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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Welcome!

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To my website of my misjudged automotive meddling with a few other odd additional extras thrown in for good measure.
Oval pictures and the oval 'Auto-TaT' logos are links to more pages.

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", "_cid": "s48MCQYojq", "_anchor": "header1-f", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = \"color\")": { "background-color": "@bg-value" }, "& when (@bg-type = \"image\")": { "background-image": "url(@bg-value)", "& when (@overlay)": { ".mbr-overlay": { "background": "@overlayColor", "opacity": "@overlayOpacity" } } }, "img, .item-img": { "width": "100%", "& when (@autoSize)": { "height": "100%", "object-fit": "cover", "& when (@showCardTitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showCardSubtitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showText)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showButtons)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" } } }, ".item:focus, span:focus": { "outline": "none" }, ".item": { "cursor": "pointer", "margin-bottom": "2rem" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding": "0", "margin": "0" } }, ".item-wrapper": { "position": "relative", "border-radius": "4px", "background": "@cardsBg", "height": "100%", "display": "flex", "flex-flow": "column nowrap", "@media (min-width: 992px)": { "& when (@showButtons)": { ".item-content": { "padding": "2rem 2rem 0" }, ".item-footer": { "padding": "0 2rem 2rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "2rem" } } }, "@media (max-width: 991px)": { "& when (@showButtons)": { ".item-content": { "padding": "1rem 1rem 0" }, ".item-footer": { "padding": "0 1rem 1rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "1rem" } } } }, ".mbr-section-btn": { "margin-top": "auto !important" }, ".mbr-section-title": { "color": "#232323" }, ".mbr-text, .mbr-section-btn": { "text-align": "left" }, ".item-title": { "text-align": "left" }, ".item-subtitle": { "text-align": "left" } }, "_name": "features3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Current Projects

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Scimitar SE5
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Race car project. Being stripped of as much weight as possible combined with a Jaguar (Ford) all alloy V6 conversion.

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The 'Black Pudding'
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Made from all the bits nobody wants.
1979 Scimitar SE6a with the first known 3.0ltr Omega V6 conversion (carried out by previous owner).

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Range Rover P38
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Daily driving what some people would have you believe is the worlds most unreliable vehicle.

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", "_cid": "sKTj4l369R", "_anchor": "features3-l", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = \"color\")": { "background-color": "@bg-value" }, "& when (@bg-type = \"image\")": { "background-image": "url(@bg-value)", "& when (@overlay)": { ".mbr-overlay": { "background": "@overlayColor", "opacity": "@overlayOpacity" } } }, "img, .item-img": { "width": "100%", "& when (@autoSize)": { "height": "100%", "object-fit": "cover", "& when (@showCardTitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showCardSubtitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showText)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showButtons)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" } } }, ".item:focus, span:focus": { "outline": "none" }, ".item": { "cursor": "pointer", "margin-bottom": "2rem" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding": "0", "margin": "0" } }, ".item-wrapper": { "position": "relative", "border-radius": "4px", "background": "@cardsBg", "height": "100%", "display": "flex", "flex-flow": "column nowrap", "@media (min-width: 992px)": { "& when (@showButtons)": { ".item-content": { "padding": "2rem 2rem 0" }, ".item-footer": { "padding": "0 2rem 2rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "2rem" } } }, "@media (max-width: 991px)": { "& when (@showButtons)": { ".item-content": { "padding": "1rem 1rem 0" }, ".item-footer": { "padding": "0 1rem 1rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "1rem" } } } }, ".mbr-section-btn": { "margin-top": "auto !important" }, ".mbr-section-title": { "color": "#232323" }, ".mbr-text, .mbr-section-btn": { "text-align": "left" }, ".item-title": { "text-align": "left" }, ".item-subtitle": { "text-align": "left" } }, "_name": "features3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Past Projects

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Escort Upgrades
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Technical and modification guide to the Mk3 Escort using parts from contemporary Fords of the era, plus a 2.0ltr Zetec. 

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Cosworth Cortina
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1982 Ford Cortina 2.0 Ghia.
Uprated front brakes.
2.9 Cosworth BOA V6.

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Project: Bratwurst
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1992 BMW525 Stripped and race prep'd on a shoestring to compete in the 2010 PPC magazines £999 challenge.

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", "_cid": "sKTjUwn5hD", "_anchor": "features3-m", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = \"color\")": { "background-color": "@bg-value" }, "& when (@bg-type = \"image\")": { "background-image": "url(@bg-value)", "& when (@overlay)": { ".mbr-overlay": { "background": "@overlayColor", "opacity": "@overlayOpacity" } } }, "img, .item-img": { "width": "100%", "& when (@autoSize)": { "height": "100%", "object-fit": "cover", "& when (@showCardTitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showCardSubtitle)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showText)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" }, "& when (@showButtons)": { "height": "(@imageHeight * 100px)", "object-fit": "cover" } } }, ".item:focus, span:focus": { "outline": "none" }, ".item": { "cursor": "pointer", "margin-bottom": "2rem" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding": "0", "margin": "0" } }, ".item-wrapper": { "position": "relative", "border-radius": "4px", "background": "@cardsBg", "height": "100%", "display": "flex", "flex-flow": "column nowrap", "@media (min-width: 992px)": { "& when (@showButtons)": { ".item-content": { "padding": "2rem 2rem 0" }, ".item-footer": { "padding": "0 2rem 2rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "2rem" } } }, "@media (max-width: 991px)": { "& when (@showButtons)": { ".item-content": { "padding": "1rem 1rem 0" }, ".item-footer": { "padding": "0 1rem 1rem" } }, "& when not (@showButtons)": { ".item-content": { "padding": "1rem" } } } }, ".mbr-section-btn": { "margin-top": "auto !important" }, ".mbr-section-title": { "color": "#232323" }, ".mbr-text, .mbr-section-btn": { "text-align": "left" }, ".item-title": { "text-align": "left" }, ".item-subtitle": { "text-align": "left" } }, "_name": "features3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Technical Guides

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Ford 2.0ltr Zetec
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Preparing the ever popular engine from the Mondeo for transplant.

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Ford 2.9 Cosworth BOA V6
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Quad cam 24 valve cologne based lump from the range topper Granada Cosworth.

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Jaguar 3.0ltr AJV6
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All alloy 3.0ltr V6 as found in the rear wheel drive Jaguar S-type (the re-dressed Lincoln, not the original).

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In-Tank Electric Fuel Pump
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Fitting a modern high pressure electric fuel pump assembly into an old fuel tank.

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Bosch K-Jetronic
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A simplified guide to the workings of the famous Bosch K-Jetronic mechanical fuel injection system.

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DH106 Comet XS235 'Canopus'
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She was the worlds last flying example of the worlds first ever jet airliner and I used to maintain her in her final years of service.
Photo library of her more intimate areas just before her final flight to retirement in '97.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
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De Havilland 106 Comet 4c
XS235 'Canopus'

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Photo archive of what was the worlds last flying example of the world first jet airliner. I maintained her for her final years in service. The following photos were taken with permission following her decommissioning, shortly before her final retirement flight to Bruntingthorpe.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Flight Deck Entrance and location of Fwd Galley (never fitted)
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Looking aft from missing fwd galley position. Notice no overhead storage (never fitted)
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Also visible are:
Canberra WT308?
Comet 4 XV814
Chieftain ZA622
Tornado ZA326
Met Herc XV208 'Snoopy'
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Looking aft from central bulkhead towards missing aft galley (never fitted). Commercial aircraft would have had electric heating under the (missing) carpet.
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View off area of missing aft galley (never fitted). All that is present is one section that provides kitchen facilities. Double doors lead to wardrobe and on to rear dome freight bay.
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Stbd rear toilet (Port similar)
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Gallery with Popup Slider

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Battery Bay

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Gallery with Popup Slider

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Fwd Freight Hold

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Looking Fwd. Note the additional power socket. This was in addition to the standard ground power connectors to allow connection to different available ground power sets around the world.
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Looking aft. Full of rotary inverters to provide power requirements of the various trials equipment on board. These made quite a noise when they were all running!
Also note the detachable wandering strip light that has been fitted in addition to the standard freight hold lighting.
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", "_anchor": "gallery5-2j", "_isUserblock": true, "_cid": "sKX40Ic2Jl", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 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Hydraulic Bay

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Looking fwd from above. Visible are three of the four hydraulic system reservoirs. I painted the coloured squares on them to aid identification.
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Port side viewed from below. Visible are two of the accumulators and the 'Red' system electrically driven pump.
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Stbd side viewed from below. Visible are more accumulators, two isolation cocks in the foreground (green and Blue systems) and behind them the four flow sensors (one for each system).
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Stbd side viewed from above giving a clear view of the four flow sensors.
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Aft wall of the hyd. bay with clear view of one of the cabin pressure control valves. In normal operation the cabin is constantly fed pressurised air from the conditioning system and the two pressure control valves control how quickly the air is allowed to bleed out of the cabin.
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Centre 'Split Flaps' Jack Bay

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This single very large jack operated the split flaps located under the jet-pipes each side. The flaps were moved by the thick cables via pulleys and bell-cranks.
Also visible is the lower beam of the centre section rear spar and the join with the Port wing rear spar.
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This area is usually filthy. I spent a couple of days cleaning it all out so that I could see what I was actually looking at during inspections.
Also visible on the aft wall are the output levers from the Aileron Servodynes that again use thick cables via pulleys and bell-cranks to move the ailerons.
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Aileron Servodyne Bay

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Viewed from above (cabin floor) looking fwd.
This is what those two big leavers mentioned in the previous photo are connected to.
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Port side with the fourth Hydraulic Reservoir (Yellow system) in view.
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Stbd side with Yellow system electrically driven hydraulic pump in view.
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Looking aft. This is the second cabin pressurisation control valve.
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Odd bits

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Nose leg looking fwd.
The black cannisters on the upper right are full of silica crystals and are plumbed into the flightdeck windows to prevent condensation between the panes.
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Stbd main undercarriage (viewed from outboard).
Number 4 engines door is open in view, the little red square in the door being the fire extinguisher access panel for the ground crew fire lance.
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Access door under no. 3 Intake looking inboard.
Visible are two pairs of hydraulic ground connections for connecting an external hydraulic rig. The Hyd. bay is the other side of that skin. The 'roof' of this bay is the intake skin. Visible to the left is the front spar.
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Access door between no.3&4 intakes looking inboard/fwd. This is one of the cold air units for the cabin conditioning system. It is part of the cooling system for the hot air bled from no.3&4 engines compressors. This is what is behind the small grill between the two engine intakes.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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RR Avons

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No.4 ECU (Engine) looking outboard.
The big black pipe is the fuel supply pipe. Also visible is the engine driven hydraulic pump (light grey), the red fire access panel in the door as seen previously, the generator (big black thing near the top of the photo) and the funny looking red thing is a mechanical fuel cut off leaver. In the event of a wheels-up landing the guard breaks away on contact with the ground and the lever is pushed backwards shutting off the emergency fuel cocks to the engines.
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No.3 ECU looking inboard.
Big black fuel supply pips, engine driven hydraulic pump, the oil tank (top left with sight glass) and also visible in the same area are the fuel cock and throttle control rods (one black one yellow).
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery4", "_sourceTheme": "mobirise5", "_customHTML": "
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Boscombe Down Families Day Circa 1995

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This sequence of photos have not been doctored and the camera (35mm film SLR, this was the 90's!) was kept horizontal throughout so that last photo is genuine.

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", "_anchor": "gallery4-2p", "_isUserblock": true, "_cid": "sKXuSAnbdF", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Title

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In 1997 'Canopus' left Boscombe Down on her final flight into retirement at Bruntingthorpe in Leicestershire where up until recently (due to a change in use of the airfield) she used to carry out high speed taxi runs along the runway.
She is maintained by a team of volunteers and their efforts can be followed on their facebook page linked below:

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'Canopus' facebook page
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\n \"Mobirise\"\n

\n Text

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Bosch K-Jetronic

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\n A simplified idiots guide (as written by one) to the operation of the Bosch K-Jet mechanical fuel injection system.
I'll apologise now for the fuzzy images. I didn't draw them like that, it has happened during conversion to the required file format.

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\n LEARN MORE\n LIVE DEMO\n
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\n General Overview

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Although it's name suggests that it may operate under electronic control, the K-Jetronic injection system is purely mechanical in operation. It is in fact one of the simplest mechanical fuel injection (MFi) systems around as unlike many other contemporary MFi systems it does not incorporate any mechanically driven parts. Instead, it uses mass airflow to meter a constant flow of fuel to the injectors making it a continuous injection system. There are some additional parts that are electrically operated that deal with cold starting etc.. but the primary operation of the system is purely mechanical.\n
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The main system consists of the following:\n
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Pressurised Fuel Supply System
Fuel Pressure Control Valve
Fuel Metering Unit
Injectors
Air Bypass

Plus the cold start and warm up system

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\n Pressurised Fuel Supply System

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The job of the fuel supply system is simply to provide a constant supply of fuel to the metering unit but at a stable rate. It consists of four components: Fuel Tank, Pump, Accumulator and Filter.

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\n Pressurised Fuel Supply System

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Fuel Tank

The fuel tank doesn't need much explanation other than it has the usual outlet at the base of the tank to feed the external electric pump and a return for excess fuel sent back by the main system.\n
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\n High Pressure Electric Fuel Pump

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\n The fuel pump is an electrically driven self contained device that is mounted close to the fuel tank.Fuel pump output is approx 75psi.The pump is actuated by the fuel pump relay.

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\n Fuel Accumulator

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\n The fuel accumulator is necessary to ensure a steady stable supply of fuel to the metering unit. It is basically a small spring loaded reservoir that is half filled by the fuel pump against the pressure of the internal spring and effectively dampens out any pulsing effects from the fuel pump. It could be thought of as a kind of fuel filled balloon.

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\n Fuel Filter

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\n The final item is the filter and is also pretty self explanatory.

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\n Put it all together and you get the
Pressurised Fuel Supply System.

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\n Fuel Pressure Control Valve

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The fuel being presented to the metering unit from the supply system needs some measure of control to keep it at the correct pressure. This is achieved with the fuel pressure control valve.The valve is built into the side of the main metering unit and comprises of a simple plunger and spring arrangement. The spring tension is pre-set with adjustment at the factory being achieved with the use of shims under the spring.

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\n As the fuel pressure entering the metering unit overcomes the spring the plunger is pushed off it's seat opening up the return passage to the fuel tank. When fuel flow demands are low the excess pressure will hold the plunger far off its seat. As the fuel flow demand increases and the system pressure starts to drop the plunger is pushed towards its seat by the spring against the reduced fuel pressure reducing the bleed off until equilibrium is restored.. This results in maintaining the correct fuel pressure to the metering unit as less fuel is now being bled away.

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Fuel Metering Unit

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This is the main component at the heart of the system and as with everything else it's operation is pretty simple. It adjusts the amount of fuel flowing to the injectors by a direct mechanical link to the amount of air flowing into the engine. It comprises of two parts, the fuel metering device and the air flow sensor. Both of these two items are completely mechanical and will be looked at in turn.

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Fuel Metering Device

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\n The general layout and operation of this device is best described by using diagrams. Remember that the diagrams are simplified to aid explanation but as you won't ever be taking the unit apart the minor detail changes do not mater.

The picture shows a very basic diagram of the Fuel Metering Device located on the large Fuel Metering Unit. As can be seen, it has a fuel inlet to receive fuel at a controlled pressure from the Fuel Pressure Control Valve. It also has the supply lines leading away from it to the individual injectors. Finally it has a Fuel Metering Plunger.
This component is at the heart of the Fuel Metering Devices operation.

