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Posts posted by Thrashed

  1. October/ November 2020

    Now, it has been an age since I even opened the garage door.  The good news is I got through the final exams and managed to pass them all first time.  The down side is that the exams, running the business and a very heavy workload meant the kit has not had a look in.

    The work situation is not likely to slow down any time soon, so I started looking at other options.

    Option 1 - sell the kit as a nearly finished project.

    Option 2 - just mothball the kit work on it as and when I get spare time

    Option 3 - find a 3rd party to finish the kit

    A separate issue and solution has also arisen as we need more office space so one way or the other the kit need to be moved as the garage is getting converted to office space.  The good news is a local friend has a storage unit.  It is on a farm with 24/7 access and only a couple of miles down the road.  It is an old barn that was used to store potatoes.  So, the kit is off to the spud shed!

    This means after loads of consideration I will keep the kit.  All of the other option for a weekend toy just don’t work for one reason or another, although getting back into bikes I very tempting!

    This is when all the stars and planets aligned to answer my prayers.  As you will have seen, our very own Richy B has opened his own business for all things, kits, classic, American and cool!

    As soon as I got wind of this I jumped onto the phone and discussions started to get to the top of the list.  

    Richy has some tidying and organising at the Unit so we have set a date for the kit to get moved over to him in Tamworth to get the kit finished!

    I have given him a very poor scrap of paper with a to do list, but the main part was that Richy has complete licence to do what he sees fit to fix the issues I will have caused and finish the bits on the list. Anyone who knows Richy or has seen his 2B with a V8 will know his attention to detail and skill level so I know the kit will come back better than I could do myself or even imagine.

    No timescale was set so this would allow Richy to run this as a project in the background whilst still working on other paying customer cars.  

    Stay tuned for the car being moved and Richy working his magic.

  2. 26.07.2020

    Been a while since the last update.  The last few months has mostly been faffing about to get the screen sitting perfectly.  This has involved the screen coming on and off about a million times!!

    It turns out the reason it would not sit straight is that the car is not square!  To be more accurate it is the scuttle.  The measurable centre point is around 20mm from eyeball centre.  Weeks of measuring and trying did not work, so i decided to make it look right, rather than being measured right.  Just hope not one takes a tape measure to it!

    After i figured this out, i then fitted the glass for the final time.  I left the rubber trim long at this stage.  This will help when it comes to painting.  I will be able to mask under the rubber, spray the frame and then cut back the rubber for a nice neat finish.

    This is what it looks like now


    Overall I am pleased with the result, but it has been a lot more work that I first thought it would be.

    Next up is to fit the wiper.  First off I started with the wheel boxes.  It all sits reasonable well and sweeps as well as i would expect.  It's not perfect, but for the number of times it is likely to be used it will do.


    The next job will be to fit the wipe motor.  Luckily I have enough space to fit either side of the scuttle, but my preference is the passenger side.  The motor is reversible so once it is fitted it can be adjusted to ensure it pushes/ pulls the correct way.

  3. 18.5.2020

    So a little milestone this weekend.  The bulk of the windscreen frame has been completed.

    It wasn't that bad a process in the end, i was conscious i only get one go, so it had to be right.  Just a bit of time and thought on the best way to do it was all it took.

    Below are a few pictures.  Trying to do it and documenting the job is not easy as you need 3 hands at the best of times.

    First part was getting the side frame and lower rail clamped together.  I used an M4 bolt, drilled the hole at an appropriate angle and clamped it all together.

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    This pulled everything nice and `tawght!.  I played around with which way to feed the bolt and settled on the head inside the lower rail.  This allowed me to countersink the side frame which with a ground down bolt keeps is very low profile to the side frame

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    I was concerned about how much clamping force I could apply.  I wanted to make sure it had enough to hold the glass in place, which is why I went for the bolt, rather than a screw.  I was not happy a screw would have enough threads biting into the frame.

    My first attempt proved I chose well as I managed to bend a bolt tightening it up.

    This was a double edge sword as it proved i had enough clamping force, but also that i didn’t need to use maximum effort to get the result i needed and wanted.

    Next up was to be brave and fit the actual glass!!  I was very nervous and very careful, but it went like a dream.


    I am well happy with the result and fit, so next job was to fit the rubber into the channel and make sure it all lines up.

    I also trimmed the ends of the side frame.  I decided to go with the curve of the lower rail.  


    A bit of lube on the glass and rubber and it all slid together nicely.  The next job will be to pull it all aparts again!  This will be to drill and tap/ helicoil the side frame for the side supports.  I am not brave, accurate or skilled enough to risk doing it with the glass still in, but felt like it needed to be complete so I can fit the car perfectly.

    Once this part is complete I will be able to trim the rubber and cut down the bolts.  Then it will be onto the painting!

    As a side to the windscreen I had a little delivery from Dan.  He was kind enough to mill an EGR blanking plate.  It is just a cover/ beautification plate, but man it looks good.  It fits a treat and really finishes the side of the engine.  It is a shame it is hidden away behind a fuel pipe and wiring as it deserves more of the limelight.

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  4. 3.5.2020

    A little progress this weekend.  The fittings for the brake and clutch lines arrive during the week.  This was a case of screwing them in and nipping them up.  All easy enough and the net result looked good.

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    Next job was to add some fluids!

    I started with the coolant system. The system took just over 7 litres.  I thought this sounded like a lot but when i checked the Haynes Book of Fairy Tales, it suggests that an MX5 system takes 7.5 litres.  The good news is that i have no leaks.  This is without the engine running, but still a good sign.

    Next fluid was the clutch.  The gear stick turret needed filling with oil.  The HBFT suggests that this be filled with 300cc of gearbox oil.  The clutch reservoir was next to get filled.  I also did some research on the fluids.  It suggested the Dot 4 is able to deal with higher temperatures, but the Dot 3 is more resistant to moisture.  I used a Dot 4 fluid.  This was the suggested oil in the HBFT so it seems good enough.

    With fluid in, the next job was to bleed the system.  I turned to the trusty Gunson Easibleed.  This has never let me down and has always made brake bleeding quick and easy.  That was except this time.  The caps that are supplied with the Easibleed are far too small for the Compbrake reservoirs (girling style) which are about 65mm.  The option was to but a cap big enough or a more modern version.  I decided to take the opportunity and upgrade to a pneumatic fluid bleeder.  This will connect to the air compressor and will pull the fluid through the system, removing the air as it goes.  

