It's Alive

August 2014

After a couple of weeks checking things over and having to contact Omex, thanks to Omex for pointing out my wiring mistake, I managed to get the ECU to communicate with the software on the laptop. This bought up a range of readings and indicated the sensors were registering.

After a couple of turns of the key to allow the fuel pump to prime and send fuel to the engine I turned the Key to the start position.

The result can be seen below.

On with the rest of the build

I'm Exhausted...mainly cos it's so hot out!!

July 14

July saw the fitting of the manifold, lambda sensor and silencer. Not much more to say really.....

The Car as it Stands

Cooling Times

June 14

I have finally managed to get around to sourcing the cooling system pipework, which has allowed me to plan how I am going to mount the radiator, after a couple of attempts of trial fitting and bracket alterations the radiator is fitted, I have also fitted and wired in the fan.....time to fill the header tank.

Oops, I have a leak, the seal around the temperature sensor for the ECU  is leaking, I managed to rescue 1 litre of coolant before removing and re-sealing the sensor. Take 2.....no leaks.   :)

Time to Pedal and Brake

View of Pedal Assembly from above

The Pedals have now all been fitted, with the clutch throttle cables fitted and secured in place, along with the push bar for the Master Cylinder.

I have fitted some anti-slip coating to the pedal faces , this should make the IVA man happy.

Pedals

I have also taken the time with the pedals in place to bleed the brakes, Thanks Anna for your assistance in pressing the pedal.

Long Time No Update.....

Saturday 5th October

I only managed a short time on the car, I marked up the position for where to pass the lambda sensor wiring through the body work, removed the exhaust manifold and drilled the hole and fitted an appropriate grommet, I need to cut the current connector off the sensor wiring and re-wire it once I have passed the wiring though the grommet, slight annoying but it will look tidy.

Sunday 13th October

I have started marking up the dashboard layout, ready for fitting the gauges, warning lights and switches, this will allow me to crack on with the wiring behind the dashboard, tidying up all the wires as a I go.

Saturday 26th October

With the dash all marked out I thought I would drill the holes for the clocks, 3 out of 5 done, as I have no 80mm hole saw for the tacho and speedo....time to add to my tool collection.

Saturday 23rd November

Alternator Set-up

Today I managed to drill the two holes for the 80mm clocks in the dash, once I get back from my holiday I will start wiring the dash……..….Two weeks in Florida. J

Since the last update I have managed to fit the alternator and complete the fitting of the brackets, (with thanks to various other blogs on the net)

Wiring in the warm.

Friday 27th December

Rather than spend the evening out in the cold garage, I bought the car into the warm lounge, wiring the dash is the task in hand.

Saturday 18th January

This wiring lark is very time consuming, what started as a loom in the form of cooked spaghetti now appears to be a loom in the form of cooked spaghetti with some connectors on the end, a little more work is required I think, on the plus side most of the switches are wired so I can start wrapping the wires in loom tape. I have also fitted the front brake callipers and plumbed in the brake pipes which are all secure. 

Looming....

Friday 30th August

I decided to break open the ECU loom box and start considering the routing around the engine bay, the loom is a nice plug ‘n’ play arrangement from harnessing solutions (www.harnessing-solutions.co.uk), once I had located the relevant sensors and connections I roughly ran the loom through some cable ties and plugged in what I could, I still need to wire in the relays for the fan and the fuel pump but I will do this once I have fitted a plate behind the dash for mounting the relays and fuse box.

Wednesday 4th September

I have turned the Zetec fuel rail around so I do not have to run fuel hose the length of the engine bay and back again, this simple mod provides a neater solution, the fuel filter is also mounted and plumbed in.

Saturday 14th September

Bodywork all loaded up
ready for the trip home

Progress has been a little slow in the last week or so, mainly because I am taking my time to familiarise myself with the wiring loom and what the best way to route the loom is, although I have managed to fit and plumb in the catch tank.

Today I took a road trip to Hereford to pick up the body and a few other bits such as the exhaust system and prop shaft.








Friday 20th September

4 into 1 exhaust manifold

I managed to get a few hours working on the car, I fitted the starter motor, trial fitted the exhaust manifold so I could determine where the hole in the body work for the lambda sensor wiring needed to be and I have also made a start on fitting the alternator brackets. The propshaft is in place but not yet secured as I need to source some appropriate bolts.

Starter Motor Fitted

Propshaft in place

It's Home...And has an engine.

Friday 26th July

The car is now at my house, hopefully it will progress a little more.

Saturday 11th August

The fuel tank has been fully plumbed in, with the feed and return connected up and a rollover valve fitted. The bellhousing requires some trimming to provide clearance between the chassis once mounted in the car, this has been trimmed, bolted to the gearbox, the clutch fork fitted and along with a new release bearing.

I have also fixed the new lowline sump in place of the old 2-piece sump.

New Sump fitted

Engine in

Monday 26th August

I have managed to bolt the engine and gearbox to one another so it is now ready to drop into the car for fitting.

For lowering and manoeuvring the engine and gearbox into the chassis I enlisted some help from my other half and my dad, which was a good job to help ensure clearance on all sides, the process didn’t take too long and after a bit persuasion and adjustment it was all ready for the engine mounts, I placed the mounts on some blocks of wood and drilled down through the chassis, once the holes were drilled I replaced the wood with the rubber mounts and added some loctite to the engine block mounts and ensured the gearbox was fully bolted down.

I have a choice of what to start on next…the time consuming wiring…the alternator  (inc brackets)…the radiator…. I do know my first task is going to be plumbing in the fuel filter and engine fuel rail.