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The Fuel Metering Device houses a number of chambers, one for each injector. The above picture only shows two of these chambers for clarity. The chambers are split through the middle by a metal dividing plate giving an upper and a lower section. The lower sections are fed pressurized fuel via internal passages. The upper sections are connected to the Injectors.\n
Now, in order for the fuel to get to the injectors, it must somehow get past the metal plate to get to the upper section of it's respective chamber. This is where the Fuel Metering Plunger comes in.

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\n The plunger has a number of grooves in it, one for each injector, or more correctly, one for each chamber. It sits in the centre of the Fuel Metering Device in the middle of the four chambers. Each chambers upper and lower sections are connected to the plunger via passageways that line up with each of the previously mentioned grooves. It is these grooves that allow the transfer of fuel from the lower section of each individual chamber to it's corresponding upper chamber.

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The further into the unit the plunger is moved the more of the groove is exposed to each chambers passage and so the rate of fuel flow is increased.\n
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So we now know that the rate of fuel flow to each injector is controlled by the position of the central Fuel Metering Plunger. But what controls the position of the plunger? It's time to look as the Air Flow Sensor.

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Air Flow Sensing Mechanism

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The airflow sensor mechanism consists of a lever pivoted at one end with a counter balance and attached to a large circular plate at the other. The circular plate is positioned in the shallow end a conical tube, the larger end being attached to the engines inlet manifold via the throttle butterfly. The other side of the tube below the plate is open to atmosphere via the air filter. Just next to the pivot on the lever is a contact point that acts on the plunger in the middle of Fuel Metering Device.

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\n Now, in order to allow for a certain amount of adjustability, the contact point on the lever for the fuel metering plunger is adjustable as shown below. However, it is factory set on a rig and should not be played with.

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The whole assembly is mounted in the Fuel Metering Unit box as shown. The Fuel Pressure Control Valve and the Fuel Metering Device have been simplified for clarity.

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Now, this next bit is important. It is not the pressure of air rushing in pushing up on the bottom of the plate that makes the arm swing upwards on it's pivot. It is the drop in air pressure above the plate caused by the vacuum of the engine sucking in the air in the inlet system that causes it to rise. As it does rise it pushes the Fuel Metering Plunger further up into the Fuel Metering Device uncovering more area of the grooves to each of the passages to the upper sections of each chamber, thus allowing a higher rate of fuel flow to the corresponding injectors.\n
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Now you might be thinking \"Why doesn't the plate just go all the way up each time?\" There are two reasons for this, firstly the fact that the metering plates is in a conical tube means that the further up it rises the larger an area of bypass around the edge of the plate is opened up. Secondly, the Fuel Metering Plunger itself has an opposing force applied to its top end supplied by fuel pressure. A tapping from the internal fuel passageways in the Fuel Metering Device supplies fuel pressure to the top side of the plunger. Of course if it was just subjected to full fuel pressure then the airflow sensor mechanism would never over come it. Therefore the fuel pressure is bled away through a restricted orifice back to the return line.\n
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So we have the force of the airflow sensing mechanism trying to push the plunger up to increase the rate of fuel flow and a restricted fuel pressure bleed acting on top of the plunger trying to resist upwards movement. This results in the plunger finding it's point of equilibrium where the opposing forces match. But what changes the amount of influence that the airflow sensing mechanism has on the position of the plunger? Well, quite simply as its name suggests it's the amount or rate of airflow through the conical tube. But what effects this rate of airflow through the tube? Well, one is the RPM of the engine. More RPM results in a higher rate of airflow to meet the demands of the engine as it draws in more air. There is of course something else involved though, something that gives us control over the engine. The Throttle Body.

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Throttle Body

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\n The throttle body is basically like a tap that controls the amount of air available to the engine. It is mounted directly onto the end of the plenum chamber on the inlet manifold and contains a simple but accurately fitting butterfly valve.

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\n In order to provide a degree of adjustability for the idle speed a small air bypass is incorporated into the throttle body with an adjustable restrictor. This allows just enough air to pass round the closed throttle butterfly valve to maintain idle running speed of the engine.

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\n The open end of the throttle body is connected via a large flexible rubber pipe to the large open top of the conical tube on the Fuel Metering Unit. Thus the whole basic package resembles that shown.

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\n You can see we have now also added the Fuel Injectors to there respective fuel lines. The injectors are purely mechanical and very simple. They are not pulsed open and closed like electronic injectors in modern EFi systems, as already stated this is a purely mechanical system. Instead they simply open as soon as a high enough fuel pressure is applied to them to overcome the internal spring loaded valve. This ensures that a high enough pressure is present to achieve the correct spray pattern through the injectors nozzle and also prevents fuel from dribbling out of the injectors when the engine is switched off. There is of course no sequencing system on this injection system so once the engine is running fuel is constantly being sprayed from all four injectors regardless of what stage of the four stroke cycle each particular cylinder is at. The amount of fuel being sprayed is of course metered so that when the inlet valve does finally open the amount of fuel sitting behind the valve in the inlet tract is correct for that charge.

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\n So now by adding the supply system we nearly have the full basic set-up.

There's just one more thing to add, the Air Bypass Valve.

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Overrun Shut-off Valve (Air Bypass)

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The overrun shut-off valve is an add on to get around an inherent problem with the basic system.When the throttle butterfly is suddenly closed (by you taking your foot off the accelerator when changing gear etc...) the airflow sensor plate tends to hang in the air whilst the air in the inlet system continuous to pass by to fill the depression or vacuum in the inlet trunking between the airflow meters plate and the now closed throttle butterfly. This of course holds the Fuel Metering Plunger in the raised position resulting in over fueling and possibly stalling of the engine.

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\n To get around this problem, an air bypass valve called the Overrun Shut-off Valve is fitted. This is plumbed in between the bottom side of the airflow metering plate and the trunking at the top side of the metering plate. It opens whenever the throttle is closed to allow direct access for air trapped below the airflow metering plate to get past and fill the void in the inlet trunking.
This valve is a simple solenoid valve that is either open or closed with no in between settings. It is normally in the closed position sealing off the bypass but is activated open by a small switch on the throttle body that makes contact whenever the throttle is fully closed.This may seem at odds with the components name 'Overrun Shut-off Valve' but it effectively shuts off the fuel supply by causing the airflow sensor plates to drop back to its idle position.

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\n To put it all into context, here it is fitted.

So there you have the basic system. Fuel from the Fuel Tank is pressurized by the Fuel Pump, passes through the Fuel Accumulator which smooths out any pulsing effects from the pump that would upset the operation of the metering unit, and from there is routed through the Fuel Filter and on to the Fuel Pressure Control Valve. This supplies a set pressure supply to the Fuel Metering Device, the excess being routed back to the fuel tank.The Fuel Metering Device distributes fuel equally to each of the constant flow injectors at a metered rate determined by the position of the Fuel Metering Plunger. The position of the Fuel Metering Plunger is controlled by the position of the Air Flow Sensor that reacts to the differing pressures and rates of airflow in a conical section of the inlet tract. Airflow through the inlet tract is controlled by the Throttle Body and an Overrun Shut-off Valve is fitted to induce the rapid resetting of the Airflow Sensor Mechanism to it's idle position whenever the throttle is fully closed.\n
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There is of course a bit more to it than that though, this basic system may be fine for normal running but there's the cold start and warm up system to add to it yet.

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\n Cold Start and Warm Up System

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As most older readers will know (showing my age now as well), engines equipped with a Carburetor (google it!) came with a device to assist with cold starting known as the 'choke'. The choke was a simple affair that did two things. First it opened the main throttle butterfly via a cam arrangement to increase the airflow and so power setting into the engine. Secondly, it simultaneously closed a second butterfly valve upstream of the main throttle butterfly causing a restriction to the incoming airflow. Without getting too technical, what this did was increase the amount of 'vacuum' being felt on the jets in the carburetor drawing more fuel out than would normally be drawn. This resulted in a richer mixture.\n
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So the results of its actions were to increase the amount of basic air/fuel mixture entering the engine by slightly opening the throttle and to then richen the mixture by increasing the amount of fuel entering compared to the amount of air.\n
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The Cold Start System does pretty much the same thing, it just does it in a different manner. We'll start with increasing the amount of basic air/fuel mixture entering the engine. This is achieved with the help of the Auxiliary-Air Device.

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Auxiliary-Air Device
This is basically another air bypass valve mounted alongside the throttle body, only this one is progressive in operation and temperature controlled. At first glance you could think it could be compared to a modern Idle Speed Control Valve but its operation is very different.\n
I'll start off with explaining what it does first as it's very simple. By providing a bypass route around the closed throttle butterfly it allows more air to enter the engine. This is just like the cam on the old choke mechanism cracking open the butterfly valve in the old carburetor. This increase in air flowing into the engine is of course felt by our old friend the Airflow Sensing Mechanism in the Fuel Metering Unit. This starts to lift, pushing up the Fuel Metering Plunger and proportionally increasing the fuel flow to the injectors. So there we have the first part completed, the increase of the basic air/fuel mixture entering the engine. Here's how it works:

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The valve consists of a sliding gate valve controlled by a bi-metalic strip. Now, for those who didn't pay enough attention in science class, a bi-metalic strip is quite literally two strips of metal stuck back to back. The two strips are of different types of metal with noticeably different rates of heat expansion. This means that as the bi-metalic strip heats up, the differing expansion rates of the two metals cause the strip to bend as one expands more than the other. These strips are commonly found in kettles where the heat of the steam from the boiling kettle causes a bi-metalic strip to bend and switch off the power.

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Now, in the Auxiliary-Air Device, the free end of the bi-metalic strip is attached to the gate valve. In its cold state with the strip straight, the gate valve is held fully open giving full extra airflow through the bypass. But as the strip starts to warm up and so starts to bend, it moves the gate valve towards the closed position. By the time the strip has reached normal running temperature the gate valve is fully closed blocking all airflow through the bypass.

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\n So what causes the bi-metalic strip to get hot? The strip is heated by an electric heating element inside the unit. This element is activated on engine start and so starts to heat the bi-metalic strip straight away. It does however take time for the strip to expand and close off the gate valve. The Auxiliary-Air Device is also carefully positioned so as to be exposed to the general heat soak of the engine which will also cause expansion of the bi-metalic strip. This means that if the engine is already warm on starting then the Auxiliary-Air Device already be closed.

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Here it is added to the system.

Now we need to richen the mixture. But if the fueling is being controlled by the position of the Fuel Metering Plunger within the Fuel Metering Device, and that itself is controlled by the Airflow Sensor Mechanism, how can we richen the mixture without further increasing airflow? Well, there are two ways actually.

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Warm-Up Regulator\n
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Going back to that Fuel Metering Plunger within the Fuel Metering Device, if you remember it is pushed up by the Airflow Sensing Mechanism to increase fuel flow with increasing airflow. Now, opposing this force and maintaining some form of control over the Airflow Sensing Mechanisms influence on the plunger was a fuel pressure tapping that returned to the fuel tank through a restictor. How about if we reduced the pressure of the fuel above the plunger to allow the Airflow Sensing Mechanism to push it up further for any given rate of airflow? It wouldn't be hard to do, you'd just have to have less of a restriction in the return line to the tank to allow the pressure to leave quicker. I think it's time to take a look at the Warm-Up Regulator.

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\n Now the observant amongst you might notice a few similarities between this and the Auxiliary-Air Device. That's because it is extremely similar to the Auxiliary-Air Device. The only difference between the two is that this device slowly closes off a fuel bypass as opposed to an air bypass. Well that's not quite right, it never closes off fully, it just reduces flow to a predetermined minimum setting.

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\n Just like the Auxiliary air device it has a bi-metalic strip to do the work which is electrically heated on starting the engine.

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\n It is also strategically located on the engine so as to be exposed to the effects of heat soak from the engine which also causes the bi-metalic strip to bend as the engine warms up.

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So that's how it works, but how does it fit in with the Fuel Metering Device? Simple, it replaces the restrictor in the return line to the tank from the top of the Fuel Metering plunger thus:

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Wow, we're almost there. Just one more bit to add now. You see, even though the Warm-Up Regulator performed fine whilst the engine was warming up, the engine still needed a fuel boost for initial starting when cold that the Fuel Metering Device just could not provide in anything like a controlled manner. In the old days of carburettors that were common place when this system was developed you could give the accelerator pedal a couple of pumps and the accelerator pump within the carburettor would have supplied that extra boost. But there is no accelerator pump on an injected engine, all you are doing is opening the throttle butterfly. Therefore there was only one thing to do, add an extra fuel supply!\n
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Cold Start Valve\n
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The Cold Start Valve is merely an extra fuel injector and is rather rudimentary by todays standards. It is mounted just behind the Throttle Body in the entrance to the Plenum Chamber and pre-primes the air entering the cylinders with a mist of fuel. Unlike the main injectors this one is electronically triggered. It still isn't pulsed like modern injectors, instead it provides a steady flow until the electrical supply is removed. It receives its supply of fuel from a tapping from the main Fuel Metering Unit.

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\n The valve is electrically activated as soon as the starter motor is energized to start the fuel flowing and from then on is controlled by a thermo switch in the engine block so that when the engine passes through a pre-determined temperature as it warms up the injector is de-energised. This thermo switch is nothing more than yet another bi-metallic strip only this time it is merely breaking a circuit just like the one that switches off your kettle once the water has boiled.

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So lets add it to the big picture and see the final piece of the jigsaw puzzle slot into place!

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", "_anchor": "content5-23", "_isUserblock": true, "_cid": "sKUsRGlS1m", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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So there we have it, the basics of the wonderful Bosch K-Jetronic mechanical fuel injection system. The components themselves do of course differ slightly from the pictures I have drawn but the basic principals are the same.

I hope you find this useful and that you feel more confident about the workings of your K-Jet system because of it.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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If you are not familiar with it this is a magazine for people who aren't afraid to get the toolkit out and modify their cars themselves to make them go quicker. As the tag lines imply, it's not a magazine for chavs or trailer queens.

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After having bought the magazine regularly since issue one I was offered a position as a 'Staff Cars' writer in 2017 and have been boring people with my ramblings on a semi-monthly basis ever since.

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www.PPCmag.co.uk

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\n Unlimited Sites\n

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n 1982 Ford Cortina 2.0 Ghia

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I bought this car in 2004 not long after meeting my future wife. It was in very tidy condition and is one car I regret altering and eventually selling unfinished as project Wife & Kids took over.

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There were two main projects pursued on this vehicle, click on the photos to be taken to the relevant sections:

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\n Cosworth 2.9 BOA V6

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\n Drops straight in!.... almost. Then you have to decipher the wiring...
This section is mostly applicable to any vehicle but was carried out on this Cortina so all of it is relevant.
With hindsight I wouldn't have done it. This engine is too heavy and spoils the handling. I would have gone for a modern four cylinder and 5-speed gearbox. Or if I were to do it now, the all alloy Jag V6 I'm fitting to the yellow Scimitar.

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Front Brakes Upgrade

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\n Contemporary bakes upgrade using Capri 2.8i vented front discs and Granada mk2 front callipers. 

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The engine conversion was a bit too ambitious at the time considering the limited time and funds available due to bringing up a young family. Coupled with the fact that the car was not at home and so could not easily be worked on ad-hoc the project dragged on over a considerable period of time during which the car started to deteriorate. For this reason, once the actual engine conversion was complete and it was capable of moving under its own new power, I put it up for sale so that someone with more time available could finish it off.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Ford 2.9ltr Cosworth BOA

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This engine is a development of the 12 valve 2.9ltr EFi Cologne V6 as found in the later Sierra's and Granada's. The engine was apparently initially developed for motorsport use in the Pro-Sports 3000 single seater series by another tuning company called Brian Hart Ltd. Cosworth it turns out bought the rights to this company in 1987 thus inheriting the engine development program. The engine was then detuned and domesticated before being slotted into top of the range mk3 Granadas in an attempt to take on the BMW 5 series. The reason behind the de-tuning of the engine was down to traction problems. The engine was never fitted to any other model and was always attached to a modified electronically controlled version of the Granada V6 automatic gearbox. Because of this, the engine is set up to favour this transmission and it is said that there is a noticeable increase in power and torque above 3,000 revs.