    In the meantime I went with a bit of pedal pushing.  This `highlighted’ the first connection that i had not done up tight enough.  It is amazing how such a small amount of brake fluid can travel.  5 minutes later, all cleaned up and ready to go again.  This bled much of the clutch, but will finish once the new bleeder arrives.

    Not having enough Dot 4 to do the brakes, i have left this for next weekend when the new bleeder and Dot 4 arrive.

    Next little tinker job was to sort the steering wheel buttons.  I have 2 buttons on the wheel.  The right hand switch is a momentary button, which will be used for launch control and the right hand is mostly likely to be used for a map switch function.  Probably a normal mode and sports mode with flames and pops!

    The momentary button is from when I had the Omex launch control.  One of the pins on the back was broken.  This was probably from when I soldered the previous connections and the plastic became hot and brittle.

    This time i will be using a different method.  I saw this on a youtube video and thought it would fit nicely for my application.  The pins on the back of the buttons are 2mm.  All the usual crimps are too big.  The method i saw was an econoseal pin.

    This then fits in the slot in the middle of the pin on the back of the button.

    The pin then folds over 180’ and is crimped on.  

    A bit of heat shrink and a rubber boot later and that is one side done.



    I will probably hot glue inside the boot as a bit of weather protection as the securing nut for the button is only 2mm thick so not much for the boot to grip onto.

    Just waiting for the other side to turn up and that will finish that job off.

  5. 27-4-2020

    Aluminium tube turned up today, so had a spare hour this evening to have a play.

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    I needed to turn this, a 1.5m length of 8mm OD tube into a tube that followed the engine from the water manifold at the back of the engine along the rocker cover above the exhaust manifold, around the front and then to the expansion tank.

    When i bought the tube i made sure it was 6063T6, to make sure it would form easily.

    I also have a mini tube bender that forms 

    6,8 & 10mm tubes. This is the first time using this and i had no idea how difficult this was going to be.  I decided buying 2 lengths of 1.5m tube was a good idea, one to practise on and then the final piece.

    It turned out not to be as hard as i imagined it would be.  The tool has reference marks for where the bend starts and degrees all the way round to 180’.

    It was just a case of measuring the length and getting to grips with the way the bends are formed but first go i ended up with exactly what i needed.

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    When placed on the engine it looks good even if say so myself.





    I just need to add a couple of rubber lined P clips to hold it all in place and some rubber hose to connect to the water manifold and expansion tank.

    The final part of the plumbing will be the final connection from the thermostat housing to the bottom of the expansion tank.  All easy enough as it is just cutting a bit of 16mm tube and silicone hose to the correct lengths.

    • Like 1
  6. 26-4-2020

    This weekend i was working on the coolant system to get it finished.  Main job is checking the plumbing routes and fitting the expansion bottle.

    The original Fiesta coolant system has a heater in the system.  My car will not have this so needed to find the correct way to plumb the engine without the heater in the system.

    This is how Ford plumbs the system:


    To me this just looked like a jumble of hoses!  I also had the added issue that very few of the hoses fit, now the engine is in a rear wheel drive configuration and my radiator is in a different orientation.

    I needed to find a way to plumb this but still make it work!

    A bit of internet digging and research i came across a good diagram on the Locost builders site.


    This was useful as it showed the water flow path to make sure i had mine plumbed up right.

    The only issue is that it does not show the coolant path for the water to oil cooler.  This was a mixed blessing as i wasnt 100% on using it and the space for running hoses was very limited because of a chassis rail.  Speaking with a few kit owners, running Duratec’s for track days, seem to agree that on the road, the oil cooler is not a major requirement, but much more useful on track days.  The 2 main reasons given have been that the water to oil cooler helps to warm the oil quicker as well as keeping the temps down on track.  As mine is a 99% road car, not having the cooler was an easy option to leave out.  This is easy enough to review if i have issues when on the road.

    With this plumbing now sorted the next decision was the placement of the coolant expansion tank.  Originally i had planned to mount this on the firewall, but i really wanted to keep this area clear for a clean look.

    Finally i decided on mounting it just in behind the radiator in the engine bay. 

    In this location i can make sure it is the highest point in the coolant system, but the added bonus is that the tank will be hidden under the nose cone.  This keeps everything nice and tidy.

    This location then presented a further issue which was i had nothing to mount it too!  The location i want would be in fresh air, so mounts are needed.

    The tank only had two mountings moulded into it.  One is a strap what would allow a 3mm thick piece to slide in and the other is an ovalled M6 hole.

    Having limited imagination and when using 2mm bent aluminium the tank was very wobbly and this was before it is filled with fluid.



    Thankfully Richy B came to the rescue again with a much beefier design.  At first glance, it looks like overkill, but Richy always knows best, so i followed the plan.


    The weekend then involved 8 hours!! To get to the finished state.


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    All in all, i am pleased with the outcome.  It still surprises me how long such a small job takes, but then Stu (The Duck) reminded me about Project Binky, and they have way more brackets than me!

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    All that is left now on the coolant system is the small 8mm tube that runs from the manifold at the back of the engine by the bulkhead to the expansion tank at the front of the engine.

    This is going to be done in one piece which will involve a few 90’ bends with short rubber hose connections at each end.

  7. I would say yes. Have a good read of a workshop or Haynes manual and just take it slow and methodically. Depends on your previous experience and confidence. Plenty of people in here have that will be able to offer help and guidance to members. 

  8. The head work I got a local shop to do but all the assembly and disassembly I did myself. I am reasonable with the spanner’s but no mechanic or engineer and I found it easy enough. Bike carbs were a bargain compared to Webber’s etc. My Dad had Webber’s on an old school Westfield as it was on the rilling road every year trying to keep them in balance. Never had that issue with the bike carbs. 

  9. 12.4.2020

    Today was planned to be a day off.  A few messages with Stu (The Duck), and he convinced me to get off the sofa!  Todays job was basic setting on the ECU.  This would allow us to check the engine will still start after all the wiring and ECU resets.  This was a good hour session, which proved the engine would start and run.  It will need some tweaking as it is rough, but i need to finish the coolant system in order to do this.  Hearing the engine run is always a great motivation, so a spot of lunch and next job was the windscreen!  I have been avoiding this as it feels like a big job.

