christim
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| posted on 1/7/16 at 09:06 PM |
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I'm going to try posting more regularly. Not that I need it, but it should give me incentive to make a little progress each week...
This week I have mostly been making mounts 
I started by measuring out the size of disc needed to fit the rubber engine mounts and drilling out the bolt hole:
Then cut the disc to shape:
Next was measuring up the box section and cutting to shape, then tacking in place. I've used 50mm box. Might be overkill, but better to be
safe:
And then fully welded then drilled out a hole to allow access to the nut:
Finally, I've started on the gearbox mount. The engine/gearbox is as high as I can get away with so hopefully I wont need to cut the sump and
will have plenty of clearance underneath (I've managed to get it down to 25mm from the bottom of the sump to the floor). This means making a
raised gearbox mount though, here's what I've got so far:
Thats all for now. Going to finish the gearbox mount then get the steering column sorted next
My Build Thread
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christim
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| posted on 3/7/16 at 09:15 PM |
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I got a couple of bits done over the weekend. Firstly making the hole for the steering column bearing. Drilling loads of little holes through 3mm
steel is so much fun...
Once the plug was out I could offer up the bearing to measure/drill the bolt's holes:
Then the column's bushing needed sanding just a hair's width to get a snug fit in the bearing:
Time to put it all together:
When the weather was ok I was outside stripping bits off the donor. Couldnt resist laying some parts on the build to see what it looks like :
The blocks of wood you can see are me working out the final ride height for the seats I wanted
(these). With everything measured up i'm going to have to change to a
different set (possibly these)
Couldnt resist a sit in it:
My Build Thread
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christim
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| posted on 10/7/16 at 10:20 PM |
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Next job on the list is the steering column support. But before doing that I had to sort out the door upright/chassis layout. I'm quite happy
with how it's turned out but will still add a final diagonal going down to the bottom rail, creating another triangulation, (and another by the
upright next to the pedal box):
With that done I could get the steering column support on. The wheel's going quite high on my build, and with the altered chassis I had to work
out some awkward compound angles, but again I think it's turned out ok:
My Build Thread
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christim
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| posted on 10/8/16 at 10:35 PM |
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Just a quick update today...I've been busy with the pedal box and nearly there with it, so I should be able to write it up on here soon.
In the meantime, I've put together the steering column. A few problems with it but all sorted now:
Firstly I cut the old shaft to extend it, then measured up the uj against my escort rack. Unfortunately my Sierra donor has power steering which means
it's rack has a different spline number/diameter, so the Sierra uj wouldn't fit onto the escort rack:
Also even if the uj had fit, because it's too short the column was fouling against the upright. So first thing to do was order a new uj (one
that would fit the escort rack and still have the trianglular Sierra column fixing):
That did the job! And as it's a bit longer I've now got a few mm clearance from the upright  Bonus. Here it is all in place:
More to come in the next few days!
My Build Thread
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christim
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| posted on 4/9/16 at 10:12 PM |
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Here it is, my next update! After trying to steal a few hours in the garage whenever possible, the pedal box is finally finished, woo! I'm
really happy with how it's turned out, given that I made most of it up as I went along.
So first off, I needed some angle steel but didn't have the right size. Oh well, box section is basically 4x pieces of angled steel right?...
The next bit is pretty standard, having cut some sheet steel i offered it up to the chassis, with the angle steel resting on the bottom rail:
Then welded the two pieces together:
And drilled the holes for the securing bolts, cables, and brake cylinder. I'm not bolting the pedal box to the floor, but onto the bottom
rail...I don't want bolt heads exposed under the floor, and as I'll be using 1mm steel for the floor I want the box bolted on to a
sturdier part of the chassis:
Next on to the pedal mounts. I started with some initial sketches then drew up my designs to make a cardboard template:
And used the templates to cut out the final mounting pieces:
Then welded these in place:
Now on to the pedals themselves. I started by using my fancy expensive metal bending jig to get the perfect curve in my pedal footplate :
Then I cut and drilled 2x lengths of steel per pedal, turned some rod on the lathe to make a few spacers, and welded on what will be the cable
brackets:
And welded it all together. (I got some - I think anti rollbar - bushes, can't remember, and pushed them in to the spacers where the bolts will
go):
After that was done I offered it up for final fitting, before welding the plate to the pedal at the right height for my foot (here it's being
held in place with a magnet):
Moving on to the brake pedal, I drilled a hole in one of spacers - that I'd set at the same height as the brake cylinder:
Then turned some steel rod in the lathe to the right size to just fit snug inside the spacer:
I then drilled and tapped the rod:
And finally, I put a thread on a different piece of rod, which now screws into the piece turned on the lathe:
This now pivots in the spacer, pushing the rod into the brake cylinder when the pedal is pushed (and added bonus, the hole in the spacer provides a
positive stop when the pedal pivots it all the way back, stopping the pedal going back any further):
That's it, all done! I just need to hook up the clutch and throttle cables, but will get to that when I start on welding all the pipe brackets
to the chassis
[Edited on 5/9/16 by christim]
My Build Thread
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Neilwilson
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| posted on 4/9/16 at 10:59 PM |
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Great progress, looks like your really enjoying the build. Keep it up matey
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christim
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| posted on 7/10/16 at 09:18 PM |
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Cheers Neil, yeah I'm really enjoying the build of it all! Sure i'll enjoy the driving afterward too, but its the build I like best
My Build Thread
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christim
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| posted on 7/10/16 at 09:59 PM |
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I've finished putting the handbrake together, so I thought an update was due!