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\n \"Mobirise\"\n


Power - 195bhp @ 5750rpm\n
Torque - 191lb.ft @ 4500rpm\n
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Although based on the 12valve 2.9ltr Cologne V6 there are no interchangeable parts with the exception of the main crankshaft bearings (not including the thrust bearing). Even the block casting is different, apart from the obvious lack of push-rod openings the Cosworth block features additional and beefed up internal webbings to increase rigidity.

It is not without its own problems though. These engines are prone to wearing out their timing chain 'blade tensioners'. These are made from nylon and wear over time, often ending their careers by eventually snapping in half. All the debris from the wearing forms a sludge which then goes on to clog up oilways causing oil starvation. Replacement parts are available, though not from Ford, so a web hunt is required. Parts aren't particularly cheap either to replace the tensioners including all required gaskets etc... Also, be careful if you ever need to remove the rocker covers as the rubber seals are bonded to the rocker covers and if you damage them beyond re-use (quite likely if they've never been off since the engine was assembled which they probably haven't) you'll have a new headache to deal with.

This Cosworth engine, named the BOA, was further developed itself later on to create the BOB. This newer engine featured among other things a re-designed plenum, revised cam profiles, a different timing chain arrangement and a variable resonance induction system. It also featured a new engine management system which incorporated the 'PATS' system which is a security/immobiliser system requiring the correct encoded ignition key to be used to disable it. This makes the fitment of this particular engine a little more complicated if you are using it's original engine management system and so the BOA has generally been the preferred choice for ease of conversion. I suspect the issue is more to do with fault finding. If your BOA conversion won't start at least you know it isn't the immobiliser!

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\n Preparing, Fitting and Wiring your Cosworth BOA V6

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I have broken up the necessary work into sections as shown below. This particular conversion was carried out on a 1982 Ford Cortina so some of this guide is tailored to that but most of it is relevant whatever you are fitting the engine to.

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\n What's Required and Why

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Your basic shopping list

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Parts Preperation

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Preparing the engine prior to fitment.
What to add and what to remove.

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\n Engine Installation

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\n Whatever car you are fitting this to you will want to remove the bonnet, radiator and grill to give best access.

For the Cortina you will also need to remove the heater unit as the LH cylinder will foul on it, more on that later. Also watch for the steering column coupling getting close to the RH exhaust manifold.
If you are using a type 9 gearbox and have not removed your prop-shaft don't forget to guide it into the gearbox as it approaches it's final position.

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Fuel System

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\n As with all EFI engines this engine requires a good consistent pressurised fuel supply. On my installation I used an external pump and accumulator as found on Bosch K-Jetronic fuelled cars but this wasn't very satisfactory. A much better solution is to fit an in-tank high pressure pump as described in the link.

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\n Cooling system

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Keeping its cool.

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\n Induction and Exhaust

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Its sucks and blows...

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Electrickery!

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This is one of the more challenging bits of any engine conversion and gives some people the fear.
Hopefully these bits of information will clear most if not all of that up.

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ECU Pin-Out List

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\n One of the holy grails of any engine conversion.

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You might think the ECU Pin-Out list is all you need, but you would be very wrong. There are a few bits within the wiring loom itself that took a bit of detective work.

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\n Rev Counter

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\n This section is very much geared to my own conversion on the Cortina but it may help give ideas for your own particular build.

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Recorded on shaky old technology with appalling sound reproduction...
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\n Any adverts are youtubes' doing and beyond my control. I certainly don't see any revenue from them!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Ford Cortina mk3 to mk5
Front Brakes Upgrade

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During the year that my Cortina provided me with daily transport it became apparent that the brakes are actually not that bad and it was quite possible to lock up both front wheels. However, what I did find was that the brakes quickly overheated causing the inevitable brake fade.

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The picture above shows the standard front brake set up comprising of a twin pot calliper and a solid disc. You'll notice that unlike modern cars the disc is mounted on the back of the hub as opposed to being sandwiched between the hub and the wheel. Modern cars brakes dissipate a lot of there heat by transferring it to the large alloy wheel bolted against the disc, effectively using it as a heat sink. On older cars such as this the disc has only the iron hub to spread it's heat to and iron doesn't make nearly as good a heat sink as alloy. The other problem is the lack of airflow to allow heat to escape. The disc is solid and there's a debris guard located against it's inner face obstructing the airflow.\n
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The ideal solution would be to fit modern vented discs that locate on the outboard end of the hub and use modern single piston sliding calipers. However, in order to retain your original wheels you may need to reduce the outer diameter lip of the hub to allow a suitable diameter disc to slide over it and you would end up with your front wheels been spaced out giving a slightly wider track. You will also need to fit longer wheel studs. This is all very do-able but there is an alternative option for a road car.

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\n Granada/Capri Hybrid

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As I stated at the start, the brakes are actualy not that bad when working properly, they just overheat quickly producing brake fade. Therefore we need to improve the cooling to them. There are two things we can do to achieve this, remove the debri gaurds to allow some airflow over the brakes and upgrade the solid discs to vented discs.\n
No model of Cortina was ever fitted with vented discs so you'll have to find some from somewhere else. The mk2 Granada uses a very similar set-up to the Cortina and the bigger models did use vented discs but they use 5 stud hubs and as a result the discs are also mounted with 5 retaining bolts as oposed to the Cortina's 4. But all is not lost as the Capri 2.8i has vented discs of the correct size and shape and is also of 4 stud hub design. You will have to raid a mk2 Granada 2.8i of it's callipers though as your originals won't fit around the thicker vented discs and the Capri callipers are of a different design.\n
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\n You will need:

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Capri 2.8i vented front discs\n
Granada mk2 2.8 front calipers (ensure spaced for vented discs)\n
Caliper rebuild kit\n
Granada mk2 2.8 front brake pads
\nSteel plate for fabricating calliper brackets
Brake fluid\n
Wheel bearing grease (and wheel bearings if you want to replace them)

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Strip down your existing brakes. You will have to remove the hubs to get the discs off.

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Gallery with Popup Slider

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Remove the old solid discs and fit the new vented discs. Clean the hubs, particularly the mating faces. Check the condition of the wheel bearings whilst it's apart. I replaced mine regardless and made sure all internal faces had a smear if grease on them to prevent corrosion.
The four disc mounting bolts are held in place with locking tab plates that should be replaced.

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The Granada calipers were stripped, cleaned and rebuilt with a refurb kit and given a fresh coat of paint. As can be seen from the comparison photo, they are not only spaced to fit around the thicker vented disc they also take a slightly larger pad.
On reassembly it was found that there is a bit of protruding casting that rubs on the original Cortina Ghia spec alloy wheels as shown in the photo so you may need to grind this off.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery4", "_sourceTheme": "mobirise5", "_customHTML": "
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Assembly

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Clean and prepare the stub axle and refit the hub with it's shiny new vented disc fitted,

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On mounting the calliper you will find that it sits too close the the back face of the disc. The calliper needs to be spaced back from its mounting lugs by approximately 7mm so that the disc sits centrally within the caliper. This was initially achieved using washers, the washers where then removed and a steel spacer strip made so suite.
Sadly I cannot find the photos of this strip so can't show you the finished article. You will also need longer bolts to suite. 

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Bleed, check for leaks, fit the wheels, check for clearance/free to rotate and off you go. In the last set of photos you can see the lug that fouled on my original Ghia alloys and that I had to grind off smooth.

Job done!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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You Will Need:

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  1. Granada Donor Car (or if not available, the engine complete with ancillaries, loom and ECU and also potentially the Rev Counter)\n
  2. Suitable Manual Gearbox - Either the old Type 9 (a little weak) or a MT75 Hybrid (more on that later)\n
  3. Suitable Gearbox Mount, speedo drive cable and possibly Custom Prop-shaft depending on application\n
  4. Manual Cologne V6 Flywheel and clutch (which type will depend on choice of gearbox)\n
  5. Crank Needle Roller Bearing (for gearbox input/primary shaft location)\n
  6. Electric Fuel Pump & Filter\n
  7. Odds & Sods - Such as wiring, tubing, bit's of metal etc...
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For Cortina Applications (as this build is based on one):

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  1. Cortina 2.3 V6 engine mounts\n
  2. If using a 5 speed type 9 gearbox, an auto Cortina gearbox cross-member\n
  3. Suitable Radiator - 2.3 V6 Cortina, 2.8i Capri or whatever you can find down the breakers (mines from a Nissan 100!)\n
  4. Electric Cooling Fan - Pusher type (in front of rad) and no larger than 10\" diameter\n
  5. Universal Air Filter
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\n Gearbox

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As previously mentioned, there are two choices for the gearbox. The easiest (as it's a nut and bolt job) is the Type 9 5 speed as found in late 2.8i Capri's, Sierra XR4i and manual 2.8 Granadas. The other is a MT75 Hybrid.

Type 9
For Cortina applications this gearbox allows you to retain the original prop-shaft as it is no longer then the old 4 speed gearbox. All that's required to mount it is the gearbox cross member from an automatic Cortina that simply needs to be swiveled through 180 degrees and all the bolt holes line up! (assuming you can find one, if not you'll have to make your own mount up) You'll also need a speedo cable from a 5 speed Sierra as the original 4 speed Cortina item will be too short.\n
However, this gearbox really is pushed to the limit with this engine and many people have destroyed their gearboxes after giving it a bit too much abuse at the traffic lights. Apparently the weak spot is the large aperture in the top of the box that the sheet metal cover sits over. Under high torque loads this weakness allows the casing to distort which results in gear climbing over each other the gearbox imploding! Stronger more rigid cast cover plates are available but I cannot vouch for there effectiveness.

\nMT75 Hybrid
The MT75 from later Sierras and Granadas is a much stronger gearbox but it has it's own drawbacks and fitting it is a lot more complicated. First of all the gear ratios are apparently not as good as the type 9 and I have been informed by some Sierra owners that it is necessary to change up to third gear to reach the magic 60mph. It is also recommended to change the fifth gear set for that of the diesel version to give better motorway cruising. However, as you will have to open the gearbox up anyway this isn't such an inconvenience.\n
There are two real stumbling blocks with this gearbox. The first problem is that you need to use a prop-shaft with a sliding joint with this gearbox which for the Cortina means having a custom prop made. The type 9 gearbox has a sliding portion at the output flange but on the MT75 the flange position is fixed.\n
The second problem is even more involved, the bell-housing on these gearboxes is cast into the main gearbox casing. The reason that this is a problem is that in manual form, the V6 version was only ever used with a 4 wheel drive gearbox. The big V6 powered Granadas all had automatic transmissions. This means that all the normal rear wheel drive gearboxes have the 4 cylinder engine bell housing cast into them which won't fit the V6 engine. To overcome this problem your only option is to build a hybrid gearbox by swapping the internals and rear end from the 2 wheel drive gearbox into the main casing of the V6 gearbox.\n
For Cortinas you will also have to fabricate your own gearbox mounts. I don't know if the transmission tunnel on the Cortina needs re-shaping at all but it's reasonably large so hopefully shouldn't.

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\n Flywheel and Clutch

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Flywheel and Clutch

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The choice of flywheel and clutch will come down to the choice of gearbox. If you are using the Type 9 gearbox then you will need to use the flywheel and clucth from a 2.8ltr Cologne. Don't forget to make sure you get the correct V6 spec clutch release arm and ruber boot for the end of the clutch cable as they are different to the four cylinder versions.\n
If you are using the MT75 then you'll need the flywheel and clutch from a 2.9i Cologne. The reason for this is the 2.9i Cologne flywheel is a bit thicker than the 2.8ltr version.\n
You will also need the needle roller bearing that fits into the back of the crankshaft and supports the end of the primary/input shaft of the gearbox. 

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Electric High Pressure Fuel Pump

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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n Being a modern(ish) Electronic Fuel Injected engine it require a stable high pressure fuel supply. When I carried out this conversion to my Cortina I used an external pump and accumulator system as found on many Bosch K-Jetronic equipped cars. But this wasn't very satisfactory and an in-tank electric fuel pump is the best way to go. Click on the picture to be taken to the in-tank fuel pump page.
You will still need a fuel filter to go with it and you will need to make up a simple loom to power the pump via a relay, the relay being controlled by the ECU as detailed in the wiring section.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Removal of Surplus Equipment

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In some installations you may need to remove some accessory equipment. Some items you may want to remove anyway. 

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\n Air Conditioning Pump

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\n If not required this can simply be removed. It uses its own bespoke drive belt so its removal will not affect the accessories drive belt.

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\n Power Steering Pump

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This is driven by the accessories drive belt.
If it is simply not required you may want to consider leaving it fitted purely as an idler pulley.
If it does need to be removed see the Accessories Drive Belt section further down this page.

On the Ford Cortina the pump pulley fouls the chassis rail. If you are lucky enough to have the rare power steering rack for your Cortina (recommended with the weight of the engine) then people have notched the chassis leg to clear the pulley. I removed the pump on mine so I'll leave it to your discretion.

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\n Exhaust Gas Recirculation System (EGR)

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\n Unless you really want to keep this 'scrape it past the emissions laws' feature you'll want to disable this feature. The EGR valve itself is on the RH exhaust manifold on the end of a rigid pipe. This pipe can be cut by its base and a neat blanking plug welded across it.
Or you could do what I did, cut the end of the outlet pipe off and fold it over. So long as it's gas-tight. You may also spot in the photo the self tapping screw sealing off the other small pipe.

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\n There is a port at the back of the manifold for the now redundant EGR system that needs to be blanked off. In my case this was achieved with the use of a blanking olive and a home made clamping plate.

There are a few electrical plugs and a black electrical control box that can now ne discarded.

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\n Viscous Fan

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\n It is most likely that you will want to junk the viscous fan in favour of an electric one. Apart from removing the parasitic load it saves you having to align the radiator and fan shroud with the engine.

On the Cortina there is insufficient space between the engine and the radiator for a fan so an electric pusher type fan will have to be fitted to the front of the radiator. 

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\n Preparing the Engine for Installation

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This will vary depending on installation but here are the common tasks.

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\n Accessories Drive Belt

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If you remove the power steering pump you of course disrupt the routing of the Accessories Drive Belt. The new route requires a shorter belt. It also requires a new method of tensioning as the original sprung loaded tensioner, apart from being in the wrong position, fouls the new belt route.

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\n The closest match for the new required belt that I found was a 5 row belt with a total length of 1013mm. If you look at the smaller number in the photo you will see that it matches - 5PK1013

This belt may seem a little tight at first, this will be addressed in the next step.

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The alternator is mounted in such a way that the bracket can be modified to provide some adjustment in the traditional manner. As can be seen on the photo, the mounting hole in the lower arm is simply elongated. I found the easiest wat to do this was to mount the alternator onto the bracket with just the upper bolts, swing it tight against the bracket and through the lower bolt hole mark the arm. Drill a new bolt hole in this position and then join the two holes to from the slot. Don't forget the slot will have to follow an arc to match the movement of the alternator.

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Bolt it all up and you are good to go.

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\n Don't forget to recheck the tension once the belt has had time to bed in.

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\n Flywheel, Clutch and Needle Roller Spigot Bearing

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\n Pretty obvious really and will come down to which gearbox you are using.