    I have read Dan’s (Brumster) on RHOCaR and Richards blog (https://richards-gbs-zero.blogspot.com/2013/06/windscreen-prep.html).  Both give very good guides on what to do and how to do it.

    I was lucky enough to `steal’ Dan’s windscreen glass template.  He has a couple of screens 

    made and drew an outline onto cardboard.  Stage 1, cut out the template to shape.


    Dan was even good enough to give me the requirements for the glass type and markings.

    Step 2 was to make a full size replica.  The screen thickness is 6mm so a sheet of MDF, a marker pen and a jigsaw, created this.


    Being sensible, this is likely to be a template I keep for future windscreen replacement, or if someone else needs a template, so i copied the specs onto the MDF.

    Step 3 was to try and make the top rail fit the curve of the screen.  This was easy enough and I added a couple of alignment marks for reference when it comes to final assembly.


    UesOgq6TusDNZ3JS931RkvmAphYljWg5IPycv0AvTPOz7qiMcQtP4KaPyHpo-B9DjN3W7RvEdGqelDL-13eb_grCqWwFVfmBIdab6qBMNmEt-Qy3IijO9DULJvg3ftjIFvi3eNZV  p-EVT0uWrDvzUWfpsLiM4wAp4UDZLENTSaYWjmIiQUAltbmVrMRDwhmESpwFPvyckEMXT7Gb3H6hbqvwBK3XaFrju6GthVHyMcvh2xCBT3FamnhFhHtTKU-f_qi7V-V7linE-18V


    The basic shape was easy enough to form as the main surround is already pre-bent.


    I used the racket strap to keep the tension on the frame sides 

    I offered up the bottom rail, but this is going to take some more research as these are several versions of the same theme when it comes to cutting and securing the corners.

    The most common version is to drill at an angle and screw to secure the side to the bottom.  Richards blog shows using a plate to add a bit of strength and i have been given the idea from Gaz (Midlands RHOCaR member) to use a 90’ plate.  All seem like a good idea and will give the fixings something extra to bit into.

    So, whilst i research the method i will adopt, i couldn't help but trial fit it to see what it looks like on the car.  

    At first i just could not fathom out why the screen looked so wrong!  Must have sniffed too many fumes for the tuning tests earlier in the day!!


    After figuring it out, got the screen on the right way and it doesnt look too bad.


    The rake of the screen looks good when the bottom of the support bracket is horizontal.

    The previous holes for the aeroscreen, should be covered and hidden by the screen, so this will decide the fore and aft position on the screen.

    Final positioning will be left until I have the wipers and demisters, so i can make sure everything fits.

    Next thing was to check the height actually fits me.

    I needed to check sight lines would work for me and that my head is actually behind the screen when I sat in the driver's seat.  I also need to check that i would have enough height for when the surrey top is made.

    This would also give me a chance to check the pedal box now it is in its final position.



    You can see above my head a piece of back conduit.  This is sat as a straight line from the top of the roll bar to the top of the screen, which will be slightly higher yet, once the screen frame is on.  This gives me plenty of headroom, which when I get a surrey top on, will mean it shouldn't feel too claustrophobic.  Also it means i will be behind the screen and out of the wind blast.

    Think i will do a parts needed list and get ordering.  I need to get onto ordering the wipers and demisters.  I also need some adapters for the master cylinders to hoses.  I am sure, once I start looking, I will have loads of bits that I need.  With the lockdown as it is, I just hope I can get the parts delivered.

    I have enough bits to be getting on with in the meantime.  I will shape the screen supports, finish the plumbing, finish tidying the wiring and more.  Lets see what i can get done during lockdown.

  10. 11.9.2022

    Only a couple of hours on the Zero today.  Most of the garage time has been tidying up!  I have 3 `scrap’ boxes.  One for metal, wiring and wood.  The metal box was starting to overflow and get in the way.  I got a bit brutal and threw away some of the smaller and less useful parts.  This means that I can now get everything into one tote box.  The wiring was actually 4 smaller boxes.  Again, condensed this into one box and the wood was tidied up in the corner in a neater fashion.  I also condensed the cardboard i have for my CAD modelling, which has given me a bit more room at the back of the garage.

    I then spend nearly an hour trying to figure out how to fit the remote fluid reservoir for the clutch.  First off I thought about using a spare threaded hole off the coil mounting bracket.  After speaking in a messenger group with the Midlands RHOCaR group, the general consensus is that just one bolt would not be enough and fixing it to the engine was not a great idea due to the vibrations this might cause.

    bJPQcZko8fTcXpJIfMI7vngXQyue58NMIldTspqdy9KDebGMiH7YEVZdNEZsAU-qwwTY7kXbzuWOn3dliM6xALfZDnHTDrQ_oDjDYNWAXmiBffvw8BiCyqZzErZnedg6NM5avvn_  WQ0-cE9qPJoBzjba3AI9P2Pah6JT8r1ZBkRfCSxEO4PQMmfyKmIZjScHFMEb8nRuVsQWzfrlfrVp6Yhnvgkk0ebncgAFIkOSt5Uh1Kh6AH08FjuzpNTOJh76uZZndK-NkD8--9Zn

    U5lobKFy7SjMXBKbacouEU6l7jraHNDhbOtVTjpLChWfPxrmnYeTbdsnahbCfqVCx_xxtP4eCccdqgnrrpLI-H4SjTVF1aVh6fR5jvfOXn3twLyVDyW4JIRGheUkfbbW87z5o7Ye  Go6ZWkPzjbIwda79VCaIT-CVOx8celju6OUKG4VbTrPIVXLPzdYzxg6IoP_id-MaOuhn-vo2LqJ2VMNBhxiGIu8hyN2MeGTNWjAX-6Z3dEPSLQ9zZ2rzXBA25VIjbtsX7YuYAoO0

    The first 2 pictures above are the area I have to work with.  The second 2 pictures were original suggestions.  The option at the end of the pedal box cover on the outside edge would not work as the hose down to the clutch master cylinder would interfere with the steering column.  The second option would cause issues with interfering with the pedals.

