GBS Zero Rescue

[Jake Gully]

First build and rescue of what I believe is a Gen 1 GBS Zero.  

I believe the kit was purchased in 2007/8 c/w a 2ltr pinto engine.    The chassis has been 30% built to form a rolling chassis and the engine was upgraded to a new black top Zetec 2ltr.  It has had spent the last 13 years stored in a garage, but is in decent condition.   All stainless steel body panels, so not the lightest around.

Initially, I am looking to remove the suspension arms for powder coating, hand paint the chassis/internals and spray the roll bar.

The side panels may need some attention as sikaflex bonding to chassis has dried and parted and probably needs redoing.

Otherwise get the engine stripped and checked over prior to assembly.   Looks like all parts and wiring are present, less first stage exhaust pipe.  Not sure on the factory exhaust manifold, but open to suggestions and can change later on. 

First build, so likely to ask many questions - especially on painting and IVA as I go through.

 

[IanS]

My experience of sikaflex is that it does not age.

I have some that was applied 30+ years ago and still a solid joint.

If it has come adrift my guess is that the surfaces were not de-greased properly or that the sikaflex was very old stock. It has a limited shelf life before applying.

I don't see a bell-housing to join the engine and gearbox in the pics.

The Zetec engine will require an ECU and things like a water rail as it is designed the the cooling connections at opposite ends of the engine. Have you got the engine mounts to fit it in a for aft orientation?

It looks like you have a fun project and with some work and head scratching you should end up with a fun car.

[Jake Gully]

Hi Ian,

Yes, difficult to get it to stick reliably to listed SS without some prep.   I will throw away the four tubes that came with it and get some new stock and Emery cloth.   Will be a bugger to get it off the chassis though.

I do have the bell housing, prop shaft, throttle body, ECU, rad, hopefully water rail - but will check and post some more pics up shortly.

Looks like it will keep me busy for a good while # not setting a deadline for now!

 

 

[Foz]

Hi Jake, welcome to the club.

It should make a cracking car when done, take your time and you'll get there.   Stick your location up and you may well find there are other members local to you willing to help or advise.

Good luck

[Jake Gully]

After a busy weeks at work, I have had the morning to go down to the unit and do a bit of a stock check and have a proper chance to assess this.    The kit appears mostly intact, but there are a few important and likely expensive parts missing and I am building a shopping list.

Gauges - I only have an oil pressure guage, so will probably want a full matched set and wiring loom.

ECU - Not sure where to go here, if I could make do with a Ford unit or should go for a programmable unit straight off the blocks - likely it will need some tweaks for the IVA.

Wiring Harness - not sure where to start on this and probably need to give GBS a call for some original documentation (apparently they weren't too big on this).   My harness and fuse/relay box looks nothing like the current issue (from build guide left and mine right) looks like I need some relays/bits and at least another block of fuse holders

Exhaust - I'm a little dubious of the fitted ford standard four into one - although it is compact/space saving, I'm not sure if it will perform:

 

Or, if I need to consider a more traditional four into one - accepting this might be harder to trim the bonnet around:

 

Other than the bagged parts, there are no standard fixings (pipe clips, rivets, rivnuts etc), though these are easy enough to source, along with paints, sealents, adhesives and other assembly essentials.

 

Trestles or axle stands.    While the wheels GBS build stand looks great, storing it would be a nightmare and I'm sure I can make do. 

Lastly, I need a temporary garage/workspace to complete the build.   My own garage/workshop is packed with lathe, mill, welding, tool grinder and far too many tools.   I'm thinking I will probably put a tented type or cheap Yardmaster style metal garage onto my drive to contain the sprawl for the next 12-18 months.   Subject to the necessary approvals from my better half.

  

 

Looking forward to getting it home and on the drive in the next two weeks.

 

 

 

 

[Jake Gully]

More wiring - this is my steering column which is likely Sierra/Scorpio, will try to find some part numbers, but at least I have the connector blocks for this:
 

[Jake Gully]

Pinning this earlier thread on wiring joys for GBS Zero Gen 1 - from Guest Sharky in 2010

 

[richyb66]

This is the wiring for the GBS plug and play loom.

GBS_harness 051516.pdf

[Jake Gully]

Posting this link for anyone looking to 3d print a cowel for the sierra steering column and stalks - not my own work, but will considerably improve the dash.

 

https://cults3d.com/en/3d-model/various/gbs-zero-ford-sierra-steering-column-cover?srsltid=AfmBOoqJdLH-NShd7F3aBjdGOiPAw5btww2oMp6EhFaRbWMLOcE_M_vH

Edited May 18 by Jake Gully

[Jake Gully]

47 minutes ago, richyb66 said:

This is the wiring for the GBS plug and play loom.

GBS_harness 051516.pdf 62.75 kB · 7 downloads

Thanks Richard, very handy though I think my gen 1 wiring may predate this.  Still likely to be some cross overs and it gives a very useful checklist.

[nelmo]

I would recommend the Emerald ECU - expensive but common and so lots of help if you need it. GBS still sell the full wiring loom - again, expensive but if you aren't happy with electrics, worth it to save the hassle. 

I bought the main loom and then made my own engine and dash loom to save cash. 

If it helps, my blog has all the details of my 2015 build:

https://zerolifebuild.blogspot.com

[Jake Gully]

13 hours ago, nelmo said:

I would recommend the Emerald ECU - expensive but common and so lots of help if you need it. GBS still sell the full wiring loom - again, expensive but if you aren't happy with electrics, worth it to save the hassle. 

I bought the main loom and then made my own engine and dash loom to save cash. 

If it helps, my blog has all the details of my 2015 build:

https://zerolifebuild.blogspot.com

Thanks Zelmo.  I did order the emerald ECU and loom on Sunday.   Had to work myself up to it, but definitely seems the right choice - especially to try and nurse me car through IVA emissions testing.  I also quite like the idea of a toggle switch to change mappings on the road and, hey one day I might go mad and get a turbo kit!

 

Thanks for your link - I will read in detail, probably a good few times!

 

Jake

[Jake Gully]

It's been an expensive week!

I have splashed on the Emerald K6+ and GBS loom for the Zetec engine, grill, badges, a pair of 600kg rated trestles (each), a 6x3m garage tent, 18m of black rubber matting, electrical connectors, quick shift and a number of minor bits.  I still need to pick up a conversation with GBS around fixings and other incidentals.  Conversations around powder coating, paints and other supplies to follow. 

 

All in probably looking around £8-9k to complete, which seems a real bargain before factoring in the time and a few required soft parts.

 

However, I received my membership pack and stickers today.  And, at some point in the not too distant future, I will have a great car and lots of practical build experience.   It's a journey!

[Jake Gully]

Had a 20 minute phone call with Steve at GBS today.  Top guy and some really important tips and tricks for parts, build and the IVA.  Even better, he had just dispatched my parcel, so bits in the post, hopefully arriving by Saturday on this bank holiday weekend - I may be going outside for some time....

[Jake Gully]

Quick visit to the store this morning to do some checking and measuring.

Most important job was to remove plugs, squirt some 3in1 into the cylinders and turns the engine.  Had been losing some sleep on this, but no worries and turned sweet as a nut.

Checked I had brought the correct stacking relay mounts - check  

Did a test to remove some of the parted sikaflex seal - nice and easy with a Stanley knife.  New sikaflex 552 and aktivator-205 on order  

Removed stalk switches to check p/ns and age for correct wiring diagrams - sierra 1990

Garage tent arriving on Tuesday, so hopefully will be bringing it home next weekend.