2.8 Cologne for the type 9 (don't forget to make sure you have the correct V6 spec release arm fitted to the gearbox)

2.9i Cologne for the MT75

Don't forget to fit the needle roller bearing in the back of the crankshaft for the spigot on the end of the gearbox primary shaft to engage in!

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\n Heater Pipes

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\n If you need to alter the heater pipes for your application you had better do it now whilst you have access.
The upper pipe routed through the valley of the engine comes from the back of the thermostat and the coolant flows out of it into the heater.
The other pipe routed up the back of the block and pointing towards the front of the engine is the return pipe from the heater.

For my Cortina I found I had clearance issues with the bulkhead so I cut the valley pipe just before the bend at the back of the valley and the other pipe just below the white label in the photo. Ideally the cut pipes should have there ends rolled to prevent the hoses from slipping off under pressure.

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\n Engine & Gearbox Mounts

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\n These will obviously be peculiar to your installation.

Cortina - Use the 2.3 Cortina engine mounts if you can find any. When fittin them note that they are handed. You can use the Cosworth engines mounting rubbers with these.
If using the Type 9 you can use the gearbox cross-member from and Automatic Cortina, you just turn it 180 degrees and it all lines up.

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That should be it.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Cosworth BOA - Cooling

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The engine has five connections to be accounted for, three at the front for the actual cooling (two from the thermostat and one from the water pump) and two at the back for the cars heater.

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\n Thermostat Connections

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\n These are the top hose that plumbs directly into the top of the Radiator and the smaller bore bypass hose. The plumbing of the bypass hose will come down to whatever you are using,so long as it is plumbed back into the cooling system somewhere on the radiator circuit (i.e. not directly back into the engine block).

The pipe I used is from an old Peugeot and has a convenient bleed screw built into it. 

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\n Water Pump / Bottom Hose

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\n Pretty much as in the photo.

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\n Radiator

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\n When choosing your radiator ensure that the main hose connections are in the same orientation as shown in the photo.

Note that the Essex radiator has the hoses connections in the opposite positions and so will not be suitable unless you have a lot of space for long hose routing.

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", "_anchor": "image1-5r", "_isUserblock": true, "_cid": "sL3H9M28qz", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery4", "_sourceTheme": "mobirise5", "_customHTML": "
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Electric Fan

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You will also need an electric cooling fan. You will need to add the wiring and control (thermal switch) for this yourself as there is no provision for it within the standard management.\n
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For the Cortina, due to limited space, this has to be a pusher or blow through type fan mounted in front of the radiator. Due to the limitations of space you cannot go any bigger than 10\" diameter. I would also recommend opening up the blanked off louvres in the front grill.

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\n 2 x Heater Connections

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\n As already covered in the Preparation section, the two heater connections are at the back of the engine.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery4", "_sourceTheme": "mobirise5", "_customHTML": "
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Cortina Heater

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Whilst we are on the subject of heaters, the Cortinas standard heater box will foul on the LH cylinder head. To get around this the heater is modified by cutting some of the box away, altering the angle of the matrix inside to give the required clearance and then making a new skin for the box from sheet alloy.
Unfortunately I lost the photos for this procedure many years ago but it shouldn't be hard to figure out.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Cosworth BOA - Induction & Exhaust

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Induction

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The induction system shouldn't present too much of a challenge. It does contain a fairly large resonator box half way through and the air filter housing is pretty big and mounts the airflow meter that you need to retain. Both are easily dealt with.

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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n Resonator Box

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\n Simply remove from the system.
The flexible rubber pipes happen to be slightly different sizes and you can quite simply slide one over the other and bond together with some suitable rubber adhesive.

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Air Filter Box / Airflow Meter

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The airflow meter mounting plate is cut from the air filter box complete with moulded in trumpet.
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This is then bolted directly back onto the airflow meter.
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Giving you something to mount the cone air filter of your choice on to.
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", "_anchor": "gallery5-69", "_isUserblock": true, "_cid": "sL4umWRnJP", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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It also provides a handy location to attach mounting fixtures to.
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Whilst yo are at it, here is my patented plastic flower pot cold air feed kit!
Part on my 'Horticultural Horsepower' range.
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Also available in carbon fibre
(style vinyl wrap).
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", "_anchor": "gallery5-6a", "_isUserblock": true, "_cid": "sL4wSkvLuz", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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This really is down to you. Just make sure that you keep the Lambda sensors in the system in the downpipes.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Cosworth BOA - Ford ECU Pinout

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Your bible. Though to be honest the major components are easy as the various multiplugs can only be plugged into the correct matching components. It's the more subtle connections that cause the headaches, such as which wire switches the blumin thing on? In this case there was no bespoke switch on wire, it was incorporated into what they referred to as the 'Power Splice'. In this case it is pin 57. But this alone won't make the engine run as the various sensors and drivers also need feeding from the power splice. Fortunately it is all built into the engine loom.
There are some additional notes at the bottom of the list.

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\n Shape your future web project with the Mobirise app.\n

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  1. Permanent Live Feed/Battery +ve\n
  2. Brake On/Off (BOO) Switch – part of diagnostics system\n
  3. Vehicle Speed Sensor (VSS)\n
  4. EDIS Module Pin 2 & Rev Counter Signal\n
  5. .\n
  6. .\n
  7. Engine Coolant Temperature Sensor (ECT)\n
  8. Kick Down Switch (KDS) for automatic transmission and also used as part of diagnostics system\n
  9. FDS2000 Diagnostics Computer Socket (later deleted)\n
  10. Air Conditioning Low Pressure Switch (raises idle rpm to maintain A.C. system pressure)\n
  11. .\n
  12. .\n
  13. .\n
  14. Mass Air Flow Sensor (MAF)\n
  15. Mass Air Flow Sensor (MAF)\n
  16. EDIS Module Pin 4 (Shielded)\n
  17. Diagnostics Socket – Fault Code Reader (3 pin socket under bonnet)\n
  18. .\n
  19. .\n
  20. Ground\n
  21. Idle Speed Control Valve (ISCV)\n
  22. Fuel Pump Relay Switching\n
  23. .\n
  24. .\n
  25. Air Charge Temperature Sensor (ACT)\n
  26. Throttle Position Sensor (TPS) & Exhaust Pressure Transducer (EPT)\n
  27. Exhaust Pressure Transducer (EPT) Signal\n
  28. FDS2000 Diagnostics Computer Socket (later deleted)\n
  29. HEGO (Lambda) Sensor – L.H.\n
  30. Park/Neutral Switch (automatic transmission)\n
  31. Canister Purge Solenoid (EVAP) –part of fuel tank venting system\n
  32. .\n
  33. Electronic Vacuum Regulator (EVR)\n
  34. Signal to Trip Computer\n
  35. .\n
  36. EDIS Module Pin 3\n
  37. Input from Power Splice – Power splice also supplies Sensors and Relays\n
  38. .\n
  39. HEGO (Lambda) Sensor – R.H.\n
  40. Mass Air Flow Sensor (MAF) & Battery –ve\n
  41. .\n
  42. .\n
  43. .\n
  44. .\n
  45. .\n
  46. ACT, EPT, TPS & ECT Sensor Supplies\n
  47. Throttle Position Sensor (TPS) Signal\n
  48. Diagnostics Socket- Fault Code Reader (3 pin socket under bonnet)\n
  49. Engine Ground\n
  50. .\n
  51. .\n
  52. 3rd/4th Gear Shift (automatic transmission)\n
  53. Torque Convertor lock up solenoid (automatic transmission)\n
  54. Air Conditioning\n
  55. .\n
  56. EDIS Module Pin 1\n
  57. Input from Power Splice – Power splice also supplies Sensors and Relays\n
  58. Injectors 1, 2 & 3\n
  59. Injectors 4, 5 & 6\n
  60. Battery –ve
    61. \n
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Redundant pins:\n
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Total: 2, 3, 8, 9, 10, 27, 28, 30, 31, 33, 34, 52, 53, 54\n
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These consist of:
Autobox Pins: 8, 30, 52, 53\n
Emissions Pins: 27, 31, 33\n
Non – essential: 2, 3, 9, 10, 28, 34, 54 

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Cosworth BOA - Engine Harness / Loom

\n

In the Granada the ECU is mounted behind the glovebox and so the engine wiring loom is laid out to reflect this. Therefore, when transferring everything into the new vehicle, it would be beneficial to mount the ECU in a similar position. That way the loom can be laid out in a similar fashion.

The majority of the connections will be pretty obvious due to the way that the loom naturally lies and the fact that the plugs will not mate with the wrong sockets.
There will be a number of redundant plugs but hidden amongst them are some crucial connections. These are:

1) Ignition switch signal to turn it all on. This is the supply to the 'Power Splice'
2) Rev counter output\n
3) Fuel pump relay feed and switched earth

The signal for the engine temperature gauge is not actually included in the engine harness, that was part of the vehicle main harness so use your cars existing wiring for that.

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Ignition 'On' Signal & Rev Counter Signal

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The first two hidden items are in the same two pin multiplug. This is a white plug with one black and one green wire. It naturally runs across the bulkhead, please see the photos below.
I'm afraid I cannot be more specific but I did not decipher this part of the loom until after I had installed it into my Cortina.

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White two pin plug with black and green wires.
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Black Wire - Ignition 'On' Live Connection
Green Wire - Rev Counter Signal

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\n Fuel Pump Relay

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\n The two wires (live and switched earth) that operate the fuel pump relay are hidden in this 6 pin oval plug that would have originally been located behind the dashboard near to the ECU. The two pins that are used are the middle pin of each row as seen in the photo.


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", "_anchor": "image1-6v", "_isUserblock": true, "_cid": "sL5NCJTylo", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n This rather rudimentary sketch I made at the time identifies the other pins in the plug.

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", "_anchor": "image1-so", "_isUserblock": true, "_cid": "sQ5Nk8H7pG", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Remaining /Redundant Connections

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Not an exhaustive list but here are some of the unrequired lose ends.

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EGR System connections. These naturally lie behind the RH headlight area and are surplus to requirements.
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Engine Diagnostics Ports.
This is before the introduction of the standardised OBCD port. Located near the LH side of the bulkhead (engine side).
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Would have been behind the dashboard originally so will want to naturally lie in that position.
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\n I can't remember, but it isn't critical. Sorry.
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If I find any more of my notes I will update this section but everything required to get the engine running is in here.

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", "_anchor": "content5-6y", "_isUserblock": true, "_cid": "sL5RKJIzM1", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-6s", "_isUserblock": true, "_cid": "sL5wdLnkOl", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-6r", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} }, { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Cosworth BOA - Rev Counter.html": { "settings": { "title": "Cosworth BOA - Rev Counter", "order": 70, "meta_descr": "Cosworth BOA V6 Rev Counter" }, "components": [ { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "background-color": "@bgColor", ".mbr-section-subtitle": { "text-align": "center" }, ".mbr-text": { "text-align": "center" } }, "_name": "content5", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Cosworth BOA - Rev Counter

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This is going to be very vehicle specific but apart from being for a six cylinder engine the signal feed to the rev counter was totally unsuitable for my Cortinas old Rev counter. Therefore I made a hybrid by fitting the Granada donors rev counters internals into the Cortinas instrument cluster.

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", "_anchor": "content5-71", "_isUserblock": true, "_cid": "sL5Syqd0k5", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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Granada Rev Counter

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\n The donor rev counter is removed from its cluster. The needle, needle park pin and dial face are removed.

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", "_anchor": "image1-75", "_isUserblock": true, "_cid": "sL5ZdO2Xxy", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Cortina Rev Counter

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\n The Cortinas rev counter is also removed from its cluster and dismantled to its major components - Housing, Mechanism, Face.

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\n Granada Rev Counter

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\n The Granada rev counter is secured by three plastic pillars and securing screws. It has a small circuit board that protrudes to the side.

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", "_anchor": "image1-77", "_isUserblock": true, "_cid": "sL61usMrf7", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Gallery with Popup Slider

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The Cortina rev counter housing needs additional holes to be made and enlarged as required to accommodate the Granadas mechanism. 

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Granada mechanism offered into position and rotated to find best fit with consideration given to central alignment of dial, location of mounting legs and any obstruction to the protruding circuit board.
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\n Large central hole drilled to clear three pins on the back of the Granada mechanism.
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Hole elongated as required to ensure clearance. Holes also drilled for mounting pillar screws. The pillars must be kept clear of the illumination bulbs in the housing. It is only possible to use two of the three mounting pillars, the third having to be cut off flush.
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Window cut into side to clear protruding circuit board.
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Window cut into side to clear protruding circuit board.
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Circuit board protruding through the window.
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The Granada mechanism isn't as deep as the Cortina mechanism so the pillars are spaced out with a stack of alloy washers to push the dial face out far enough.
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The original Cortina dial face is mounted in place on the Granada mechanism with double sided tape (use a decent brand).
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The excess plastic is trimmed away.
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The spindle of the new mechanism is slimmer than the original so the Cortina needle is a loose fit. The Granada needle has a small metal sleeve in its pivot so this needs to be withdrawn and insert into the Cortina needle. The hole will need opening up slightly for this. Sadly I have lost the photos.
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A new stop pin is added by drilling a very small hole in the required position and fixing a piece of stiff wire into it.
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The new hybrid instrument is refitted to the Cortina cluster ready for the next stage.
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The original flexible circuit board from the Cortina rev counter needs adapting to work with the modified instrument.
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Sections have had to be carefully cut away to clear the back of the new mechanism. The three pins protruding from the back of the new mechanism are the electrical connections.
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The corresponding connections from the Granada instruments circuitry are removed and attached via thin flexible wire (car speaker wire) to the relevant parts of the Cortinas circuitry.
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Wires are also added to transfer power to the illumination circuit as some of the had to be cut away.
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All back together.
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Looks completely original.
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", "_anchor": "gallery5-79", "_isUserblock": true, "_cid": "sL62WiIuT9", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n In-Tank High Pressure Electric Fuel Pump

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During the quest for an in-tank electric high pressure fuel pump for my Scimitar I discovered that Land Rover used a nice self contained unit complete with sender on a range of their vehicles that can be found in the aftermarket world for extremely reasonable prices. A benefit of these units is that they are mounted on sprung shafts and so have a certain amount of automatic built in depth/height adjustment.
There is nothing special about the Scimitars fuel tank so this guide should be suitable for most applications.
Your tank will need a flat mounting surface on the top of at least 150mm (6\") diameter at the position you want to fit it. This should of course be directly over the lowest part of the fuel tank.

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\n You Will Need:

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  1. Land Rover Fuel Pump Assy. Part Number:
    ESR 3926 (255mm to 295mm tank depth)
    STC 4344 (305mm to 384mm tank depth)
    or similar derivative
  2. Alloy plate: 5mm thick, 150mm x 400mm
    (1/4\" thick, 6\" x 15\")
  3. Hex Head Machine Screws (12. off)
    M5 x 25mm length
    (10unf x 1\" length)
  4. Countersunk Machine Screws (4. off)
    M5 x 15mm length
    (10unf x 1/2\" length)
  5. Sheet gasket material
    150mm x 600mm
    (6\" x 23\")
    6. \n
  6. 3D Printing Service (numerous online)
  7. Hole Saws
    110mm diameter (good quality)
    90mm diameter (reasonable quality)
  8. Tap Wrench & Tap - M5 (10unf)
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The tools mentioned above are in addition to your standard tool kit of course.

