Chr!S
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| posted on 23/1/07 at 12:19 PM |
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Hi!
Hi! just thought id say hello. My name's chris and im an engineering student at the University of Exeter. Have been building in between exams,
here's the current ingredients list:
Chassis built from the book but widened 4". [Anyone else notice ludicrous dimension errors?]
Sierra rear shafts/hubs/box - need to build a solid axle to link it all up still...
2.0 Zetec w/fiesta sump (so now its the same height as an RS1800)
For later: zetec turbo parts and ancilliaries in a box somewhere along with a pre-prepared manifold 
I do have a few quick q's (yes i DID search...)
1) The front end: Escort mk2s are an impossable find so are cortinas. So im using seirra uprights, but i take it they will need different
wishbones?
2) The donor: i need an MT75 and an ABS rear end - is it only the 2.0 sierras that have this? Do you find the locost is ok w/o ABS? ive grown up used
to it...
3) The rack: again sierra. I can get transit rods but im not sure if I can use the sierra one as everyone seems to tell me its esc mk2 or
nothing....
Hopefully when its finished i can unvail my final year project: Involving a custom chassis and a mitsubishi 4wd turbo....
Thanks in advance, Chris
Edited for rouge spelling errors :p
[Edited on 23/1/07 by Chr!S]
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macnab
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| posted on 23/1/07 at 12:26 PM |
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hi, photo's ?
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Winston Todge
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| posted on 23/1/07 at 12:27 PM |
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Hi Chris from another Chris, who incidentally went to Exeter University 2000-2003 and 'studied' (using that word loosely...) Engineering
too.
I'm not much help on the chassis front as I went for the quicker option of buying in my chassis from MNR. (Great company, btw...)
Just curious if the Formula Student took off ever? We started it in '03 but never quite got enough (any..) backing from the Uni. Maybe something
to look at?
The Lemmy still standing is it?!
Chris.
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Chr!S
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| posted on 23/1/07 at 12:52 PM |
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Lemmy is still in full swing, with a £1 million re-furb 
Formula student never took off. I remember emailing you to try and do it - nothing ever got done by the uni
I have competition though: two off road buggy chassis have sprung up over xmas! Did you know storeman dave has been building a locost for 4 years!!!
its being fired up finally for the first time soon
btw i dont have any photos yet as its still under construction! I have a solidworks model....
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ecosse
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| posted on 23/1/07 at 12:53 PM |
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Hi Chris
Different size bones are required for the sierra uprights
Don't know about ABS, how would you control it, standard ford ecu?
You can use the sierra rack although it will probably need shortened, what width front end are you using, also +4 or standard book (442 Mcsorley
style)?
Why the fiesta sump (and what fiesta sump fits out of interest?)
Cheers
Alex
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mcerd1
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| posted on 23/1/07 at 01:03 PM |
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quote:
Originally posted by Chr!S
Sierra rear shafts/hubs/box - need to build a solid axle to link it all up still...
Do you mean your going to build a DeDion axle?
quote:
2) The donor: i need an MT75 and an ABS rear end - is it only the 2.0 sierras that have this?
Does it have to be an MT75 gearbox ?
If yes, then be aware that there are 2 kinds of MT75 box - one to fit ford 4cly engines and one to fit ford V6's (2.8 and 2.9) and you
can't change the bellhousing on either of them
You'll find the 4cly version in 2.0L 8v DOHC sierra's and Granada's
The ABS rear end has discs and bolt-on driveshafts (rather than drumns and push-in) they will more than likly be on the same car as the DOHC engine
and MT75 box (unless its a very cheep model without ABS)
I think all the Granada's would have the rear end you want, but they have 5 stud hubs (and you won't be able to use the Granada fornt hubs
easily)
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Chr!S
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| posted on 23/1/07 at 01:06 PM |
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all the horizontals were taken as +4 inches.
I noticed the weird book errors so kept as many 'main' dimensions as i could, added 4 to the horizontals, then used 3D modelling to give
me the correct chassis lengths and angles. Its pretty similar to the GTS (i think its gts) sierra plans but some of the derived and defined dimensions
are interchanged.
I really dont want to cut into a steering rack, id rather leave it in one piece if I could. I found some esc mk2 racks on ebay including some
quick-rack ones so might have to go for those?
The ABS is done with the standard Ford ECU. The only addition is a 'piggy-back' system and ignition amp for the tuning. When i've
made the TBs it should see 160hp or slightly more....
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Chr!S
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| posted on 23/1/07 at 01:10 PM |
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thats what i thought - the 2.0 w/ABS should have everything I need. Yes im going DeDion, though still am trying to work out how to free up the lateral
link, as it's technically going to lock stiff, even with spherical joints, unless the shaft is slightly extensible. I def. dont want the V6
MT75, one option id seen is a cheapo MT75 from a transit - obviously being the 4 cyl variety - confirmed by the ribbed casing and the standard reverse
location (other box is type 9 on the trans - reverse up and left i think)
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Chr!S
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| posted on 23/1/07 at 01:14 PM |
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the fiesta sump allows the engine to sit lower (its too high in 2.0 form). Sorry about being forgetfull and posting 3 damn times....