    This gave me the idea below.  This would mean a small hole in the battery tray panel, but as it is not likely to be coming off anytime soon, this does not cause any issues to me.

    A couple of Rivnuts and M6 bolts and job done.  The bracket itself was from the original pedal box kit.  It had the bracket which allowed for 3 reservoirs to be connected in a line, so a bit of a shop with the angle grinder and a single bracket was created.


    Not much progress for 4 hours work, but a step forward is progress, so onwards we march.

  11. 10.4.2020 - Good Friday

    So, today was all about the pedal box.  I fixed the footwell end panel which was easy enough other than access.  I had to use my hand riveter as the air riveter would not fit.  Luckily it was only 8 rivets, which by hand was hard enough.

    Next was to figure out the throttle cable.  The pedal box needed a small hole drilling to take the 90’ adjuster.  This then fits to the pedal and is secured with a solderless nipple.

    I then found a nice route for the cable to the throttle bodies.  The end of the cable has a welded on nipple which fits into the socket on the cam pulley.  I used a couple of rubber lined P clips to secure it all in place.

    jxwIqxa-hRmVyMzNRwFbEHVzlso10kknlq-Tg3AjF_A1wATudHBX8dEqSGZvW-XdBs83ayPNK-45revhtPSLmdPFx1nW0bYNgxpN07ybAWRgJY5KMyQweB6PNtRlBn9MguihPk3b Z73pTGzWF7yl1KSsfj1U652ecfOwsOZQhJyt1cVrtSegbIz3BUI0PmwTtwJjY38pql0kqnIAhA3gegiiw8amBSbEv3AciGfMfLcY3dIT0QF7jFb5buAtxYzk1QHF4M2DHGXswSzC

    Next up was to get the pedal box back in.  This was just a case of bolting up the 8 securing bolts.

    Next in was the master cylinders.  As this had already been fitted in the mock

     up, this was easy enough to fit in. Fitting the balance bar was a bit of a struggle.  As the bars that fit to the cylinders did not twist, it meant having to spin the whole cylinder.  Got there in the end, but this was a bit of a faff and i am sure there must be an easier way to do this.





    After fitting up the throttle cable, I had to make a bit of an amendment to the coolant top hose.  This was to get around the throttle cable bracket, as this sits at a specific angle so that the cable pulls straight.

    It just meant a slightly longer aluminium pipe.  I beaded the ends and fitted this to the silicone.

    Not bad a bit of progress for half a days work and with this being the Easter bank holiday weekend, i should be able to get on with a bit more over the coming days 

  12. 5.4.2020

    So, the good news is that the aluminium sheets arrived.  With the world in lockdown i bought twice as much as i needed, just in case!

    I need to make the end panel, which i had already made a CAD (Cardboard Added design) template for!  This was easy enough with a bit of fettling and edge trim to fit closely around the steering shaft.



    Next was to work on the top cover.  The shape is a weird one and has the added issue of the steering column cutting through the top edge of it.

    A few measurements and a bit more CAD and I had a rough shape.

    F72HqrGNHfUE8Dxtnb6tg8xZMtJIYv8xNS_9PahU7-_GfE9_XRsmmAfXPrLLtBdEfmNStSNt2B-jmiPSLge683HZVMH5Mefd0T3IvE5Z0wCauhk_lz1wKS4vlH8n7p8Nl6WvZVaK  I-DwiHWlVSnCuN76WqN8b1yWbiOJBLs3SmW0ivIkrOSaYeeNg5g_-_mULzGm_fGTya9DXQhce6Lc6B9cFJAC6F6vmSMilGY31yy6-neVqJgle9yz_A3iwuk5_QIJwdEzgcymTCV0

    Finding a way to cover the steering column was not so easy.  I ideally wanted something that was just big enough to cover the column, a wedge shape, with no fixings showing.  Sounds easy enough.  

    Ea0y_I3yZguNnB-E3WIzQCEcHlbZngqtOag6tztSVk7OrmSltlDSPSwYZSv5BS9S5KahqcYzk96p48MWmiEsqIM34129iecqPfJLwhorQuOIJyZbx7wu7EpSYZvJr0uGMj7xXm6P  qCGteoP5bWYd6J-pPdg0nov4zXPFIwxrwgCzFc7J4q0SedDGV8beB8B73ucahdnkOVDYEN1xsjvuyNmORXCPLZEC4jQzJu_QMXezS5V3s3FSgw8-2s7YQ17U5sIN21d2npkfqMtF


    Plan 1, was to use some square plastic tube.  This had the right finish as it is gloss black.  Cutting to size and in a wedge shape was easy, trying to bend in a return lip for the hidden fixings, not so much. If you tried to cold bend it it would break, If you tried to heat and bend it the bend was not a tight 90’.  After about half a day of messing about, including trying super glue, I gave up on the plastic idea.  It was just not going to work!

    Plan 2, make it out of aluminium.  This would mean having to wrap it, but as the panel was going to get wrapped, this was not such a big issue.

    The next issue was getting the aluminium into the right shape and with nice tight bends.  To achieve this I have a sheet metal folder.  The big issue was getting the folds in the correct order so that I can get all the bends in the folder.

    Net result meant having to increase the size slightly, but it worked.  A bit of carbon vinyl wrap and a few rivets we have a panel.

    Still a bit of finishing to get some of the air bubbles out of the wrap, but i think it looks OK.