You will also need to ensure that your fuel tank has not only be drained and flushed but has been extremely well ventilated to ensure that no trace of fuel vapour remains in any seams. My tank had been dry for over a year before I started this.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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The Pump

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Fuel Pump P/N: ESR 3926
Tank depth range: 255mm to 295mm\n
Fitted to: Discovery Series 1 V8
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Fuel Pump P/N: STC 4344
Tank depth range: 305mm to 384mm
Fitted to: Range Rover P38 V8

Note that the grey plastic top cap on this pump incorporates a thick breather pipe.
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Mounting Collar

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Other than the differences in length and the addition of the breather connection on the Range Rover P38 sourced pump, both units are identical.\n
On original fitment they sat in a mounting collar moulded into the original plastic fuel tank with a large retaining ring screwed down over the top. There is a 4mm wide lip running around the top of the top cap to facilitate this.

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\n The 4mm lip doesn't give much margin for error and is insufficient to enable a good seal. Therefore an adapter ring is required.
If you have access to a machine shop you could make one on a lathe.
Alternately you can do what I did and have one 3D printed.There are plenty of online service available and I will happily send you the file if you email me.
It needs to be printed 100% solid as you will be drilling mounting bolts holes through it later.
The ring has a 150mm external diameter, 110mm internal diameter and is 7mm thick.
The internal diameter is increased to 120mm diameter of a depth of 2mm on one face to accommodate the lip.

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These are obviously later photos as you can see I have drilled the holes for the mounting bolts and the big hole in the fuel tank but you can see how it fits snugly around the pumps mounting cap.

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Clamping Plates

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Please pay careful attention; this work needs to be carried out in the order shown.

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Cover one face of the alloy plate with masking tape.\n
Cut the alloy plate in half to give two matching squares.\n
Find and mark the centre of one of the plates.\n
From this point draw:

150mm dia circle - This is the external diameter.\n
130mm dia circle - This is for the mounting bolts.\n
90mm dia circle - This is the top clamping plate clearance hole.

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The 130mm dia bolt hole circle needs 12 equally spaced marks around its circumference for the bolt hole positions.

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Shade the area outside the 150mm dia circle.
Shade the area inside the 90mm dia circle.
These are the 'waste material' areas.

Draw a small triangle within the resultant ring between two of the bolt hole positions. This is your alignment mark.

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Place this plate on top of the other (both plates masking tape face up) and place them both on a piece of scrap wood of at least the same size.
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Drill a hole through both plates in each corner in the outer waste material area and secure the stacked plates to the scrap wood with self tapping screws.

Drill four holes through both plates in the inner waste material area and secure with self tapping screws. It is best not to make these inner screw holes uniformly spaced so that the two plates only align in one position.

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Now that the two plates are locked together work can start on fabricating the clamping rings themselves. A pillar drill would be advantageous.

Check the diameter of the pilot drill in your hole saws and drill a hole through the centre of the plates to the same diameter. If the pilot drills are of different diameters then drill to the smallest one (hole not yet drilled in the photo).

Careful! Drill the pre-marked ring of bolt holes but to the diameter hole required for the tap!  M5 = 4.2mm dia      10unf = 5/32\" (3.9mm) dia

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\n Unmount the two plates from the wood and carefully separate without disturbing their orientation.
Copy the alignment mark made earlier to the lower plate between the same bolt holes. This will ensure that any variance in the positioning of the ring of bolt holes is accounted for.
Draw the 150mm dia circle onto the lower plate (which is the upper one in the photo still on the piece of wood. Sorry).

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\n Danger!

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This next bit involves using an electric powered, spark and heat inducing piece of equipment on a container that has spent it's entire life exposed to petrol vapours. If you really need me to point out the danger of this then perhaps you shouldn't be doing this.
My tank had been empty, flushed and venting for over a year and I still filled it with water before proceeding.

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Identify where on your well ventilated tank you want to mount your pump. Take into consideration the location and swing of the level sender if you are not using the item built into the pump, or the direction of swing of the level sender on the pump if you are using it. Also look out for any obstructions to the top of the tank when the tank is mounted back in the vehicle.
Apply masking tape to the area

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\n Mark out any internal baffles in the tank or areas to be avoided (ignore the four small circles).

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\n If the edge of the tank is curved like mine, lay a flat edge along it and mark where it starts to curve. You need to ensure you allow for the internal clamping ring to sit flush against the flat surface when positioning.

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Place the top plate in position with the alignment mark lined up to a reference point on your tank (filler neck, corner etc...)\n
Mark through the inner waste material screw holes onto the top of the tank.

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", "_anchor": "image1-z2", "_isUserblock": true, "_cid": "tbXEuiePgR", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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Remove the top plate and drill these four holes to a size suitable for pilot holes for the screws you used previously to mount the plates to the scrap wood.

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Assuming you survived, reposition the top plate (remember the alignment mark) and secure to the top of the tank with the four self tapping screws.\n
This has just become your drill guide!

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The ring of bolt holes in the top plate are currently undersize for the tap. These need to be opened up to the correct size to clear the bolts.
With the top plate secured to the tank, open up the ring of bolt holes drilling all the way through the top of the tank at the same time.

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\n Remove the top plate from the tank and admire your handy work.

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Re-secure the top plate (on its own) to the piece of scrap wood with all eight self tapping screws.
Using the 90mm hole saw cut out the large central hole. This will be heavy going so be patient, you don't want to damage the hole saw.
Once done remove from the scrap wood. The central waste material section can now be discarded.

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", "_anchor": "image1-8h", "_isUserblock": true, "_cid": "sLfJvFTAU6", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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Cut around the 150mm diameter line to create a ring. A band saw would be great but a hacksaw and file will get the job done.\n
Write 'Top Plate' on it to avoid any mishaps, ensure that the alignment mark is still clearly visible.\n
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Put the top clamping ring to one side.

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Re-secure the lower plate (on its own) to the piece of scrap wood with all eight self tapping screws.
Extend the alignment mark to the inner wast material area.
Using the 110mm hole saw cut out the large central hole. This will be heavy going so be patient, you don't want to damage the hole saw or oversize the hole.

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", "_anchor": "image1-8c", "_isUserblock": true, "_cid": "sLfDCXP3lJ", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 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Title

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Once done, remove the central waste material section and, with reference to the alignment mark, screw it down onto the top of the fuel tank. This has just become a drilling fixture!

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Only do this on a well ventilated tank! Mine had been washed out and left to vent for the best part of a year! If the dangers of this procedure are not immediately obvious to you then you shouldn't even be reading this!

- Take a deep breath -

Using this new drilling fixture, take the 110mm hole saw and drill out the top of the fuel tank.
Take it slow and steady, you don't want to build up heat. I sprayed plenty of WD40 on my stainless tank. Not only to lubricate it but it smokes as it gets hot which provided a good indicator of when to back off and pour cold water over it.
As you finish the hole be mindful that your drilling fixture will become loose!

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Retrieve center waste material.
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Mount onto fuel tank in correct orientation
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Use as drilling fixture to keep hole-saw centered and prevent wandering.
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Take it steady, use lots of lube and keep temperatures down.
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Remember the fixture will become loose near the end of the drilling operation.
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Success! De-burr all the holes, clean out the tank of all the swarf and cutting compound/lube and then have a beverage to celebrate!
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\n Remove the lower plate from the scrap wood and cut around the 150mm dia circle line as before to create a ring.
Tap the clamping bolt holes.

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Cut through the ring at the alignment mark, directly between the two bolt holes.
Chamfer the cut edge as shown on the lower surface of the ring (non-masking tape side), this will aid insertion into the tank later.

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\n Hold the two clamping rings against each other in their correct orientations with alignment mark and cut slot lined up.
With a file, make a permanent mark on the edge of the top clamping ring in line with the slot of the lower clamping ring.
Extend the mark part way over the top face. This will not only give you a reference for orientation, but will also indicate which side is the top face.
Remove the masking tape and carry out any necessary deburring.

That is the top clamping ring complete.

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Returning to the lower clamping ring, mark out, drill and tap four more equally spaced bolt holes along the 130mm dia line mid-way between the clamping bolt holes. These are for the countersunk screws.
Remove the masking tape and carry out any necessary deburring.

That is the lower clamping ring complete.

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Mounting Collar

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\n Mounting Collar

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\n Clamp the top clamping ring onto the 3D printed (or machined) mounting collar with the 2mm deep recess against the bottom face of the clamping ring. Make sure that they are aligned to each other.
Using the top clamping ring as a guide, drill the 12 clamping bolt holes through the mounting collar.
Whilst still clamped together, using a file, extend the alignment mark on the edge of the top clamping ring onto the mounting collar.

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Detach the top clamping ring from the mounting collar and clamp the lower clamping ring in place, clamping ring top face against mounting collar bottom (flush) face. Ensure that the split in the mounting ring is lined up with the new alignment mark on the mounting collar.
Carefully mark through the positions of the four additional holes onto the mounting collar.
Detach the lower clamping ring and drill four clearance holes at these locations.

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\n From the top (recessed) face of the mounting collar, countersink these four additional holes to suite the countersunk screws.

That is the mounting collar complete.

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\n Locate the mounting collar onto the tank ensuring that the alignment mark is lined up with whatever tank reference you used and that the central hole and all 12 clamping bolt holes line up.
Mark the positions of the four countersunk screws onto the tank.
Remove the mounting collar and drill four clearance holes for the countersunk screws.
Remove the masking tape from the tank, de-burr the tank as necessary and clean out any debris.

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\n Finally, make three sealing gaskets using the lower clamping ring as a pattern.

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Test Assembly

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\n You should now have a kit of parts

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery4", "_sourceTheme": "mobirise5", "_customHTML": "
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Gallery with Popup Slider

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Carefully feed the lower clamping ring into the tank as shown. Be careful to make sure it is the right way up (bevelled edges away from the tank skin).

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Slip the mounting collar over your wrist with the recessed face facing up your arm.\n
With the same arm, reach into the tank and pull the lower clamping ring up into position against the tank skin. Make sure the slot is aligned to the reference point and that the bolt holes line up.\n
Slide the mounting column down your wrist and into position in the tank surface with the alignment mark lined up with your reference point and the bolt holes lining up. With your free hand, loosely fit the four countersunk screws so that they are holding everything in place without being nipped up.

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Carefully feed the new pump assembly into the tank being careful of orientation of the level sensor. Note that the fuel pick-up point should be at the lowest point. You may find that this conflicts with the level sensors requirements as it did with mine. If this is the case refer to the section on repositioning the level sensor at the end of this guide.

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The top plate of the pump assembly should want to sit a bit proud of the mounting collar so that when pushed fully home the springs provide some tension to push the pump unit against the lower tank skin.

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Position the top clamping ring, paying attention to the alignment mark. Check all the bolt holes line up and fit all of the bolts but do not tighten.

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Check that you are happy with the fit, the positioning of the pipe connections and that the level sensor has full and free movement.
Once happy, remove the pump, mounting collar and clamping rings.

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Final Assembly

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Final assembly follows the same steps as above only this time the components are wet-assembled with sealant. Wet assemble the lower clamping ring and mounting collar with gaskets this time into the tank with an adhesive sealant and allow to set, fitting one gasket inside the tank between the lower clamping ring and the tank skin and another between the external tank skin and the mounting collar. These components should never need to be disturbed again as they do not need to be dismantled if you ever need to remove the pump unit in the future.\n
The pump unit and top clamping ring should be wet assembled with a liquid gasket such as blue hylomar and the final gasket.

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Mounting collar and lower clamping ring permanently installed with gaskets and sealant and left to set.
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Pump being installed.
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Top plate wet assembled with gasket.
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Pump orientation checked and clamping bolts tightened.
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\n Re-locating the Level Sender Unit

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Re-locating the Level Sender Unit

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Depending on your application it may be desirable to relocate the level sender. It was in my case as my tank is tapered so having the fuel pick-up for the pump chamber at the lowest point would have had the fuel level sender float poking through the front wall of the tank. Fortunately the level sender is detachable and there is space to remount it on the other side of the pump chamber.

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\n The level sender is a separate unit secured to the pump chamber by a self tapping screw.
There is space on the other side of the pump chamber to mount it on a new bracket.
The new bracket is cut from extruded alloy 'L' section (or 'T' section with one edge cut off in my case). Folded sheet metal is likely to flex under the weight of the moving fuel (cornering etc...)

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\n This is bolted through the top of the pump chamber with metal spreader plates fitted inside to spread the load. The pump chamber body simply unclips from it's top plate.

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\n The original sender hole is then blanked off with a disc of metal using new original style seal and retaining ring.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Ford 2.0ltr Zetec

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The Ford Zetec was manufactured from the early 1990's and is a conventional four cylinder engine comprising of a five main bearing cast iron block, a twin--cam 16 valve alloy cylinder head, hydraulic cam-followers and a conventional cam-belt. It is available in three sizes, 1.6ltr, 1.8ltr & 2.0ltr.
There is also a 1.25ltr Zetec fitted to some Fiesta's but these are merely a re-badged Mazda engine and so bare no resemblance to the larger Zetecs.
Thanks to Ford standardising the bell housing size and bolt pattern across there range of engines and gearboxes, the Zetec can be mated up to most Ford gearboxes but care must be taken when selecting a flywheel.
All versions came with full electronic engine management and fuel injection. There were no carburettor options and there is no distributor drive.

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The Zetec comes in a few different flavours as it was developed during it's production run. The engine being referenced to and fitted in this guide is the common Zetec-E. This is the standard Zetec engine fitted to most Escorts and Mondeos of the 90's. There are some minor differences to some of the parts between Escort sourced Zetecs and Mondeo sourced Zetecs that are covered later in this guide.
Pre '94 engines apparently suffered from sticking valves due to a shoulder formed in the valve stem during manufacture fouling on the valve guide. Most engines should however have been rectified by now.

\n
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Later engines from the Focus are very similar and the induction system is interchangeable but they aren't ideal when being transplanted into a front wheel drive Escort or Fiesta as they use a new block design resulting in a physically longer engine. They also use smaller width main bearings and so may not be as strong as the original engines.
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\n LEARN MORE\n LIVE DEMO\n
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", "_cid": "sLOmXE40l6", "_anchor": "content4-9h", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Getting to know the Zetec

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I stripped and rebuilt my Zetec and whilst I don't intend to document the rebuild here I will include a collection of photos to give you some familiarity with the engine.

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\n Zetec Parts Options / Swaps

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\n There are some differences between Escort and Mondeo sourced Zetec engines which could be of benefit to your application.
For fitment to the Escort mk3/4 the all of the Escort sourced parts covered in this section are required.

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\n Engine Mounts

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\n This is obviously bespoke to your own application but if you happen to be fitting the engine to a mk3/4 Escort then read on.

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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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Installing The Engine

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\n This section is obviously mk3/4 Escort specific.

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", "_anchor": "image1-an", "_isUserblock": true, "_cid": "sMiwL5mhlV", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Electrickery

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\n Wiring up the Ford EEC IV engine management system (with PATS).

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", "_anchor": "image1-aw", "_isUserblock": true, "_cid": "sMjFkrsMuK", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Zetec Strip & Build.html": { "settings": { "title": "Zetec Strip and Build", "order": 56, "meta_descr": "Zetec Familiarisation through Strip and Rebuild" }, "components": [ { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Zetec Familiarization

\n

I took the following photos (and more that have since been lost) during the strip down and rebuild of my engine. They are included here purely for familiarisation.

\n
\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Zetec Strip

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Basic dismantling of the engine. Some photos (Oil pump, Pistons, Con-Rods and Crankshaft removal) are sadly missing.

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", "_anchor": "gallery5-9p", "_isUserblock": true, "_cid": "sLU8dlVo3t", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Block Rebuild

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Again some photos are missing.