I had a spare Focus handbrake cable, which i preferred the look of rather than the Sierra handbrake as it's adjustable - and less rusted 
The cable being adjustable meant altering the handbrake, so i started by removing the 'crescent moon' shaped cable guide:
I then put a thread in the bolt (for the adjusting screw) that will go through the newly created hole in the handbrake arm:
And cut the adjustable screw part off the cable. (I dont need the extra length of cable as the trans tunnel is so short):
Also the cables from the zetec are far too long, so these were cut down to length:
(I then splayed out the wires and melted it all back together with a blob of weld)
And thats it done!:
The other ends attach into the drums ok, with a bit of fiddling and adjusting needed. Also I've not yet fixed the cables to the chassis as I
want to get the brake and fuel cables in place, and the fuel tank. Then I can work out the best route for the handbrake cables.
After that, it was on with the wheels again and she saw her first light!:
It's great to get to this stage...I now have a rolling chassis which means that I can get more space in the garage, and work on both sides of
the car now. I've sorted the passenger side door upright, and am now working on the exhaust. I wont be able to finish that until the bodywork
support framing starts going on (more about that when I start on the bodywork) but I can at least get the bits cut to length:
(Using the blue string to help show my brake pipe routing )
My Build Thread
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christim
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| posted on 17/11/16 at 10:32 PM |
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Time for an update I reckon!
Carrying on from last time, I've been sorting out the brake/electric/fuel line brackets. I've cut up some steel strip to go in various
places along the tunnel and across the rear diff cage, drilled holes ready to take rivets, which will secure p-clips throughout:
Half way through I may have got a bit side-tracked and decided I needed to get the bulkhead in place... But to get this done I'd need a sheet
metal bender. I knocked something up cheap and quick, but it worked great! (Also it seems you can't get a bender capable of doing 1m without
paying stupid money..and they're so simple to make!?) I already have plans to make an even better V2.0
With that done I could then bend the piece needed:
And put in it's place:
A bit of trimming and profiling needed, but not yet sure of the final shape so I'll leave it there for now.
Next I really wanted to sort out the seating, so I can get the rails in place and get the chassis one step closer to being finished. Earlier on I
mentioned my dilemma about which seats to get. So as a test run I got my hands on the original one I wanted. Putting it in place it fits to the
millimetre! Ok, when the side panels are carpeted it'll be snug..but it fits! I'm really pleased it means I can have the seats I
wanted:
Not sure about the colour mind, that'll change.
For the past few weeks there's not been much progress, as I've been on the computer designing the bodywork. I hope in a couple more weeks
I'll be done and can get some pics posted up here of what it'll look like
My Build Thread
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christim
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| posted on 24/1/17 at 10:22 PM |
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I've not posted in a while as I'm still either inside on the computer working on the bodywork design or outside stripping the
donor...it's been sat on the drive long enough and time for it to go!
I've been workng on stripping the electrics out and this weekend managed to finish that job:
Finally got it all out of the donor:
And all packed away ready for when it's needed:
I've labelled all the connections....I just hope I can figure out what I'm doing when it comes to connecting them all up to the zetec! 
My Build Thread
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christim
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| posted on 18/12/19 at 02:57 PM |
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Whoa...coming up three years since any progress or update! So what's happened?...I had a lot of problems trying to do my own bodywork and
realised I'd bitten off waaay more than I could chew (see design and thinking
thread here). A couple of catastrophe's and I got really deflated about the whole thing.
I got to the point of *almost* finishing the rear (see pic below) when the whole thing collapsed and it was back to square 1. This and the fact that I
was already daunted by creating a full bespoke GRP bodyshell having never fibreglassed before, I now see how naive it was to think I could do this. It
took me until this summer to admit defeat on the whole design.
SO...I've closed that chapter, and since buying a full set from Equinox i'm back on with the build, making much better progress and will
try to update here as I really want my build thread to be a complete one and see this thing on the road
Still think it would have looked aces mind...
[Edited on 18/12/19 by christim]
My Build Thread
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christim
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| posted on 8/1/20 at 02:14 PM |
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Screw Photobucket. Imgur is the way forwards!
So i've made a list of things that need doing before I can get the chassis powder coated, and now working through that list...
I'm going to attach the nosecone (which i'm joining to the bonnet so it's a single structure) with heavy duty cabinet door
hinges:
I've finished the radiator mounting brackets:
(Nosecone only just clears the radiator)
Also done the front brake brackets:
My Build Thread
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christim
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| posted on 11/1/20 at 02:10 AM |
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Got a few more jobs done in the last few days..
- I've cut off the handbrake cable bracket and will weld on a new one vertically, rather than in line with the seat back angle as the book says.