    _NGTMZu_-tbscqhqs8OHIax0XSMrYOT8XKJ83OXhp_iGRwubW5Faju5SctVPziRitULpOIL9wT0nGjnISl_xNURlfSdoFddD-nBvLmvcG3BQiqY3syvrAk06ftkJ67x8G4SqLj2L1yZ0D0jFLAVnEQhv5zKTu_HgyVO5MlHhRtR-IM5rs-ITNIZ_8hpQKY6KnDbSoJhdMZwY29PoHvE0jEHYfV2Kx2rgnrr-Xl09LT5mZuroOExU7kyWlJf6VhrYDOoBt5LrkcyLxqLS  nFjni5KtgT7bllWK_X9o4tXrqZ2lsL1vbyoFKvqeSBpbATr_ExZgelalcRAnqQVIC9yLSfhfvOmEKW1EJ__us5ChF-ARjP6axMIgzBah8iKa2Ujj8xvhDPR4MVwiTJ90U9CY-f1Z

    -JHwdtGAZgwFuDdXEIOltc2phLHNm7Xn65ZkinT19hgYBvUjRldsF2Ksnj3JTEBhqgVmUgaeP9iw4pFr0GnEuF6oOrWokl7uZkyFJop9Oe9TBPinyXkRg7yipiODM_N2CR1JrMf-  oCJ6FL-W6W8sSMeBHg3NlWQlNccOMetgZxMkw3UuR5II9iCQKqNJvR7409EsNb2LFtWcSfIBYRBposWPr7vYZJNFWOOTDQB2wZOU_euWIZQzVQX0QlinYKr7ccqyW5zwo0xDYbYH

    … and the finished item.  Still a few very small bubble, but you can only see then at the right angle in the right light, so as it will be under the bonnet most of the time, this will do.

    blAVICnQMx0v_PxDeLGIbBg0RvxSKH6YjAuZcxRCX5N7hDIVpgNsduSGSrbpfGxPANKcrv1GMzii5_i1cLYRXlDNHG4jCn8cCWzYYoY0NEMjADKCn0fQ3IIqOiHm8vvucm7Y2vkV  kAgkjiLgVA-Pehs5tf9KHpGA8fP65Uo1th7j4kdlC-RbdLPibU33hprCnXPyEb8i5V2ph4fvLOaKfKQAfkrg9wOMcwrNDarscX1shLF7dbNqscY0YnU70q9OB9T6y5_wUJXJXeaW

    Next jobs will be to get the pedal box back in and connect up the hoses and see if they will hold fluid!

  13. 29.3.2020

    So, COVID-19 has proper hit.  Lockdown has started and deliveries are slowing down so this week whilst i wait for the aluminium sheet to arrive, i started on the calibration of the coolant temperature sensor (CLT) and the air intake temperature sensor (IAT).  After the issues with the TPS, i wanted to make sure these are working.  Net result, they are not!!  The ecu is not reading that the sensors are plugged in or exist.  Over the last week I have been working through the wiring to make sure this is all correct.  I tested the wiring and this had continuity all the way back to the ecu.  After finding the dodgy power wire in the ampseal plug i checked and one of the sensor grounds was slightly iffy too.  Unpinned this and reinstalled and this made no difference that i could notice.

    Next step was to test the sensors.  Hot air gun on the IAT and not a thing.  Tried the hot air gun on the CLT and again, nothing??  Next step was to test the sensors themselves.  CLT is easy enough to test.  It just reads resistance, so off the car and into the kitchen.  Sneakily put the CLT in the fridge, whilst SWMBO wasnt looking.  Temperature probe on the multimeter said the air temp in the fridge was 6’ and room temperature is 18’  I pulled the CLT out of the fridge, measured the resistance.  Waited 10 minutes for the sensor to reach room temperature and measured the resistance.  Next was to get a hot reading, boiled the kettle and `plonked’ the CLT in a small jug up to the brass part of the sensor.  Wait a minute or so and measure that resistance.

    This gave me the 3 readings that the ecu needed, but for a standard Ford sensor, this is majorly different to the standard Ford setting in the ECU.  Good news is the sensor works and the readings are in line with what the Haynes manual says for a Duratec MX5 should be.

    Plugged the sensor back into the car and entered the new readings into the ecu.  This made no difference??  I tried just randomly messing with the readings and found that when you get to a low enough resistance reading at zero degrees the temperature would swing from reading 81’ to -18’.  Bit of google and help from a Facebook group and the general consensus is that it is an earthing issue.  Double checked all of this again and there is definitely not an earthing issue.  

    Thinking back over the issues with the ECU and the fact I still don't think I got back the original ECU after having it sent to be checked, as a last resort, I decided to do a full firmware reset.  Take everything back to the factory settings and also upload the most recent version of the firmware.

    This was not overly difficult and only took about 15 minutes to figure out and action.

    Reconnected the ECU and started a new project.  First and easiest test is the hot air gun on the AIT, Hay presto!  The AIT is taking readings.  Next was to put the CLT into a jug of hot water.  Again, getting readings.  Now the kicker is the readings are not accurate.  What is strange is that the resistance readings i took for the CLT don't give the correct readings on the ECU.  Also the AIT with the stock setting does not read below 21’.  This is just a calibration issue, so should be easy enough to figure out.  Just over the moon that I don't have to rip out the wiring loom!!

    Now to get on with the rest of the build!

  14. 22.3.2020

    Managed to buy some 1mm wall aluminium tube.  This was much better and the bead rolled in much easier and without cracking the tube.


    I cut the tube to length and beaded the ends.  All replaced on the engine and hose clips in place.

    All this should be leak free but i still have a few bits to finish on the expansion bottle side, so not the end of this story yet.

    I then moved onto the master cylinders…..

    The original plan was to mount the fluid reservoirs up on the scuttle area,  This was causing plumbing issues and space issues.  Plus it just looked a bit rubbish.

    The hoses from the master cylinders were getting caught in the pedals and the reservoirs themselves were high up and causing clearance issues with the bonnet.

    Plan B was to mount the reservoirs directly to the cylinders for the brakes, but the clutch cylinder is very close to the chassis rail and will have to be remote, which for just the one reservoir is not an issue.


    This all fits nicely with enough space around the reservoirs and the caps fit on easily.

    The next job was to box this all in.  I wanted to keep the fluids away from the pedals, but also my feet away from the reservoirs in case I have a pedal-panic moment.  I don't want to go breaking the reservoir of the cylinder!

    The original plan would not now work as the reservoirs are now in the way.  After a bit of head scratching I came up with a new plan.

    The original panel was on the outside of the chassis rails, but this meant the hoses needed bulkhead fittings.  This means more chances of leaks, which i definitely don't want.

    The better plan was to panel from the inside of the chassis rails.  Good old CAD to check for clearances. And everything looked OK.


    Up next was to make the panel.  This meant removing the pedal box and the cylinders to gain access.

    It was then a case of cutting and folding the panel.

    Then it was a trim and refit until it fitted like a glove.


