02:50:50
Drivers side
Drivers side
0 2022/06/05 03:14:34
Passenger side
Passenger side
0 2022/06/05 03:14:42
I have cut off the rear section and welded a captive nut on to the plate I have cut out, now I can bolt through and work back to the true centre 4mm forward. Then I will tack that in place and cut off the front which needs to be 62mm in front of the rear plate. This then makes it bang on opposite the other side. I was looking down at the gearbox tunnel wondering why the gear selector was so far off to the passenger side…4mm at the front equates to a massive deviation that far back.
I have cut off the rear section and welded a captive nut on to the plate I have cut out, now I can bolt through and work back to the true centre 4mm forward. Then I will tack that in place and cut off the front which needs to be 62mm in front of the rear plate. This then makes it bang on opposite the other side. I was looking down at the gearbox tunnel wondering why the gear selector was so far off to the passenger side…4mm at the front equates to a massive deviation that far back.
0 2022/06/05 07:46:38
There are 4 of these highlighted plates, the front one on the passenger side is 4mm shorter than the one on the drivers side, it seems they may have measured from the back of the shorter one as the measurement is exactly the same as the error.
There are 4 of these highlighted plates, the front one on the passenger side is 4mm shorter than the one on the drivers side, it seems they may have measured from the back of the shorter one as the measurement is exactly the same as the error.
0 2022/06/05 08:03:11
Stitch welded the tunnel so now I can add a thin bead of seam sealer
Stitch welded the tunnel so now I can add a thin bead of seam sealer
0 2022/06/17 05:33:50
Had to add a small extension to the transfer tunnel but not a huge amount. The other side needed more mods.
Had to add a small extension to the transfer tunnel but not a huge amount. The other side needed more mods.
0 2022/06/17 05:33:56
0 2022/06/19 09:20:09
Front crossmember on their jig.
Front crossmember on their jig.
0 2022/06/19 09:20:11
Drivers side compression mount about 5mm from the spirit level that I clamped square on the cross member.
Drivers side compression mount about 5mm from the spirit level that I clamped square on the cross member.
0 2022/06/19 09:20:58
Passenger side is 17 mm from the spirit level clamped to the cross member.
Passenger side is 17 mm from the spirit level clamped to the cross member.
0 2022/06/19 09:21:05
Spirit level clamped to the cross member.
Spirit level clamped to the cross member.
0 2022/06/19 09:25:29
Ghetto jig. The masking tape is used to mark the precise position of where the comp strut mount goes. I have wound the comp strut all the way home and the track control arm is hard against the stop on the cross member so this is the furthest back it can ever be. I have locked off the comp strut so it is fixed length that I can match on the other side.
Ghetto jig. The masking tape is used to mark the precise position of where the comp strut mount goes. I have wound the comp strut all the way home and the track control arm is hard against the stop on the cross member so this is the furthest back it can ever be. I have locked off the comp strut so it is fixed length that I can match on the other side.
0 2022/06/19 09:25:36
Final position marked
Final position marked
0 2022/06/19 09:25:42
Tacked the drivers side in place. I will now measure EVERYTHING so I have multiple datum’s and will probably get a big set square and laser then mark across to fit the other side with the exact same compression strut length.
Tacked the drivers side in place. I will now measure EVERYTHING so I have multiple datum’s and will probably get a big set square and laser then mark across to fit the other side with the exact same compression strut length.
0 2022/06/19 09:25:48
The mount also has bolt holes to bolt it to the chassis, I can plug weld through those too.
The mount also has bolt holes to bolt it to the chassis, I can plug weld through those too.
0 2022/06/19 10:00:32
0 2022/06/24 08:00:57
Tonight’s reading
Tonight’s reading
0 2022/07/01 09:09:27
Manual rack, no rubber and hole seems a few nths more than 12mm (m12 rattles in the hole)
Manual rack, no rubber and hole seems a few nths more than 12mm (m12 rattles in the hole)
0 2022/07/02 03:00:36
Power rack has rubber bush and sleeve.
Power rack has rubber bush and sleeve.
0 2022/07/02 03:00:44
Top
Top
0 2022/07/02 03:04:18
Underneath (seems slightly tighter)
Underneath (seems slightly tighter)
0 2022/07/02 03:04:25
Been welding up the floor
Been welding up the floor
0 2022/07/02 10:48:57
Lots of rust treatments next.
Lots of rust treatments next.
0 2022/07/02 10:49:04
Looks the same.
Looks the same.
0 2022/07/02 12:52:12