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Author: Subject: Chris' Haynes Build
christim

posted on 14/5/24 at 11:49 AM Reply With Quote
As posted elsewhere my IVA is now booked for 12th July, so countdown is really on!

a few things to finish off....I've 3d printed and fitted new rear light mounts (added a 7 degree horizontal angle so they point directly backwards)



I've fitted trim between the bonnet/scuttle



I've drilled new side repeater holes in the headlight units so they now comply with the IVA manual (5 degree vertical visibility). I've disconnected the lower ones so they don't blink...again IVA requirement that only 1 set of side repeaters are fitted.



An upgrade to my 3d printer...I treated myself to a laser cutter. Designed and etched this manufacturer's plate, 'Roadster' logo pulled from the book.
The name and VIN have also been etched in using the laser





With that all done in theory I'm ready for IVA! Been out a few times though (on private road not public highways ) and have some issues to sort:

It was squealing when getting warm, which meant an air leak to the manifold. I found when I disconnected the crankcase breather/rocker cover breather pipes it stopped (they were connected to the vacuum side of the inlet as per OEM design). To fix this I removed the pipe from the catch can to the inlet and blanked it off. This effectively blocked off the breather pipes though and the pressure built up in the crankcase and has blown a hole in the crankcase breather gasket, so oil everywhere I'll need to fix this.
I'm going to add a filter to the catch can so venting to atmosphere
While I'm fixing that I'm also bringing forward what was going to be a 'future upgrade' and getting a raceline sump

When taking foot off the accelerator the engine wasn't going back to idle. I thought this was the control valve being the wrong way round. I 3d-printed a new IAVC mount so the tubes were reversed and refitted the valve but found it was worse. I think the idling issue was also because of the breather pipes being routed into the inlet (not sure why, as again this would be how they're routed normally). So back to original design for idle control valve. (BTW....not all idle control valves flow in the same direction! seems 99% flow opposite to the ones fitted to a 1999 2.0 Mondeo. I wish they'd put arrows on them showing airflow direction!)

The rear brakes lock before the front. The front brakes have always been a problem (even after several bleeds): too soft, bleed nipples needing to be excessively tight before it stops leaking, etc. I'm upgrading to Wilwood Powerlites - got the kit from RallyDesign and ready to fit

I tried setting the speedo (Smiths Electronic) but it doesn't pick up the pulses until I hit about 20mph. I've currently got the ECU wire wired up to it, and the original donor electronic speed sensor from the type 9 gearbox wired to the ECU. I'll need to play around with some options...maybe wire the speed sensor directly to the speedo, maybe run a separate feed from the manual speedo hole on the opposite side of the gearbox

Any opinions or experience on the above issues welcome!





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MikeR

posted on 15/5/24 at 12:41 PM Reply With Quote
could me completely wrong but i think you'll fail the side repeater by having two in the headlight. I've got a memory of only 1 should be visible.

(you've done amazing building the car, really hope you get a first time pass)

Rear brakes, some people fit pressure reducing valves which may help.

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christim

posted on 15/5/24 at 10:44 PM Reply With Quote
quote:
Originally posted by MikeR
could me completely wrong but i think you'll fail the side repeater by having two in the headlight. I've got a memory of only 1 should be visible.

(you've done amazing building the car, really hope you get a first time pass)

Rear brakes, some people fit pressure reducing valves which may help.


Cheers Mike, fingers crossed!
There's only one set of side repeaters now....the old ones are ornamental bits of orange plastic with absolutely no other function

(On a serious note I may end up changing the lamps anyway to a slightly smaller set, as the current ones limit my turning circle)





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christim

posted on 22/5/24 at 10:43 PM Reply With Quote
I've sorted the Speedo problem now. Still not sure what the issue is...I did some testing on the loom and confirmed the electronic speed sensor is sending pulses, but checking with the OBD reader the ECU isn't reading any speed...until about 20mph then it does. Could be the two are just incompatible (type 9 vss and '99 Mondeo ECU).
So I've cut the wire from the Speedo to the ECU that receives the pulses, and bridged it onto the feed directly from the sensor....so now the sensor sends pulses both to the speedo and into the ECU (not sure there's any need for the feed into the ECU but cant hurt and its future proofed for any ECU upgrade in future)

Anyway here's a picture of the spliced wiring (a right pain having to disconnect everything, take the dash off, cut out the loom tape etc, but it's done now and all back together)



Remaining items:
Fit Raceline sump
Fit brake upgrade kit - now also includes making the brake reservoir remote and mounting it higher, after reading info on fitting the Wilwood brakes I suspect the reservoir being lower than the calipers was causing a brake fluid flowback issue. Options are to fit a residual pressure valve or raise the reservoir





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christim

posted on 17/6/24 at 02:21 PM Reply With Quote
Brake upgrade...

Off with the Sierra calipers



And on with the Wilwood Powerlite kit from RallyDesign





Then I made a mount for the remote reservoir. I wasn't sure where to mount it but lack of space elsewhere means it's only really an option above the master cylinder. Will make access a bit awkward if needed but not a huge issue



I turned out some remote reservoir adaptors on the lathe



And plumbed it all in





Another item off the list. It's definitely an improvement, but the rears are still locking before the front. I've got a brake proportioning valve ordered & will fit that next.
Also, although the brakes are firm and not spongy (so bled ok), there's a lot of travel on the pedal before the brakes bite. Possibly that's just me being used to servo brakes, or the pushrod is too close to the pivot point.
I'll see if all's well at the IVA, but potential future upgrade is remote servo.





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