theduck

You've not had much luck have you? Will be worth it when it is on the road! Have put some responses to some of your issues in red below Metered Emissions - the HC reading was 4260 when the max is 1200. The car struggled to run at the required 2,000 rpm it just kept hunting between 1,000 and 3,000. The reading from the garage prior to attempt one was fine, well below the limit. I suspect I have messed up the mixture after the carb rebuild. I would suggest getting the engine setup properly on a rolling road, there is a multitude of things that could need addressing here and this would be best way to find and fix them all. Brake pipe or hose must not be exposed to excessive heat. The car has the original sierra manifold and the exhaust has a heat wrap around it. The servo is close to the engine and heat shield I made is obviously not up to the job (see picture, although the heat shield has been removed). I am thinking about removing the servo all together as described in other posts and then make a bigger heat shield. I removed the servo on mine and did not have a heatshield fitted and not had any issues. Brake warning light - The light on the dash functions with both the handbrake and the low brake fluid level switch. However, the low fluid switch doesn't seem to work. Am I correct in thinking that if I fix the low brake fluid switch and can prove it works by unscrewing the top that will pass? I can test the light from the driver’s seat using the handbrake or do I need a separate switch? Handbrake is fine to test the light, and yes if you remove the cap and the light comes on, that confirms it is working correctly. Headlight aim was out, I must have knocked them as they had been aligned by the garage. They will go out of alignment very easily just driving it a few miles on the road, most IVA inspectors will allow you to align using their equipment on the day

Sounds like a plan.

Road tune Sunday then?

Can confirm you purchased 1 ticket on 30th April.

Just seen on the news that the early may bank holiday, the weekend stoneleigh is normally on, is being moved to the following Friday for 2020 as part of the 75th anniversary VE Day celebrations. I wonder what this wilL mean for stoneleigh next year? https://www.bbc.co.uk/news/uk-48565417

Should be able to download it now

I would check the valve clearances. I had a 1600 that seemed to run well other than was massively under powered and it turned out the valve clearances were a mess.

Lovely looking car

it maintains an equal pressure difference between the fuel rail and the inlet. Are you on a stock zetec ecu or aftermarket? If aftermarket and has been mapped as it is now will be fine without, if it is stock ecu it will run better under cruise and part throttle conditions with it connected.

There should be a vacuum line from the inlet to the fuel pressure regulator

If it is injectors, it would run worse under heavy load, so high revs, accelerating etc. Which fits what you are saying, plus if it is the fuel line breaking down, it could be even though the LP filter is clear. Also LP filters alone arent good enough for fuel injection as they generally arent as fine a filter. As for the R9 fuel hose, I'd still remove some and check it, there was a lot of fake stuff knocking about, even from reputable retailers! Even though it is better than the older spec hoses, its also still not completely ethanol proof, so will deteriorate over time.

Why no high pressure fuel filter? These are critical to stop any crap getting into and blocking your injectors. Do you not what grade your fuel hose is? With modern unleaded having an amount of ethanol in, if your rubber lines are not ethanol safe they can break down fairly rapidly, which combined with no high pressure fuel filter would cause your injectors to become blocked.

I assume you have a monocoque with inboard suspension? In which case around 120lb is recommended.

Yep that sounds right