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ecosse
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| posted on 23/1/07 at 01:15 PM |
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If the front end is +4 than the escort rack should be a straight fit 
You didn't comment on the fiesta sump, but presumably it is shorter than the standard zetec, but is it also bolt compatible or does it need
modified?
I'm not sure that the standard ECU would be much good for TB's although I'm no expert on it, I'm going TB's and
megasquirt with mine though.
Not sure on this but I think the transit box is different to the sierra, different housing and gearchange position for sure.
Cheers
Alex
Opps, soz, u posted b4 me on the fiesta bit, cheers 
[Edited on 23/1/07 by ecosse]
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Chr!S
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| posted on 23/1/07 at 01:22 PM |
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Fiesta sump is the mk3 fiesta sump. Need to change the oil pickup pipe and then bolt on the new sump IIRC. I will have to check as I did it for a
fiesta 2.0 Zetec conversion a while back...
The ECU should be ok with a piggy back as its not a large increase... Could always scrap the ECU and ABS and do DIY management...
Ive only ben informed about the transit, but will be having a look on the weekend
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ecosse
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| posted on 23/1/07 at 01:28 PM |
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I have a transit sitting in the drive at the moment if you need any info, although it is the diesel type so maybe not much help?
Never knew a fiesta sump would fit the zetec, from what engine model (sorry asking more questions than you now)
Cheers
Alex
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Chr!S
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| posted on 23/1/07 at 01:36 PM |
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mk3 - it utilises a 1.6 zetec sump, which is the same as the RS1800 sump (sump taken from 1.6 si see below)
Do a google search for zetec fiestas! You need to prep a mondeo engine by moving some things around and changing the sump and inlet manifold.
Its a VERY cheap (under £300 ALL IN) conversion if you fancy a quick motor (faster than standard Fiesta RST) while a locost build is happening. Some
people with very mild tuning or stripping have posted 6.9 0-60s - quite nice in a chuckable mk3 fiesta chassis. Though i'd recommend starting
with a mk3.5 (Si 16) as its slightly stronger on the front
[Edited on 23/1/07 by Chr!S]
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mcerd1
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| posted on 23/1/07 at 01:54 PM |
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Yep - Type 9's have reverse in the top left (and you push the lever down a little) - MT75's have reverse in the bottom right (with a lift
ring thing)
Transits of a similar age do have MT75 boxes (I don't know if the 2.5D has the same bellhousing or not though ?) but all transits have a
different gear linkage/ tailhousing
I think the MT75's are a bit stronger than the std type 9 (is that why you want one?) but they are also quite big - have you thought about a T5
box ? (from a 2wd cossie)
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Chr!S
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| posted on 23/1/07 at 02:04 PM |
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I figured a T5 box would be too expensive. Its not that ive heard of MT75s being strong - but of Type9s being weak! The original plan was to use my
'spare' toyota 3SGE @ 199 bhp (so nearly 200 ) and a toyota T50 but the toyota box wouldnt take it, so decided to keep it all ford.
Will the type 9 take 150-160hp abuse everyday? Im the sort of person who WOULD have this as a daily drive and go everywhere in it...
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arrybradbury
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| posted on 23/1/07 at 02:15 PM |
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Lol, it's a small world.....!Chris, would one of those off road buggies have been red framed with a 600cc bike engine and quadbike wheels? With
a red and black bucket seat?.........
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Chr!S
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| posted on 23/1/07 at 04:39 PM |
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unbelievable!!! theres another Ex exeter student that said hi a minute ago too 
was it you who nicked all that tube i ordered?????
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arrybradbury
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| posted on 23/1/07 at 06:51 PM |
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Nah, i'm a bath engineering student But two of my best mates are in the group of 3 that are building that one! I helped with the front
wishbones during the summer when it was back in cornwall. Can't help you with the tube, sorry
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Chr!S
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| posted on 23/1/07 at 07:05 PM |
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haha no worries. Someone nicked all my 1" tube that was lying around and has built a new frame with it. Using a black racing seat...? A new
design maybe?
I saw the buggy a whlie back as the rear axle was being fixed or something and was hanging around in the welding bay when i was doing mine. Ive done a
total of 9 days work on it and im up to the top/bottom decks all done. Having to linesh the f tubes is annoying... but after that they're all
cut almost to size to should be a fairly swift chassis build...
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MikeRJ
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| posted on 23/1/07 at 11:38 PM |
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quote:
Originally posted by Chr!S
I really dont want to cut into a steering rack, id rather leave it in one piece if I could. I found some esc mk2 racks on ebay including some
quick-rack ones so might have to go for those?
Avoid the Sierra rack if you don't want to modify it (though many of the kit suppliers will do this job for you).
The Escort rack is just about the perfect length for a +4" chassis to minimize bump steer. However you will need to fabricate some small track
rod extensions as the track rods won#t be long enough to reach the track rod ends.
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Chr!S
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| posted on 25/1/07 at 02:28 AM |
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dammit! thanks for pointing that out! Don't the SVA people forbid welding on steering components? Just a though in passing as it looks like im
going to have to make new rods? Unless someone has a photo of an extension as I have no idea what the transit rods look like...
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