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Bare Block
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Main shells fitted
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Centre 'Thrust' Bearing Shell
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Crank-shaft fitted
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New bolts
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Main bearing caps fitted
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Note mounting for under piston cooling oil jets (2.0ltr only).
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Note mounting for under piston cooling oil jets (2.0ltr only).
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Under piston cooling oil jet fitted (2.0ltr only).
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Under piston cooling oil jet fitted (2.0ltr only).
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Escort spec Oil Pump required for transplant in mk3/4 Escort.
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Escort spec sump fitted for exhaust clearance in mk3/4 Escort. The corresponding oil pick-up pipe and dipstick assembly are also required to match.
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A bit of porting to smooth out the steps in the port and blend into the valve seats,
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Inlet - More blending around the valve seats.
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", "_anchor": "gallery5-9r", "_isUserblock": true, "_cid": "sLUexbgjfB", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Zetec - Parts Options / Swaps

\n

\n There are a few subtle differences between the parts used on the Escort spec Zetec and the Mondeo spec Zetec.
This can provide some options to overcome potential obstacles to your application.

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\n LEARN MORE\n LIVE DEMO\n
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The difference between the Escort and the Mondeo oil pumps is the filter mount. The Escort unit is slightly more compact and mounts the filter at a different angle.
In the Escort mk3/4 application there is not enough clearance for the oil filter when using the Mondeo pump so the Escort pump has to be fitted.

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Escort Left - Mondeo Right
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Escort Left - Mondeo Right
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Text

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Escort
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Mondeo
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Escort
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Mondeo
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", "_anchor": "gallery5-9y", "_isUserblock": true, "_cid": "sLWe0UkltH", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Water Pump

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There are two differences between the two water pumps. The first obvious difference is the angle of the output hose connection.
For Escort mk3/4 applications the Escort sourced pump is required as the Mondeo version will foul the alternator and cause plumbing issues due to the tight bend that would be required to connect to the radiator.

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Escort Left - Mondeo Right
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Escort Left - Mondeo Right
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Title

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The other difference is the direction of rotation of the two pumps.
If you look closely at the two grainy photos you will see that the pump vanes are angled opposite to each other.
The reason for the different directions of rotation is because the accessories drive belt is routed differently on the two cars. On the Escort the water pump is driven conventionally and so it uses a normal grooved pulley. The Mondeo pump is driven by the back of the belt and so it uses a smooth pulley.\n
So make sure you use the correct pulley and route the belt accordingly!

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Escort Water Pump
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Mondeo Water Pump
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Escort Left - Mondeo Right
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Sump

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The sumps are different between the two donor vehicles that may give clearance options for cross members and steering racks in rear wheel drive applications or exhaust routing in front wheel drive applications. You will also need the corresponding oil pick-op pipe for the oil pump and the correct dipstick complete with outer tube.
For Escort Mk3/4 applications the Escort spec sump is required to provide clearance for the exhaust.

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Mondeo - Central Sump Bowl
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Mondeo - Central Sump Bowl
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Mondeo Oil Pick-Up Pipe
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Escort - Forward Sump Bowl
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Escort - Forward Sump Bowl
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Escort Oil Pick-Up Pipe
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Alternator Mounting

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The Mondeo mounts the alternator high up on the inlet side if the engine.
I cannot remember how or where the alternator is mounted on the Escort sourced engines.

For mk3/4 Escort applications the alternator is mounted in the same position that it was in on the original engine, low down on the exhaust side. An original CVH alternator bracket can be bolted in place onto the block but these brackets came in a variety of styles. If you are lucky you will find one with provision for mounting the slotted mounting arm that facilitates tensioning of the belt. on the CVH there was a bolt hole in the block that the original tensioning arm was bolted to but this is not present on the Zetec so you may have to fabricate a bracket.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Inlet Manifold

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There are a number of options for the inlet manifold from the Mondeo, Escort or even the mk1 Focus.
The early Zetec powered Escorts used a cast alloy inlet manifold with a forward facing throttle body with an intake pipe routed straight over the top of the engine. This arrangement will work in mk3/4 Escort applications but there is a better option.
The Mondeo inlet manifold is a plastic affair that sits down the back of the engine block with a vertically facing throttle body. This manifold is too bulky for use in mk3/4 Escort applications as it fouls on the brake pedal cross-bar.
The mk1 Focus manifold is also made from plastic and is very similar to the Mondeo item but it is slimmer in overall size (not in port diameter) and so fits in mk3/4 Escort applications and is what I used. It also comes in 2.0ltr guise so can be had with the correct size throttle body and injectors.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Exhaust Manifold and Crankcase Breather

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This is probably more applicable to front wheel drive / transverse applications than rear wheel drive applications.
The two stock exhaust manifolds angle and route the exhaust systems differently, hence the different sump designs.
Whichever you use, be sure to use the corresponding crankcase breather system oil separator as they are different shapes and will foul on the manifold/downpipe if the wrong one us used.
For Escort mk3/4 applications the Escort manifold and downpipe are required.

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Escort breather system oil separator
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Flywheel and Clutch

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The choice of flywheel and clutch will of course depend on what gearbox you are using.
The Zetec requires a 36 tooth trigger wheel to provide crank position data. As standard this is incorporated into the engine facing side of the flywheel so ideally a flywheel with the same arrangement is required. you may well be able to use the Zetecs original flywheel, you will have to research this for yourself.
Be aware that the Escort flywheel is slimmer than the Mondeo version and so the clutch will sit a bit closer to the engine.
For the mk3/4 Escort application using the cars original BC gearbox the ideal flywheel is that from the rare CVH EFI Escort.

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Back of the block with the CVH engine to gearbox bell housing sandwich plate fitted. The crank position sensor is clearly visible to the left of the crankshaft output flange.
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CVH EFI flywheel fits but will need the mounting bolt holes enlarging by 0.5mm.
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Uprated organic CVH Escort RS Turbo clutch kit.
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Note the toothed wheel cast into the back of the flywheel. This opening needs to be sealed.
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Original CVH engine to gearbox bell housing sandwich plate with extra section welded in place to close the opening.
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The join of the extra metal can be seen clearer here.
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On the mk3/4 Escort BC gearbox the lower debris guard also needs modifying.
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The crank seal housing is a slightly larger diameter to the curved flange needs cutting away to suite.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Zetec Engine Mounts

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\n The engine mounts will be bespoke to your own application, though there are a number of aftermarket bolt-on options now.
This section purely covers the modification of the CVH engine block mount to fit the Zetec for mk3/4 Escort applications. There is only one mount involved in this application as the gearbox carries the rest of the engine.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Modifying the CVH Mount

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The CVH engine mount is used in the same location on the Zetec as it was fitted on the CVH. Fortunately the upper two mounting bolt holes line up with existing threaded holes of the same diameter in the Zetec block. There is even provision for the lower mounting bolt but this is mounted higher upon the Zetec block and so the mount will need modifying to use it. The lower bolt flange of the mount fouls on the oil filter mount so needs to be cut away anyway.
Unfortunately there are some photos missing in this sequence.

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The CVH mount has been offered up to the Zetec and marked where it needs material removing to clear the oil pump housing.
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The mounting lug on the engine for the lower bolt was painted and whilst the paint was wet the mounted was bolted in place via the two upper bolt holes to clearly show where third bolt hole needs to be.
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Hole drilled.
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As you can see, this is too close to the structure of the mount to be useable as it is. Besides, it should really spread the load into this structure.
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A suitable thick wall tube is required for the bolt to pass through. In this case, the inner tube from an unused suspension bush.
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Mount cut away to accommodate the tube.
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Check for fit.
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Mount bolted in place with all three bolts and the tube tack welded in position.
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Mount removed and tube seam welded.
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Top face ground flat for bolt head to clamp against.
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Primered.
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Painted.
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Fitted.
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", "_anchor": "gallery5-af", "_isUserblock": true, "_cid": "sM8pbsb0P6", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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There are a number of variations to the available rubber mounts and the majority of them are too big, fouling on the oil filter mounting.

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The mounting rubber you need. If it looks a bit odd it's because it is upside-down in the packaging.
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Size and shape comparisons.
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Correct mounting rubber with plenty of clearance.
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Clearance issue with an incorrect mounting rubber.
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", "_anchor": "gallery5-ah", "_isUserblock": true, "_cid": "sM8r2u4gCq", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-ad", "_isUserblock": true, "_cid": "sM8nGeKE9o", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-ab", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} }, { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Zetec Install.html": { "settings": { "title": "Zetec Install", "order": 59, "meta_descr": "Installation of Zetec into Mk3 or Mk4 Escort" }, "components": [ { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 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Installing the Zetec

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Obviously this is going to be completely mk3/4 Escort specific.

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Engine ready to recieve the gearbox
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Lining up the spline in the primary/input shaft with the clutch plate.
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Gearbox mounted (or at least it will be once all the bolts are in).
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Engine fitted from below as per the original engine, hence leaving the head off to improve clearance.
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Slid into position.
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Car lowered over it.
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Engine and transmission assembly raised on scissor jacks. Gearbox mounts fitted (cross member in the case of mk4 Escorts).
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Engine block mount fitted.
Ignore the rusty oil filter thread, this was later removed and a new portion fitted.
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Oil filter pre-filled and fitted. The rigid brake pipes in the background may need a little massaging to improve clearance (to allow for engine movement).
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Basic assembly mounted in place. All jacks supporting the engine removed.
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Checking accuracy of TDC mark on the crank pulley. It was spot-on.
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Head Gasket
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Head fitted and torqued down. 
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Cam Timing Tools
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Cams locked in timing position.
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Cam timing set.
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Crankcase breather system oil separator, exhaust manifold and heat shield fitted.
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Thermostat housing and coil pack fitted.
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Rocker cover and cambelt covers fitted.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Show/Hide
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Cooling System

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Bottom Hose

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Original plumbing from Mondeo mk2 donor car.
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Dismantled into it's component parts so that the pipes angles can be adjusted to suite its new application.
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'S' pipe length trimmed.
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Re-assembled but no clips fitted yet until final assemble in the car to allow for repositioning.
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This connects the water pump to the radiator bottom hose connection stepping neatly over the alternator.
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The 'T' pipe from the bottom hose connects to a plastic water rail...
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that runs along the top of the radiator.
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This also comes from a Focus.
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The connection is too small a diameter so in intermediate diameter hose was squeezed over it with sealant.
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The two connections at the other end connect to the thermostat housing and the long heater return pipe from the bulkhead fitting.
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Title

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Top Hose

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Mondeo top hose with built in Coolant Temperature Sensor.
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Length at radiator connection trimmed back.
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Fitted.
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", "_anchor": "gallery5-ar", "_isUserblock": true, "_cid": "sMjjU1Qcnb", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Induction System

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As mentioned in the parts swap section, a 2.0ltr Focus mk1 inlet manifold has been used.

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Focus mk1 inlet manifold connections.
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Fitted with good clearance.
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Fuel rail with injectors.
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Fitted.
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Shiny new 2.0ltr Focus mk1 throttle body.
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The Throttle Position Sensor (TPS) doesn't match the plug on the engines loom...
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But the TPS sensors do send the same signal so...
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A suitable plug is simply spliced into the loom in place of the original.
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Fitted.
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The accelerator cable bracket requires some modification to move it a bit further away from the throttle lever on the throttle body. Otherwise the throttle won't close any more than half way.
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Top pipe - Focus mk1 leading to the original XR3i pipe.
Bottom pipe - later Escort Zetec.
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Airflow meter mounts in the same space originally occupied by the Bosch K-Jet metering head when using the Focus/XR3i induction piping as I have.
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Universal cone filter in a plastic flowerpot cold air induction kit, part of our 'Horticultural Horsepower' range.
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Airflow meter mounted to it.
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Final part of the induction pipework is from...
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A hole was carefully cut into this section to accept the Inlet Air Temperature probe.
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The system complete.
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", "_anchor": "gallery5-ao", "_isUserblock": true, "_cid": "sMiGJRHGEo", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Exhaust System

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The Escort Zetec downpipe is used and mated to the original exhaust system at the standard join (though in this case an aftermarket Janspeed but the join is still in the same place.)

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The standard Escort downpipe has a small catalytic converter that had already been cut from my pipe. It would probably have to be removed anyway as it would have made the pipe too long to mate up with the rest of the standard exhaust.
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A local exhaust specialist provided a length of pipe of the same diameter that they flared on one end and also a matching flange to bot up to the existing pipe. This was welded onto the end of the Escort Zetec downpipe. Note the lambda sensor.
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Lined up ready for bolting together.
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Complete.
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", "_anchor": "image3-ak", "_isUserblock": true, "_cid": "sMipitOjys", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Zetec Electrickery

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This is of course one of the more daunting aspects of a conversion and information is often hard to come by. The engines come with there own looms which plug into the main vehicle harness to cover all the ECU's requirements and any power feeds required (such as HEGO/Lambda sensor power supplies) and signal outputs (Rev counter signal, coolant temp sensor signal etc...). Depending on which vehicle your loom came from it could have either one large connector (Mondeo) or two smaller connectors.

One thing to note, if your donor was an automatic then you will find that you have a rev limit as without the gearbox feed it will think it is in neutral. There is likely a pin that can be shorted to earth to overcome this but as the ECUs are obviously configured differently I don't know if the maps might also be different to better suite the characteristics of the automatic transmission.

The following is all based around the loom that I used ('98 Mondeo 1.8 LX 'Silver-Top') but should be common to most. All required connections are made via the large black square 42 Pin vehicle loom connector with the exception of two separate power supplies, one for the PATS (Passive Anti Theft System) Transponder Ring and one for the admittedly optional fault diagnostic connector also known as the Data Link Connector (DLC).

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ECU Pin-Out List

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\n Often the starting point so I shall get it out of the way first.
Below is the complete pinout list for the ECU along with which pin it connects to on the vehicle loom plug as this is the main interface for the conversion. A blank entry means that pin is not in use.
The numbers in the description denote the corresponding pin on that items connector.

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Vehicle Loom Connector

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This is the real interface between the engine management system and the rest of the car.
This is the interconnection between the engine loom and the vehicles main loom, everything travels to and from this plug. However, not all of the 42 pins need connecting; the table below details each pins function and whether or not it is required.
The table below the photos explains each pin in detail. The fifth column headed 'Connection Details' list the minimum requirements in red and optional additional connections in blue.
As you have all the details here for you I would recommend wiring up the diagnostics port or DLC connector and the corresponding Clutch and Brake pedal switches to allow full functionality. The two switches can just be wired into simple push switches rather than fitting switches to the pedals themselves, though the clutch pedal switch is also supposed to induce a 4,000RPM limiter to prevent over-revving the engine during gear changes.

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This is the location of the single 42 pin plug on the mk2 Mondeo.
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This is the interface between the engine management and your car.
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Don't go and hack the plug off, this photo was taken after the installation was complete. In fact it might be tidier to use the plug in your application.
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Rear view showing the plug pin numbering (the reason why I included these two photos).
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", "_anchor": "image3-b2", "_isUserblock": true, "_cid": "sMn4jHvM4T", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Vehicle Side Connections

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You will need to make up a power supplies circuit and you will need to connect to the PATS transponder ring and the engine management light. There is also the optional data link connector and the brake & clutch pedal switches.

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Fig.1 - Power Supplies Circuit
Make up this circuit and connect as identified.
There is one item missing. It needs a crash switch adding to the fuel pump circuit to cut power to the fuel pump in an accident.
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PATS System Connections.
Really very simple BUT you must have the engine management fault light wired up or it will stay immobilised.
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Hmm, I don't appear to have finished this diagram. Answers on a post card...
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\n That should be it. Good luck!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Jaguar AJ-V6

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\n The Jaguar AJ-V6 is a modern all alloy 24 valve V6 engine with two stage variable valve timing on the inlet cams.
It comes in 2.5ltr and 3.0ltr capacities and came in both transverse (Jaguar X-type) and longitudinal (Jaguar S-type) configurations. The Jaguars S-type application also benefitted from a three stage variable length inlet tract system.
The AJ-V6 is a development of the Ford Duratec V6 which itself is a development of a Mazda engine.
It employs a timing chain rather than a cam-belt and the block is constructed in such a way that the lower portion of the block is a separate structure and creates a girdle type arrangement incorporating the main bearing caps, greatly increasing rigidity.