    Everything is looking good.  I just need to find a way to secure the panel.  I haven't decided if i am going to bond it in plan or make it removable for future access.

    I will then get the pedal box bolted back in and the cylinders back on.

    The top panel will take a bit more creative thought as it will need to clear the steering column.  The original box is not so great and again didn't look good.

  15. 13 hours ago, Peter Bell said:

    You could try annealing the aluminium tube, but be careful it melts quite easily. If you rub soap on the tube and gently heat until the soap turns brown you should be ok.

    Thanks for the tip but actual fixed the problem by buying the correct grade of Ali tube. From the conversation with a local Ali supplier there are 2 grades. One for forming and bending the one that does not!  

  16. 1.1.2020

    Well, first day of the new year and not to bad a hang over from the night before means a bit of garage time.

    The next job is to build back up the calipers with the new pistons and seals.  This was reasonably easy and the kit that i ordered came with everything needed, except new guide pins.  The pins i have are in good condition for a bit of a clean and they were good to go.

    luHGxr_Vbac7fT3zZ5W6t3pd4xNSjJbLhVvum8YVWTXp-2f3ffmJLX9GBPYGdK-viU2_024eoZj_it3vmxKUm0CZcr3sIwEkucKfkgg_ylapsgukej0e-9mEv_MCDOV6uJ8pNrLt rvpy05s_2nFlQI92JPVoaTP_03_ZdADZilzXbFsXDnFotkgxQ0iHZ9RH3q9wDz2FMPOXCmrg_wdHVeVZl2W2FTgarcvTlMAsU31_3-MQv_TKbyiv2QYXs9KiJx0edaA2BoO-5Es-


    The next job was to fit is back to the car.  The sierra hubs had a 10mm hoke for the original calipers but the mondeo bolts are 12mm.  This meant drilling out the hub holes to 12mm.  No going back now!!

    The carrier needed spacing from the hub too, so that the disc sat square.  This was done with washers for now, but I will get some proper spacers made up along with proper length bolts for the final fitment.

    QRQBGvHyHJ9HDWvklAYkREUSiDb9DhGcI85Y6vfp_bArnH3aR_e0CM1ZbjRdk0RFtJ3Z8MA4Hhe-f3-yNpNplJrYaer70AatLlsIhY1iaNNNP96Nzw_uamDBljW2EAxCSShWN4NA  WVcTauqY3kuZH14FE9prOyMwLsDT96fET-JlEazPj-bH4jT1TkXvv-9UsnRV0Ax7bRXX41M8D8N3OF9miv0IrZTokPMt4fQ6Mq6tddNy16a0ZQTX9jWX0AYQYPy1-5xnMerrfK21  gRvB9XzNwAZhvi9uYNDFZ6_7OpzYh4Dgg7Z43rKlgytQthiw3d2xKjR5AsWTyqyiUYm6AXWm3Oqnjk63wbFOiCZJSp5N1NPmUm6v0yzEvNutDUPa5P5VOgy5zo-d0S0r3NiBecAl  0M47e4psXKKTf0Wqe_bU9EFoNx1GGKOo6YtVj_p-Y0K_QLW9LxcXXG9evY1raY6DfdNWJDelRA-MAqdk-zkxF_sP6_FKBAKolMDoRs1Ys4RT7SPwrVbR5NNvxSGhgakADHCpoS-K

    Everything fitted up and the clearance to the wheel is tight but it fits.

    MdrEK0w_LJplkC7E_aMFsddoILSdGZ4Mhn9qPhKAyVWfY00E0scwgUJl-4Jr1DOsQwhNflmZHxw5AHUtDbb-ad31zqKXl4K0O5OfV-l45GIwqdHYHFavo5IoorA5JlY0osLtWQla  b8dbX5mxQjd0fQCfpaQ2sjUOZrcjgnwOxCgkKqkIwXhhzWmE7zWOiMnYH_hDZ5UY1JfJSVszaZgtPUcHEpw-6aK_okQ38LxkwWCpaT03zSS2CFg1JBO_cQObbWauYy8BaA6NfUTc  i_tRf2w96UCmvcsJ_1JM8G3hpnz3jcgKfOn8UduwjtHvwOjBY_HZNBuL1aGK_ZmQRt1gt8Tq8TDS5Y-39FSseBSdXoP2n3prVcgrpBcbEVHlkUXSDmo2QVkV4V3VwXJQJRn45Zu2

    Once i get the spacers and bolts i can go for the final fit.  The passenger side caliper will need a bit of paint touch up as it has got a bit bashed around being fitted.  I will then do the drivers side, but this should be a quick job now i know what i am doing!


    Been a while since i had a chance to work on the car.  Had a half day spare so thought i would get the brakes finished off.

    I have made and cut the spacers.  I made these out of some connector nuts, that i cut to size.  I then drilled out the threads leaving a spacer 14.5mm long and a 12mm hole.

    This allowed the disc to sit right in the middle of the carrier as i had a total of about 3mm clearance. 

    TqMM5b8OVNCIZX5O0N5HO9bYJq6qbMYlhQgi9PdOapXJl6wTkGN_oPqu0MCoZbLBb7EcOKgvpyOVBAiSfccw6M_EpYiU43dpKp6m95UfmYL0DgtyroMM4cbOxzyTVcJRVICeOd-a vh7OFEPKu61i_uvi3lkQs73UW_K4eKuWzxPi63p5LHvDk1I35PMd-U2W6tCG6XTl3JdGjZVvgF1V_pSxhRfUMDx3u0sLYH9lRLPUb4j7dnWPB_-ViMiWtEaVm30iZTIeOQsaPq_y

    uwcF6lNv2AXUAxRLGniU6AREj4uWTlGjsXlm9OXZzY-9AbBBy-uM3ODvEsZjVy3ERKi-GuBRCthZNGt1gaoXL94BC5c64WUqhsKjX8zTI5HGWEbdI-VPhG-rodpldwZHt2ROgUJY 649X54piKpxvlvIWzH5B9SoWuqxcXh0ccjfx19lFz4hla4_Xb5F630eVP2JT9LjRve4SOUofTNw93I5zGkqBb591mqxZ13574kkw5xOeUKAKUzM66Q3mx8UL02m39MgDdd5nPVhy

    All fitted and looks good.  I put an air line in the fluid feed to check the pistons were working.   It locked up the brakes hard enough that i could not turn by hand and nothing is catching or rubbing that shouldnt.  Wont know for sure until its on the road!