The handbrake cables were pointed right into the diff before (a tip from Rosco a few years ago I've only just got round to doing)
- I finished off the roll-bar mounting plates; so the side panels fit snugly and i can weld in some mounting plates for them
- Finished the diagonals around the engine bay:
- And have now fitted the seat belt mounting points (driver's side points circled):
- Finally for now I've got together all the parts for the complete fuel system, so I can now get the back of the car's chassis
finished:
My Build Thread
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big_wasa
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| posted on 11/1/20 at 10:39 AM |
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I bought one of them tanks for mine.
In the main I am really happy with it for the money.
I think the guy under sell's his work a little with very sparse adverts.
Mine did come with a really odd size filler neck.
I've had to turn up an adapter and weld it on.
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big_wasa
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| posted on 11/1/20 at 10:44 AM |
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My suggestion would be to also re look at your belt mounting points.
My opinion is they look a little on the thin side ?
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christim
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| posted on 13/1/20 at 11:26 AM |
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Yep I agree, the tank's great money for a good quality item, and a good guy to deal with (My Hermes 'lost' the first tank he sent
and fair play to him he made and sent another one...hope he got some compensation from MyHermes for that).
Didn't even think to measure the filler size! Cheers for the heads-up. If needed i'll look at some sort or reducer
Yeah the seat belt brackets are 3mm (5mm angle for the seat back mounting point). The one in the corner is strong but I'll reinforce the trans
tunnel ones
My Build Thread
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rusty nuts
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| posted on 13/1/20 at 04:38 PM |
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The seat belt on the tunnel looks too far forward to me as well as a bit flimsy . Would also suggest welding nuts on the inside and fully welding
them.
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christim
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| posted on 14/1/20 at 11:13 AM |
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quote:
Originally posted by rusty nuts
The seat belt on the tunnel looks too far forward to me as well as a bit flimsy . Would also suggest welding nuts on the inside and fully welding
them.
I'll get some tube in place to reinforce it as yeah it's a bit thin. The height is ok, it was measured with the seat in place. Working on
the seat mounts at the moment so more pics to follow of the final fit
For the fixings, good suggestion...i'll check the seat belt pack see what nuts came with it. they might be high tensile but may be better to
weld one in
My Build Thread
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rusty nuts
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| posted on 14/1/20 at 06:50 PM |
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You need 7/16” UNF nuts, standard thread for seat belts
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christim
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| posted on 15/1/20 at 02:35 PM |
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A couple more items ticked off the list before i can get the chassis powder coated...
The seat mounts are now in:
And a little place to mount the horn:
My Build Thread
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christim
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| posted on 23/1/20 at 05:38 PM |
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Couple more jobs done...
For the brake/ fuel/electric hoses going through the tunnel i'm p-clipping them, so have cut up some brackets and added rivnuts:
Then welded in place:
I've also added rivnuts where the scuttle will be secured to the chassis:
7/16th UNF nuts have arrived so I'll weld those on next, then on to working on the rear section
My Build Thread
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jps
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| posted on 24/1/20 at 09:06 AM |
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As i've only thought about 4 point harnesses, I'm a bit surprised that your lower seat belt mounts aren't parallel and would have
thought the tunnel side bolt hole would be nearer the floor. Are you using a 'production car' style 3 point harness?
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christim
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| posted on 24/1/20 at 10:59 PM |
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quote:
Originally posted by jps
As i've only thought about 4 point harnesses, I'm a bit surprised that your lower seat belt mounts aren't parallel and would have
thought the tunnel side bolt hole would be nearer the floor. Are you using a 'production car' style 3 point harness?
I am, it took a bit (a lot) of faffing to get the final alignments right though. The tunnel side mount was originally a lot lower and further back,
but the (strap? wire?) to the connector is a fixed length, with the point of reference being that connector; I need it just above the seat (see pic
above, yep like a production car) as there's zero space to have it down between the seat and the tunnel.
Yes, a longer - let's say wire- would mean the mount being further back, long enough and it could be against the rear and parallel to the other
mount, but still the connector needs to be
(The corner mount is where it is so when the belt isn't in use the webbing is out of the way neatly behind the seat)
My Build Thread
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christim
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| posted on 29/1/20 at 10:02 PM |
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A few more updates...I've put a couple of brackets in the engine bay corners with holes to take bonnet locating pins:
And I've built up a diff rear bracket to give extra support:
Also tacked in the rear brake mounting brackets:
And one of the jobs on my list I'm glad to get out the way is cutting out the old handbrake cable bracket and put a new one in at a more
sensible angle...vertically (was suggested a couple of years ago by Rosco and definitely makes sense rather than fighting to get the cable over the
diff).
I also attached a little spur to take the brake line T connector
So that's a few more pre powder-coating jobs ticked off the list. Here is the list by the way - lots of brackets and mounts! I''ll
finish it soon if I stop adding more things to it, ha:
My Build Thread
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MikeR
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| posted on 29/1/20 at 10:22 PM |
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im jealous at your progress - when you've finished could you spend a couple of days on mine?
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