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There are a number of important differences between the transverse configuration and the longitudinal configuration as follows:

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Water Pump

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Unlike most conventional engines of the past, the water pump isn't incorporated into the block. It is a separate unit.
On the longitudinal (S-type) version the water pump is mounted on the front of the timing cover protruding forwards and driven by the back / outer face of the accessories belt.
On the transverse (X-type) version it is mounted at the flywheel end of the engine overhanging the bell housing and is belt driven via a large pulley from one of the camshafts.

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Starter Motor

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The S-type version uses a conventional starter motor mounted alongside the engine block and acting directly onto the starter ring gear.
The X-type mounts the starter motor alongside the bell housing. It incorporates an intermediate gear rather than acting directly onto the starter ring gear.

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Flywheel

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The flywheel is slimmer on the X-type version, probably to keep the bellhousing as compact as possible.
Due to the difference in the starter motor configurations the X-type ring gear does not incorporate engagement chamfers on its teeth as it is in constant mesh with the x-type starters intermediate gear.

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", "_anchor": "gallery5-bn", "_isUserblock": true, "_cid": "sMvRUL2GEh", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Sump

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The sumps are very different shapes between the two versions.
The S-type version has a very forward mounted sump bowl extending under the front pulley.
The X-type version has a more conventional central sump bowl.

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", "_anchor": "gallery5-bo", "_isUserblock": true, "_cid": "sMvTcXPBBB", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Adapting the Engine to Fit

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\n The following is based on my experiences with my Jaguar S-type sourced engine and manual transmission and its adaption to fit to my 1971 Reliant Scimitar.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-bp", "_isUserblock": true, "_cid": "sMw8LCZqed", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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Sump (Including Baffles)

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\n Options and baffles

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Dual and Single Mass Options

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\n Engine Mount / Remote Oil Filter

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If you are installing the engine in a rear wheel drive / longitudinal orientation then it makes sense to look at the S-types stock engine mounts. But the left hand mount on the S-type version is a large bulky item incorporating oilways and mountings for the standard oil cooler and oil filter mounting. It is pretty much guaranteed to foul on something. Here is how I got around it.

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\n Cooling System

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\n Accessories Mounting and Drive

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\n Relocating the alternator and adapting the accessories drive belt path to suite.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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AJ-V6 Sump

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As already mentioned, the AJ-V6 was available in both longitudinal (S-type) and transverse (X-type) layouts with different sumps to suite.\n
The S-type sump is a bit of an odd shape with a very forward located sump bowl that extends under the front pulley.
Whereas the X-type sump has a centrally located sump bowl making it much more suitable for many applications. 

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S-type - Note the two threaded mounting lug holes cast into the sump near the front. These are not present in the transverse version.
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S-type
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S-type with unusual forward extension sump bowl.
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Transverse Sump - Note lack of previously mentioned threaded mounting lug holes.
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Transverse Sump
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Transverse Sump
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Swapping Sumps

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Thanks to its Ford Duratec heritage there is also the option of the Ford Mondeo as a transverse sump donor which came with a variety of subtle variations of the same theme. There are also some American models with more variations but they all appear to follow the same central sump bowl theme with differences to the baffle plate and internal oil flow control walls\n
 In fact there are pages of discussions on the internet as to the pros and cons of the various incarnations of this sump.

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The sumps are a straight swap, the only thing to be aware of is a change to the design of the sump gasket in 2004. The gasket changed from a fairly conventional metal sandwich plate with bonded rubber seal to an all rubber seal that sits in a groove cut into the mating face of the sump. There were no changes made to the engine block so either type can be used with any engine. Just make sure you order the correct seal to suite whatever sump you end up with.

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Earlier Gasket - Conventional metal plate with bonded rubber seal.
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Later Gasket - All rubber seal that sits in a groove in the mating face of the sump.
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If changing the sump you will of course also need to swap to the corresponding oil pump pick-up pipe and dip-stick & tube.

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Oil pump pick-up pipe
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X-type / Transverse
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Dip-stick & Tube
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Sump Baffles

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The internet has thrown up the odd complaint of oil starvation affecting these engines. The internet is notorious for its ‘on-line experts’ but whilst the sump is off I saw no harm in trying to improve things a bit by making up some baffles to try to impede oil surge.

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The bare transverse sump.
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The standard set-up as shown above uses a simple plate across the top of the sump bowl as is common on most domestic vehicle engines.
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Some more elaborate aftermarket baffle plates are available but there is no reason why you can't make your own.
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The idea is to box in the area around the oil pick-up to try to keep it submerged in the oil. Through trial and error with CAD (Cardboard Aided Design), the required profile was achieved and transferred to sheet metal. A small clearance gap is maintained around the edges so as not to restrict sump draining during oil changes.
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The finished article with hinge gates fitted made from undrilled stainless steel piano hinge, note the addition of a third baffle. The final assembly is riveted together to the original plate with solid Monel rivets.
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The ends of the hinge plate are cut and bent in such a manner as to prevent the hinge pin from migrating out of the hinge and to also act as a stop to prevent the hinge moving too far at the risk of getting stuck open.
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Installed - Looking back
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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AJ-V6 Left Hand Engine Mount

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The left hand engine mount on the S-type version is a large bulky affair. It is mounted over the engine blocks original oil filter mounting face and so it contains oil passageways and new mounting faces to relocate both the filter and a small coolant cooled oil cooler.

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Left Hand Engine Mount.
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The middle (upwards pointing) face is for the small coolant cooled oil cooler. The end (downwards pointing) face is for the spin-on oil filter.
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Mount removed revealing the original oil filter mounting face.
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Mount viewed from above.
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Title

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Fortunately we are in luck, the two items, as expected, are connected in series but:
1) The centre oil passage way of the original oil filter mounting face is still connected directly to the centre oil passage way on the relocated oil filter mounting face.
2) The outer oil passage way (ring) of the original oil filter mounting is connected directly to the centre oil passageway of the oil cooler mounting face.
This means that the outer rings on the relocated faces on the mount are only connected to each other and so can be removed, turning the oilways within the mount into nothing more than glorified pipe extensions.

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Oil filter portion cut off.
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Viewed from below to reveal feed and return ports.
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If you have space and wanted to retain the small oil cooler you could tidy up the cut ends, tap them and fit the unions now.
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I then spent a considerable amount of time with various grinders and files (but evidently without a camera) removing the outer ring of the oil cooler mount.
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The blue connector is screwed directly into the original oil cooler connection. The other connection required the passage way opening up and tapping to match the connector. It was then taken to a local engineering shop where it was welded in place.
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The finished article ready to be refitted.
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\n As fitted to the Scimitar

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\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Remote Filter Head

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Obviously this is just a case of buying one from the aftermarket suppliers.
I did manage to find this tidy all-in-one filter head incorporating a thermostatic valve and connections for an oil cooler.
However, it is both un-tested and unbranded so I can't tell you where to get one from or how good it is.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Project: Bratwurst

\n

Hello and welcome to project Bratwurst! (or Bratty for short, ratty Beemer) This was my entry for the Practical Performance Car £999 challenge 2010 held at Santapod on 17th September.\n
\n
For those of you not in the know, Practical Performance Car magazine is the only real world monthly car building/modifying magazine out there worth buying on a regular basis and there £999 challenge was a much anticipated annual event, this being the fourth such event.\n
For more details on the magazine (from now on referred to as PPC) click on the link:\n
\n

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-cm", "_isUserblock": true, "_cid": "sNDFCgV1zP", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n \"Mobirise\"\n

\n How it looked in my imagination. The reality was a lot more down to earth (and green).

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\n The PPC £999 Challenge

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The challenge was simple, you were allowed a budget of up to £999 (of your own money sadly) to buy and modify the car of your choice to compete in two challenges.

These challenges were:\n
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1 ) Drag Run - Straight simple drag race.\n
2) Handling Course - Timed slalom.
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\n The Car

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1991 BMW 525i SE\n
M50B25 Engine: 2.5ltr straight 6, DOHC and 24 valves. Non-Vanos (Variable valve timing thingy).\n
Approx 189bhp @ 5900rpm and 184lbs/ft @ 4200rpm when new according to wikipedia.\n
Weight : 1.48 Tonnes\n
Value:\n
£80 at the time (2008, makes you sick doesn't it!)
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\n History:\n
The car was given to me November '08 as a spares car for my then daily driver '92 BMW 518SE and was even the same colour (the BMW alongside it was my old daily driver). The car was at the end of it's working life and in very shabby condition. The only parts of any use to me for spares were the electric window mechanisms and the four wheels as they had reasonable tyres on them. Everything else was either worn out or broken. However it did have a nice engine and it was rear wheel drive. Oh, and it was free!

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In order to make things a bit fairer and give the car a value I took it along to the local breakers for an evaluation. The theory behind this being that although not everyone was in the position to receive a free BMW, there was nothing stopping anyone from buying one from a scrapyard. I also wanted to see how much it weighed before I started stripping it out.

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The car weighed in at 1.48 Tonnes. This was with a near empty fuel tank. At present values (21/11/08) that gave the vehicle a scrap value of £59. The dealer later added that he'd give me another £20 for the alloy wheels giving a total of £80. This left a substantial amount of the £999 budget left to play with (minus another £5 for getting it weighed) which might have seemed an unfair advantage to some but bearing in mind that I had very little funds, a young family to support and two other projects all demanding there cut of my finances I couldn't see me getting anywhere near the maximum budget in my total spend!\n

And Finally, the name, why 'Project: Bratwurst'? Well, it's not entirely my own idea, I shamelessly stole the idea for the projects name from a member of the PPC forum by the username Crogthomas with his project sausage. He had a 1988 1.0 Nissan Micra project car affectionately named ‘Sausage’ by his girlfriend, “because it’s an old banger”. I liked it and decided to copy it but with an added Germanic twist!
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\n Initial Assessment

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\n What sort of condition is a free BMW going to be in?

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\n Weight Loss

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\n As Colin Chapman said, \"add lightness\".

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\n Rectification

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\n So long as the basics work...

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\n Modifications

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\n Big plans on a small budget.

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\n Budget

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\n Think 'Tesco Value'...

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The Big Day!

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\n 17/09/2010

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I did it! I actually did it! I got the Bratwurst to Santapod for the big event! I was disqualified for a minor technicality (no MOT) but so were two others but we knew that before we started and were allowed to have some fun anyway.\n
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So how did it perform? Faultlessly! Despite the drivers worst efforts! The engine never missed a beat all day even if I did miss a gear on the first go up the strip and went from 6,000rpm in third gear back down to second! It survived unscathed though and continued to put in a strong performance up the strip.
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The final best standing quarter mile time was:\n
14.9662 seconds\n
91.60 mph

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Admittedly a bit of an unfair match on this run.

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To give this some form of perspective, there were about 35 entrants of which only twelve achieved a sub 15second run. As you can see, the orange racing scheme didn't quite make it. Maybe next year.\n
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The handling course wasn't so successful. This was due in part to the front tracking be very much out of line with far too much tow-out, the opposite to what you would normally have on a rear wheel drive car. This revealed itself early on in the project when I removed the front wheels. Although they showed plenty of tread on there outer edges, they were bold on the inner edges. This meant that the car was prone to under steering. Of course, had it been set up correctly I would probably have just spun it instead as the other problem was the incompetent driver. It would have looked more spectacular though!

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Lessons Learnt & Development Opportunities

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Drag Strip\n
I was well chuffed with my results with this. I didn’t expect a middle of the range 19yr old 5 series to brake under 15 seconds with just a weight loss program!
Problems – Traction in first was terrible and not great in second. Things improved with practice but the car could easily be improved on.\n
Development – The first obvious fix is an LSD, or a could fit a welded up 518 diff that’ll give me lower gearing for faster acceleration. I wasn’t quite maxing out in fourth by the end of the strip, I think I still had another 1,000 rpm left to go. Another problem was a result of the lightening process. The rear suspension had very little load on it and as a result had become very rigid. The front though still had the weight of the engine to contend with and so was still very compliant. This of course was very much restricting weight transfer to the rear under hard acceleration. A few measurements and a trip to the breakers to find something the right size from a smaller car might be the order of the day here, or perhaps get the originals re-tempered.

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Handling course\n
I knew the car would struggle here, not least because it’s a bit big and now relatively nose heavy, but also due to the rather inexperienced driver.\n
Problems – Apart from the idiot behind the wheel, the car was carrying a problem before I even started. The original front tyres, though showing lots of tread on the outer edge, were bald on the inner edge. So it’s pretty clear that the tracking is way out with lots of toe-out. This made it’s presence felt at the big bend at the top of the course where the front wheels could be felt to scrub and break traction resulting in a tendency to under-steer. Had I got the tracking sorted then I might have been able to provide a bit more entertainment by over-steering instead and spinning off into the cones. The 2.5” suspension lift (from the weight loss plan) and the fact that the rear end was hard whilst the front was still soft may also not have helped but I think my limitations would have been reached before these had an effect.\n
Development – Get the tracking sorted! Then lower the ride height and get something softer on the back.

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Conclusion\n
In all, a very pleasing first attempt with no complaints whatsoever. Lots of development potential in the car that can be carried out relatively cheaply and easily. I was seriously tempted to keep the car, finish and flog the other projects, and concentrate on seeing just how far I could develop it within the confines of the competition.
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\n LEARN MORE\n LIVE DEMO\n
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\n The Fate of Project Bratwurst

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\n So what became of Project Bratwurst? Did it realise its full potential?
Sadly no, lack of funds and the looming loss of storage meant it had to go. So regrettably it went on ebay (old advert in the link).
But the spirit lives on. I had so much fun building and developing this car that it changed my outlook on the hobby. It's ethos lives on in the yellow Scimitar!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Project: Bratwurst - Initial Assessment

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The first stage of the project is assessing just what I've got to play with. This section will be tweaked, ammended and updated until the full starting condition of the project vehicle has been assessed.\n
As already stated, I have had the car weighed to get a starting point for the vehicles weight. This turned out to be a fairly hefty 1.48 tonnes.\n
Next on the list should really be a power run at the local rolling road to see how well (or not) the engine is presently performing. I'm sure it's down on power as I had to work it hard to keep up with a slightly chaved up mk5 Escort charging up a hill leaving a 30mph zone! However, this whole project is about minimal outlay (and in my case effort due to other more demanding projects).\n
That leaves the fault list. Oh well, here goes:
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Body & Fittings

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Dent in front off side wing causing interference with drivers door.\n
Torn seat covers and worn head liner.\n
Dog eared external body trim and ill fitting front panels.\n
Loose rear spoiler.\n
Slow intermittent door mirrors.\n
Rear view mirror in glove box!\n
Spare key snapped of in passenger door.\n
Only remaining key will not fit drivers door so the car cannot be locked.\n
Minor rust bubbles on front wings.\n
Rusted jacking points (found later).\n
Rusted rear seatbelt mounts (found later).\n
Rusted rear off side sill (found later).