    Whilst i had a spare hour i tried to make a start on beading the coolant pipes.  The aluminium pipe i had has a wall of about 2mm.  This made beading very tough and as a result ended up cracking the aluminium and making a right mess.


    To fix this issue i needed a new plan.  Rolling the bead into a 2mm tube was not easy, so the plan is to buy some 1mm wall tube and roll the bead in a more gentle fashion.

    Also the bead is much bigger than it needed to be, so will roll in a smaller bead.

    New tube has been ordered so hopefully plan B works out better.

  17. 17.11.2019

    Managed to get the calipers and brackets sorted today.

    The first part was to get them clean!  They were perfect on the inside, but the outside definitely had a good few years of rust and grime on them.

    I started with a liberale use of brake cleaner.  This with a bit of the air compressor got all the dust and loose bits off.  Up next was the wire wheel action.  It was a bit of a pain but between a drill clamped on the vice with a big wire wheel, a dremel with little attachments to get in the tight corners and a paint removal pad on the angle grinder saw them clean up well.


    1xiIVJ2MgvJoOdmPoylB4rcm2On9F3WT-VezfUsZqA87mtDyS2bCiWshm-x3hVNdXljdpxs4STDUF3xYkQf3plwpq-KpvE2xtdZYPs-pUMeiEXktQ3e5CoBwfM5i8fFC30UUA1HE -jzQNrtB6lYVOE2EOICs-5zcyUijGEUG-iubtQXxrKvVnaKmOgOmDDGKEMrbO-nZzpK2Xs04tETGNFI2_epwttqWqluniYiNeCC_jjnZpSHxd_Ft3I0YOJZkre7qr5mO8HDFIPOs 




    After the wire wheeling is was another brake cleaner bath and drying off with the air compressor.

    I fired up the garage heater as the paint instructions says it should be applied at 17-21’.  The outside temp today was a lovely and warm 6’!!

    Left the heater running whilst having a cuppa tea and also left the paint pot and brakes in the heat stream so that it all warmed up nicely.

    This worked a treat and started the painting process.  The paint applied well and the coverage is very good.  I used the E-Tech brake caliper paint.  The colour choices are very good and one of the colours was perfect for me.

    The first coat was drying nicely in the heat, so I hung these on metal rods.  The instructions say to leave these 30 minutes before the second coat.  By the time I got to the last caliper the 2 brackets had dried enough for a bit of a touch up in a few dry spots.

    I then hung them all back up and i will leave to dry for a day or two and then see if they need a full second coat.

    The initial look is very pleasing.  They have come out much better than I thought and the prep work was worth the effort.

    This is what they look like currently.  The pictures don’t do them justice as they are very bright and shiny.  They will look awesome behind the black wheels.


    VP1avMgz-hqeYWbAsoPLd4Bt33hw1CIslupDRyyhoSm7my8SmRI_efN8PGAr1XoVntKmcM6Cq7duF_HnC628j-uCs7f8VyRkYS-V8VLErpzqFSNxLVuZkza_tTDq5pTq2tDAQsgq odKX_SdCeqQriRIc1FzwWxTK1KfydQpNzgeRK43Tq5LQg5gTRMhyWYcydaaomCIAp4riarriufJIyFZUrrfNK2V1dkNgxRdx40Rm3NX6T5XVrwPtTCo9hmiY6l2e0kkUiG1ESjNg


    With these looking so good, it brings up the next big issue which is that the rear drums are orange, so going to have to do them now!!  I am also thinking of a bit of livery on the calipers in white or orange.  Need to think of something that would look good.

  18. 12.11.2019

    Another spare hour tonight to play car.

    Bit more work on the brakes.  Now i know they fit it is time to get them clean.  First job was to strip them.  They came apart easy enough.

    The carriers slider bolts are in good condition.  These will be reused.  One thing i noticed was the bolts are handed.  They are slightly different as you can see below:


    The smooth looking one fits in either end, but the one with the splines only fits in one end as it is slightly thicker.

    The rubber boots for them are also in good condition, so will be able to reuse them.

    The pistons are in reasonable condition, but for £30 i can buy rebuild kits, that include new pistons and seals, so this will be the way to go.

    The next step will be getting them clean.  I get the feeling this will be loads of degreaser and wire wheel action.  I need to get them good enough to be able to paint and look good with the wheels on.  I have decided on a colour, but that will be a big reveal at a later date!!

    Y7ibDIqgIa4YwNzmhX-X-lz2yc8FX8mLDc3vPGJZLJJJWDlRNLSXEtoMpaDjeQXAyR7Va9P6v66JeaOqw1E4QHznflR8J7uuDWNfIOVi4vAOM3yilQa-Nc06YoRj4_U5jFX83Jtw  XLTC0sLuvy5LUeZkPOB0j71gZ08zyZakABQM5CUYc0QBg_FHeK8EhK9VI3YOY7URzv0XQdF8prGDdYOudVeik2Qm3NkPlzyLvTtPr1FGz-RIvAZp1EFLOq3dDBJmBL0EPQlXRe-W  dXdk4dVGcCAgJKpb1kIFOam2cdQEm6dOCBe7gJmKtzSFIxnE1qYHdMrA8LCEwfZ2a_vhaza00ECbbrbX9-gOG9T-L0VSxF0l7lNx4TKv5YKaeWzmKocMijJ2Veu1_Eq5vy7bNr-R  R0REPHtg3CXyfjGs1JqLRARiRQg-sqc18cWtI1q2yiLS1rwOaR8L4KS6APMzbnHNRld4VyHJCA0B1MKU9MddmqkjtkUPwkEp03NKD7TKv3CSWFQftl9j06ADF90NFYYtN2qCKuJM

  19. 11.11.2019

    So a bit of spare time tonight with the motivation from the weekend, I decided to get my 3kw heater unit up and running.  Working in the garage over the weekend was bloody freezing.  Not sure if its the weather or my age but I was feeling it!  The unit needed a new plug, so swapped it over and it was good to go.  2 hours in the garage this evening with an outside temp of 4-5’ and after a bit I had to shut the heater off as i was getting too hot.  That means the winter working can continue.

