Another Zetec Conversion Thread!

[flameredturbo]

Thought I'd go for a trial run space wise. The alternator doesn't foul the steering column, the thermostat housing fits perfectly once I relocate the brake pipes! Fits under the bonnet with ease!!

[flameredturbo]

This is going to be fun and games!!

[owlman2222]

sorry couldn't make it round today, hopefully will be able to make it tomorrow if your about, looking like its going to be a nice fit

[flameredturbo]

I was pretty chuffed that it was a nice fit especially after the bitch of a morning id had with the pedal box! That's in place and there's plenty of room to plumb in the brake pipes.

 

[blue]

I have one of these pedal boxes

I used the GBS left hand drive clutch cable

And the left hand drive throttle cable , drilled a small hole through pedal put solder less nipple on end job done

All connected up to my 2.0 zetec.

My only complaint is pedal box is quite flimsy . It could do with being made about two mill thicker material

[flameredturbo]

I can feel a bit of flex I must admit, I forgot to move it to when I cut the bulkhead today and took a chunk out of it!

I think I'm going to get away with re using the cables, I'm going to mimic the original set up as much as possible.

[flameredturbo]

Pedal box progress, I know there won't be an exact distance but what kind of travel is required in the cable to function the clutch? Will the clutch hold enough spring to return the pedal?

[Longboarder]

About half an inch only. Possibly less if the clutch release bearing is held on the release fingers and play in the system is all taken up with some form of tensioning spring. The window in the bellhousing which the clutch arm sticks out of is only about an inch long and the arm only moves part way in it. That also means that the clutch pedal end of the cable moves the same distance.

 

Nigel

[flameredturbo]

Thanks, I'll tackle the throttle when the engine is settled into the bay, once the lump is bolted in I've got a funny feeling things are going to be smooth!

[Longboarder]

It's a good plan to try to attach cables so that they pivot when the pedal is pressed, avoiding repeated bending of the cable and eventual stress failure. Putting stops on the clutch and throttle pedal themselves to restrict the permitted rise when not pressed helps setting pedal height. Putting an adjustable stop on the full travel position of the throttle pedal stops you overstretching the cable or stressing the butterflies/TB mechanism. Making them all adjustable is a bit overkill. No stops on the brake pedal! It will find its own height and you don't want to limit the push!

 

Nigel

[flameredturbo]

The clutch eyelet pivots nicely will be perfect with a bit of grease.

The throttle will be a simple up and down motion.

I've made up the brake pipes today too, I'm going to have to fit a hydraulic inline brake light switch though as there's no way on this planet I'm going to be able to use the original switch.

Stops could be made with a long bolt I guess, easy to adjust too.

[blue]

I have set all the pedals at straight up (12 o clock) and the travel on clutch is perfect aas it stops on the pedal box and throttle travel is spot on full throttle on the ford butterfly

I also fitted a bias adjuster on the dash to help set the bias

All in all these boxes are easy to fit .

 

 

[flameredturbo]

I have set all the pedals at straight up (12 o clock) and the travel on clutch is perfect aas it stops on the pedal box and throttle travel is spot on full throttle on the ford butterfly

I also fitted a bias adjuster on the dash to help set the bias

All in all these boxes are easy to fit .

I've just played about with the pedal box again, my pedals are at more like 11 o'clock, not got the throttle one in yet as I need to cut a part of the pedal away to stop it fouling and I'll do it in one hit when the itbs are in place I think I'm going to connect to cables together and be done with it.

[flameredturbo]

This is normal apparently!!!

[flameredturbo]

Is this a suitable place to put my air temp sensor? I'll drill a hole and bolt it in. If not where have others put them?