First off, Hi, I'm currently volunteering at a mechanics/training institute for youths, anyway, after completing a bike engine swap I have been
tasked with trying to get a kit car running, which has been laying in the garage for some years. For doing such I'm on a pretty minimal budget,
well, no budget, but as low cost as possible.
The Tiger Avon in question is basically a rolling chassis. It has a 2.0l Mondeo Zetec Engine in it (silvertop).
Parts I know I need initially include:-
-motorcycle carb bank, I have looked around and I "think" a GSXR 750 set will work
-an alternator, vague idea which to use
-a start motor, also vague idea which to use
-a steel sump to replace the aluminium which will be cut down for clearance
-radiator, thinking polo radiator as we have one laying about
-flywheel, previously the engine was an auto, so just going for a stock Mondeo one
I'm trying to source these parts at first and then go from there and would like advice on which parts people would suggest for the most cost
effective build. Yes, I have searched, but many people use different parts and I have no idea what can be used with what and such.
Btw, I will not lie, I have only a little experience with car mechanics, I know what bits do what, and where they go, but have never under taken such
a task, however the garage has multiple expert mechanics and fabricators at hand for any technical stuff.
PS. I will get some picture links set up asap so people can see what I've got to tackle.
Why fit carbs, modern cars on the road are fuel injected. You can fuel inject it with standard ford parts for pennies.
If you have an auto zetec aswell as the fly' you will also need the crank position housing from a manual.
Starter, you have a few options but most common is the lucas lrs707
Alternator, you can most to fit if you try.
Sump, the only metal one you will find is the sierra 1800 cvh. Its 20+ years old and well roten. dont bother get yours adjusted or the escort ali sump
is a little shorter.
all In my opinion and there is allways more than one way to go about it.
Well, that's something I didn't know about, the crank position housing that is, I'll run that by them and see whether they have one
or needed to get one.
As for carbs, it's just how they want to run it, so I'm kind of running by their specs, but if you can shed light on an FI build I will
run it past them. We have all the FI manifolds and such, but I think there's a fitting issue with it.
Starter, I'll price that one up for it
As for our sump, because it's aluminium it's harder to modify, ground clearance is like two inches at best, I've been told you can
get steel ones, so I've sourced one off ebay, and going to check the local salvage yard for one, to be honest, I need to get the sump off to get
a good look at it so I know I'm looking at the right parts, that's my job for Friday.
Alternator, well we have one from a 95 Sierra, and a 97 Mondeo, I'll see how to go about fitting those and whether space will be a problem.
Yep many people have found out the hard way about the cps housing.
Will the car be going on the road or is it just a studant car that will be stripped and rebuilt yeay after year ? If its going on the road and not yet
iva'd and the engine newer than aug 1995 you may not get the carbs to meet emissions for an 1va then mot's.
Even with carbs you will still need an ecu for ignition and megajolt are not as cheap as they once where.
I am a fan of the Oem efi as its cheap and reliable.
Your correct the plastic zetec manifold may not fit, but on a budget the escort up and over manifold can be used. It will stick out of the bonet a
little but it is cheap and of the shelf and has been fitted to an avon a few times.
one I made earlier
I now make / modiffy a log style manifold bassed on the Ginneta / griffin manifolds for a neater install
I take the the loom and ecu from mondeo and chop it up and remake it for the 7
Like I say these bits are cheap. Ive paid as little as a quid for an ecu and wont pay more than £30, wirring looms, £10~£15 then its just
consumables.
The sierra 1.8 cvh sump is not just a bolt on job and is still deep. The new 1.6 cvh sumps on ebay dont fit and you still need the spreader bars and
pick up pipe. You then need to drill and tap two holes in the oil pump and the rear of the block. The windage tray doesnt fit and the main bolts have
studs that need taking of. you then have to hammer out the side of the sump to clear the pick up pipe elbow. All this on a sump that is betweeb 20~25
years old.
If you mondeo alternator has a three pin plug it uses fords smart charge sytem that is controled by the ecu so would not be ideal. The 1.8cvh
alt' is a simple lucas item but sits the exhaust side.
THX Big Wasa thats my yellow Avon in the picture the usual copyright charge of £0.00 applies to reproductions on here.
The manifold is off a Escort with a 1.8 silver top engine. Im running it with the Tiger supplied Webber Alpha engine management. It passed the SVA
as shown in 2008 once I had filed off the EFI letters and made an alloy cover for the throttle actuator level.
If your engine is a 2.0 check about the water pump. It think it runs the opposite way to the 1.8.