    Tonights task was to check the brake upgrade would fit.  The plan is to fit a well trodden path of Mondeo Mk3 calipers, discs and pads.

    I know these will fit as others have used this with success.  I removed the current standard sierra calipers and carriers and offered up the mondeo units.  

    I will need to use some 6mm spacers but they fit.  The sierra carriers fit through the hub with a 10mm hole.  This will need opening out to 12mm as the mondeo carriers use 12mm fixing bolts.


    fbq5NLaZtDiBMNS6Aqzh7_oHNvA5TluHkkrozAtn0pHanfU7ZZaI_d4hE_DBNLJlfLtJIq_S3Vnmh2YQnSmY3mIRrxSgdX5WB3Dc737JWXmHqHd8sl7YKSZlmbkTPxw6vG0-esWc  yqVM3GbOhH2l12YDt3_widpGUw9_4SrLlmPQrTMNjKdjN80NDKSn0SmsCFzJHaMQwkcYqZLRWOYIQr8VQCW8JBToN9BPTkPeRXCk8_dwfDnyldkxKqKaJSi0pWIPtr6zi0vJPvXb

    The mondeo units are so much bigger than the sierra units. 

    YNd2iA4qdRnQQ6B6TZwwvCklzUWRwGKgtFRjwM_hny2w_yT76qY4SEjIYgj0794zUF61M2nB0Lnfp1-UqP-5rXhnlGlz6r_Y-uakMqokt0EhUGpTnwORuo6NS6UlX8AWkwsbNEME2Ngf3ki9muMce2ocYAkjZB0nNvHBHEjEflLEBqOB-pe_iVZl6Pp8tEqoBhLviGYohAtZTwi6At6PfOCYDUTFbg3WWSIihl0672DiNwGBbVYTojfRutO7i6bU4qTOeyCm0_boGXxf 5IU2mgVySUrvpNE3UFVCTadpNVYaRVLRt1-XYTYjRQ5hox6uBQkpbZF16vf6gWkJ2ntqQNW5RhPjvtcVRstaUGg2qCLYWcfM44s_45xbZkNzd4QWPdoQnTyy1AoeyOw0HAZCuHb34XFhbjFc5Wk6Ncp_fi-_r3L_qVqCreRw1oQQQP3C0uHBVtSeHFivQTAPVOuDq7GcKahyuD9fTv6Ylt5FKjiNIZBKzFAKbeAQ-KCjiBuXKj34t2ICwceCniwXeJDLnPmO_AzeDm3V 


    So, now i have confirmed they fit the hubs, I will need to try them with the wheel on to make sure it clears.  It should but will check before moving on.

    Once this is confirmed, I will start the stripping, cleaning and painting process.  Trying to decide on what colour to paint the calipers.  Shall i go standard silver?  Part of me thinks go for a bright colour and i am thinking of going sky blue to match the blue on the body work.  Not making any decisions until the calipers are stripped.  They look a bit scabby at the moment and if they are too far gone, I might just end up swapping them out.  

    I have also made some enquiries about having a heated front screen made.  The company may still have the template from Dan (Brumster), when he had them quote for a screen.  They are currently searching there records to see what they can find.  Failing this they do have a standard Westfield screen pattern, which should be very close to what I need.

    Neil (Nelmo) has offered me an old screen frame that he has.  It has a bit of damage and too many holes in it but will be something i can work with as i plan to have it powder coated, so can fill the holes and prep before hand.

    The side mounts i will probably end up buying from ebay as they all seem much the same and should do the job nicely.

    Once that is all sorted i will then have to sort the wipers.  My current thought is to buy the kit from carbuilder solutions.  It comes with everything that is needed and is brand new.  

  20. 8.11.2019

    Had a half day today and no exams to revise for this week, so chance to have a look at the car.

    Cable tied the loom plug to the ecu. Like magic it seemed to work.  The TPS was talking to the ECU and calibrated.  What i thought was going to be a few hours in the garage was 30 minutes and job done.  

    Stu volunteers to pop over on Saturday and see if we can finally get the engine to run.


    Started the day with a cuppa tea, as got to be in the right frame of mind.  Plus it is bloody cold in the garage, so waiting for the little heater i have to try and take a bit of the chill out the air.

    First job was to check the TPS still worked?  Nope, something had changed and was no longer reading.  Also the fuel pump was not priming.

    So, disconnected the fuel cut off switch from the loom and bingo the fuel pump works.  The main power feed in the loom also seems to be a little bit loose.  It doesnt pull out the plug but with a wiggle the fuel pump primes and everything works.  Next was to check the TPS.  Everything is still wired correctly and the TPS tested correctly.  Only possible thing that Stu suggested was that as i have 2 sensor grounds there was some issue with the earth.  Connected the TPS to the other sensor ground and the TPS springs into life.  It calibrates and reads perfectly.

    So, the next and only item left was to start the engine.  We cranked the engine and it built oil pressure and no oil leak which was great.  The issue was it did not fire?

    After several tries, we noticed that the injectors were not `clicking’.  We checked the spark plugs and we were getting spark.  The fuel was reaching the fuel rail, but was just not getting into the engine.  We ran a logger on the cranking and it showed that the ECU got the initial signal but then dropped out.  We ran the crank logger and this was reading the tooth pattern.

    After several cups of tea and googling we came to the conclusion that everything was working as it should but the ECU was not seeing the crank signal at cranking.  In a moment of clarity, Stu changed the ECU setting to read the crank from before to after and boom, the engine burst into life within a few turns of the starter motor.  OMG, it sounds good.  Admittedly it doesn't have a silencer on it, but it sounds awesome and with a rev it barks like a proper racer.

    Here is a video of the 2nd start as we didn't expect it to start the first time.  Only ran it for a few moments as I have no coolant in it at all, but here is a short video:


    Really happy that it now works.  Just a bit of tidying on the TPS wiring and the rest of the build can continue.  I will get a bit more spare time as we move towards Xmas.  One of the first jobs will be to sort out the garage heater, its just far to cold!

    Thanks goes to Stu for his persistence in getting the issue resolved.  I would have given up ages ago without him.

    Lets see how much more I can get sorted over the next few months.

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