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\n Mechanical

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Fluid leaks from engine.\n
Suspect over fueling - dirty injectors?\n
Loose sensor hanging on wire from engine loom, suspect knock sensor?\n
Vague steering and steering wheel center offset.\n
Vibrations through steering and body at all speeds - wheel balancing?\n
Suspension clonks and suspect handling - possibly caused by above?\n
Inactive ratchet on hand-brake so will not stay on.\n
Major vibration through steering and body under heavy braking from speed.\n
Suspect loose baffle in exhaust.\n
Strange loud hissing from drivers foot well with engine running at idle.\n
Radiator shot. (found later)

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\n Electrical

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Major electrical short flattening fresh battery within a few hours with ignition off.\n
Instrument cluster not fully operational (minor warning/info displays).\n
Central locking system apparently suspect (unable to prove).

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Oh, and it's probably a bit lardy for the auto-test

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The Good Bits:

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It was very cheap (i.e. free but worth £80 scrap with alloys).\n
It has a nice looking 2.5ltr straight 6 DOHC 24 valve engine.\n
The brake discs look fairly recent.\n
It's rear wheel drive.\n
All four electric windows work well (for fitting to my daily driver 518).

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Project: Bratwurst - Repairs

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As you can see from Stage 1 - Initial Assessment there are numerous faults with the car. A lot of the faults will either not effect the cars performance in it's new role (i.e. cosmetics) or will be eradicated through simple removal of the components concerned. Therefore I shall start this section with a list of the faults that will actually need rectifying.
So here goes:

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\n Bodywork & Fittings

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Loose rear spoiler\n
I would normally remove such nonsense as spoilers as they usually do little more than create excess drag and slow the car down. However as there was an Auto-test element listed for the 2009 challenge to think about and the spoiler does a good job of acting as a visual aid to show me where the back of the car is, I was going to retain it. As it transpired, the auto-test element didn't involve any precision reversing of any significance and was in fact carried out on gravel therefore it could be removed. It is held in place by four bolts, two at each end. The spoiler is already loose on the nearside (and is letting in water) but this is due to the bolt holes in the boot skin having rusted. The original plan was to plate this area but as the daily driver that this car was originally donating spares to has now itself retired from service it shall be donating it's pristine spoiler-less boot lid to the Bratwurst.

Rear view mirror in glovebox\n
As far as I'm aware it is not an MOT requirement to have a rear view mirror (look at vans etc...) However, it would be rather irresponsible (and blumin annoying) not to have one. I could just glue the original one back on but it's rather heavy. I'll replace it with something light and plastic from a scrap car. I have some friends on the look out at the moment, one of which does the odd bit of banger racing. The replacement door mirrors will come from a similar source.

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Only remaining key will not fit drivers door so the car cannot be locked\n
It would be handy to be able to lock the car for the obvious reason that I don't want the thing to go missing! I was going to get a set from the local breakers and had been quoted £20 for a replacement set of locks and key but as the old daily driver has now been retired I'll simply take the locks from that instead. I'll still add £20 to the budget however to keep things fair as the fact that the car couldn't be secured caused the previous owners decision to donate it to me.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Bodywork & Fittings

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Rusted Jacking points\n
I found one jacking point to be rusted when removing the wheels for balancing. However, once I raised the car up and had a good poke around the rest it soon became apparent that all four jacking points had rusted and needed plating.

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Nearside Front
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Rusted seat belt mounts\n
Two plates were also required to the floor-pan at the centre rear seatbelt mount positions.

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Centre Rear Seatbelt Nearside Anchorage
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Centre Rear Seatbelt Offside Anchorage
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Rot cut out and plates let in.
Here you can also see some of the 'swiss cheese' lightening holes in the rear bulkhead.
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Rusted Off-Side Rear Sill\n
As already mentioned in stage 1, this hole was discovered later on in the build whilst prodding a bulge in the stone guard.
Sadly, as is often the case, the visible signs were just the tip of the iceberg.

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Offside rear sill hole.
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Cut out.
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Rot extends around rear jacking point.
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Function over form, and excuse the shody welding...
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The above areas are a very good representation of the main areas to look out for for rust on these E34 platform BMWs. The problem stems from the age old habit of running the sunroof drain tubes into the sills rather than passing them all the way through and outside of the car. The water collects in the sills around the jacking points and to the rear of the sills and sits there with obvious consequences. The problem doesn't reveal itself until the rust is at a very advanced stage due to the thickness and quality of the stone guard sprayed onto the outer surface of the sills. This acts to mask the very real problem developing on the inside. To be fair, you have to consider the age of these vehicles (the newest being built in '95) so they have put up a good fight really. Sadly now though many have succumbed.

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Mechanical

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Fluid leaks from engine.\n
I gave the engine a clean and they disappeared! Momentarily at least... Oil is leaking from the rocker cover onto the exhaust manifold whilst the engine is running. A new seal fixed it.

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Loose sensor hanging on wire from engine loom, suspect knock sensor?\n
I got this one wrong. In my defence I was in a gloomy workshop looking up at it from a distance. Now, after taking a photo of it outside in glorious sunshine and with the head lamp unit out of the way it's obviously not a sensor hanging on a wire. For a start it's on a tube. It is in fact a battery vent tube.

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Title

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Vibrations through steering and body at all speeds - wheel balancing?\n
Top of the list to get sorted is the apparent imbalance in the wheels to try to eradicate the vibrations. This should make it easier to assess the condition of the cars suspension and steering components. This has already been covered on the Stage 1 page but to sum up, two of the wheels were significantly out of balance and one needed a bit of tweaking. I have taken the car for a test drive since having the wheels balanced and am happy to report that up to motorway speeds all vibration has vanished.I can now better assess the cars handling.

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Suspension clonks and suspect handling - possibly caused by above?\n
Since the wheels were re balanced most of the suspension gripes have gone away. There are no bangs or clunks and the car seems to handle the bumps pretty well. It's just the steering that's not much cop but I did notice that the front tyres were wearing out unevenly with the inner edges being worn away noticeably more than the outers. I'll get the tracking checked (or I might give it a go myself) and take it from there.

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Inactive ratchet on hand-brake so will not stay on.\n
On removing the rear section of the centre console, the reason for the handbrakes failure became very much apparent. The lever has split just behind the hand grip. On straightening the lever the ratchet mechanism began to work again. Therefore the lever simply needs welding to repair the split and prevent it from bending again. Only instead of welding it I simply swapped across the assembly from the now retired ex-daily driver.
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Strange loud hissing from drivers foot well with engine running at idle.\n
This turned out to be part of the climate control. The system uses a vacuum tapping from the inlet manifold to draw air from the cabin through a temp sensor to tell the temp control system what the cabin temperature is so that it can adjust accordingly. It helps to improve the systems reaction time. There are two feeds, one in each footwell and each serving it's own system (the left and right side of the car are independent of each other, posh or what!). The drivers side system had been tampered with and so was making noise in operation.As the heater system is being removed this problem will eradicate itself.

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Radiator shot
Nothing for it but to get a replacement quality item from the local breakers. This time the yard at the end of the village I live in came to the rescue with an identical radiator from a BMW 320i for £25. Well, identical except for the coolant level float switch that lives in the bottom of the expansion tank, but this can be simply swapped across (blanking plug fitted on replacement 320i radiator).
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Major electrical short flattening fresh battery within a few hours with ignition off.\n
As described in Stage 2, I discovered what may well be the cause of the electrical faults that had blighted this car whilst removing excess wiring from the boot lid. I found that a small area of the loom had become significantly damaged where it enters the plastic conduit attached to the nearside boot hinge.The insulation had cracked in numerous places on all the wires in the loom in an area of approx one inch.

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One of those wires is an earth wire, you'll also notice one wire broken (many others were close to breaking point) this accounts for the inactive off-side reversing light. A lot of these wires aren't required, the remaining wires had the damaged section cut out and were re-soldered together.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-dw", "_isUserblock": true, "_cid": "sNJPygQKLy", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Bratty Lightening.html": { "settings": { "title": "Bratwurst Weight Loss", "order": 37, "meta_descr": "Project: Bratwurst Weight Loss - Lightening the light weight racing BMW E34" }, "components": [ { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Project: Bratwurst - Adding Lightness

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It might seem a bit strange starting the modifications before fixing the faults with the car but as the main modification is stripping as much out of the car as possible in the quest to reduce it's weight, it makes sense to do this first. A lot of the cars faults may well then disappear as the faulty items are deemed surplus to requirements and removed. It'll also improve access to the parts that do need attention.\n
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The plan is to remove anything that is not needed to make the car function, retain it's structural inegrity or to keep it within the requirements to make it road legal. Anything that cannot be removed will hopefully be either modified or replaced with a lighter alternative.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" }, "DIV": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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According to wikipedia, the BMW 525i had 187 bhp when it left the factory. The car has been weighed at 1.47 tonnes. That gives a power to weight ratio of 127 bhp per Tonne. Not a wholly unrespectable figure but one that will need to be improved upon if I've any hope of battling it out in the challenge or on the race track.\n
Now, the sensible thing for me to have done before I stripped the thing out, other than weighing it, would have been to take pictures of the wheel arch gaps and measure the ride height. Sadly I failed to do this. However, a member of the BMW5 forum has an identical model except for the colour and has kindly taken a couple of pics and some measurements for me.
Measurements have been taken from the wheel centre to the middle of the wheel arch and are with the vehicle unladen. The dimensions on the standard vehicle are:
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Front: 370mm
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" }, "DIV": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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The stripped out stance at the front now measures 430mm, an increase of 60mm (2.3/8\"), those front springs are going to need a fair bit of shortening!\n
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Just as a point of interest, I moved the car to a new slot down the works car club and parked it next to a similar 530i. The eagle eyed might also notice the third 5 series to the left, that's my old daily driver the 518. For those who aren't familiar with older cars the cool looking white car on the right is a Rover P5B Coupe. These were the first cars that the famous Rover V8 appeared in. It's very cool but also pretty rusty.

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Boot line now noticeably higher than its siblings.
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\n Sadly I was unable to get the vehicle re-weighed following its weight loss plan so I do not know what the new power to weight ratio is. But it is now a lot more nose heavy than before as there was a lot less that I could actually remove from the front of the car and still keep it driveable.
The rear suspension now doesn't compress at all. All movement is taken up by the shock absorbers upper mounting bushes.
It's also a lot noisier inside it now.

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\n LEARN MORE\n LIVE DEMO\n
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Project: Bratwurst - Doors

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Fronts\n
The first part of the car to under go a crash diet was the drivers door. The reason for starting with the drivers door was very simple, the window mechanism in my daily 518s drivers door has broken so I need the parts from this one to fix it!\n
The plan with the front doors is to reduce them to a bare shell, cut out the inner metal skin and fit light weight liners. The only items that will be going back into the doors are the handles to enable them to be opened from either inside or outside. The internal lock release pins will also be retained. The door glass and mirrors are covered in the relevant section.\n
The door cards were removed to get to the innards of the door. The door mirror and window seals are then removed to allow careful removal of the door glass and mechanism (to be used on my daily driver). On these cars the window mechanism is pop-riveted in place onto the inner door skin.

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Title

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With the door stripped it's almost time to get the angle grinder out. There's a lot of excess metal on that inner skin and with no window mechanism to support a lot of it can now come out. But first the replacement door liner needs to be made. This will show how much of a lip needs to be left around the inner door skin to hold the liner in place.\n
A rough pattern was made from a large sheet of cardboard and this was ofered up to the door and continously trimmed until the desired result was obtained. Most people use thin aluminium sheet to make there door liners from due to it's light weight and availability. I however managed to scrounge some thin hard plastic sheets left over from a job from years ago.
This is offered up to the door and whilst held in position, a marker pen is used to draw around it. The inner door skin is then cut approx 1 inch within this line to provide a mounting surface.

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These old BMWs are made of tough stuff, that was a new cutting disc when I started.
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That anti-drum / sound deadening pad adds a fair bit of weight and so was removed with a heat gun and scraper.
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The exterior handles also received attention. This is the bare handle assembly after all the electrics have been removed, it's still looking very substantial and very much on the heavy side. The big weight (to give it that quality feel) at the top of the handle doesn't exactly help matters and will be loosing some of its bulk.

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The rear doors of course received the same attention. The only difference being that the interior door handle is removed completely as it is not required.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Bratty Glazing.html": { "settings": { "title": "Bratwurst Glazing", "order": 39, "meta_descr": "Project: Bratwurst BMW E34 light weight racer glazing" }, "components": [ { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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Project: Bratwurst
Sunroof, Mirrors & Sunroof

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As you've probably already guessed, the plan is to replace all the glass with lighter perspex. The only glass to remain is the windscreen. The electric mirrors are to be replaced with light weight manual items and the suprisingly heavy metal sunroof panel will also be replaced with perspex.

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Door Glass\n
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The door glass is being replaced with a fixed sheet of 4mm perspex. First a cardboard template was made. The template was then used to cut the new glazing from the 4mm perspex sheet.
Next step is to bond the perspex to the frame with sealant and add some screws to help restrain it. Just wish I'd taken a photo of it!

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Cardboard template.
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Template covers extremities of the frame.
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Perspex replacement.
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Perspex slots behind edge of outer door skin.
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Rear Screen\n
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The rear screen is a large heavy item in itself so it too will be replaced with perspex. The rear screen is bonded in as with many modern cars but preferably needs to be removed in one piece to aid in making a template for the replacement.
Of course, in true tradition I have no photos of the finished article. It was secured in place with lots of self tapping screws into the frame and load spreading strips. I don't want this blowing out on the drag strip.

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Plastic trim removed.
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Using a scraper to cut through the bonding sealant. This took blumin ages!
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Finally it is out and in one piece.
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Making the card template.
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All of the old sealant needed removing.
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The bottom corners of the screen were spaced out with rubber blocks on fitment of the new perspex panel as the original glass curves inwards here where as the perspex was just going to crack.
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Title

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Mirrors\n
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The electric door mirrors were ditched during the strip down of the front doors with the intention of replacing them with light weight manual affairs. I was going to buy some simple plastic items from a kit car supplier I found on the internet for about £18 delivered but then, whilst browsing through the auto-jumble at a local car show I found these for £10.
I wouldn't know about the M5 bit but they definitely don't have an indicator built in. Unless that's what the mirror bit is, to indicate if there's anything coming past you! They are black though. Not that any of this matters, they are light and do the job. The glass area isn't quite as big as I would have liked but for £10 I'm not going to get too worried about it.
However, they never actually got fitted.

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SunRoof\n
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The headlining has already been removed in the Cabin section leaving just the sunroof mechanism. As can be seen, the sunroof mechanism is held in a reinforced plastic tray. This is bolted to the roof and comes out as a complete unit.
The resulting hole was covered with a piece of rigid plastic sheet, a load of pop-rivets and a generous squidge of sealant.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Project: Bratwurst - Cabin

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There's lots to do in here! Even the modest SE spec Beemer is crammed full of executive excess. By the time I've finished with it should be more reminiscent of a tin shed. Even an old Series Landrover should feel inviting compared to this car. Then again...\n
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All the seats will of course go along with the carpets, underlay, dashboard, headlining, every last bit of trim, sound deadening pads, anything and everything!\n
I'll start with the rear seat as it's easiest.\n
The base of the bench seat is removed first by simply grasping the front edge of it and yanking it upwards. It then pulls straight out. This revealed rather more than I was expecting!\n
There's a lot of wires down there and a large junction/distribution box with more fuses and probably some relays hidden away inside. Oh well, must press on.
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Lot's of electrickery going on.
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The black brackets near the top of the bulkhead are for the headrests. Note the seatbelt recoil units. On these cars the rear seatbelts are mounted the other way around to usual so the release is by the doors. Makes securing young children and their car seats so much easier!
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Bulkhead stripped.
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Rear carpet and under-seat sound deadening removed.
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Alternative battery mounting under rear seat will be utilised to move heavy battery from the front of the car.
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This revealed the rust near the centre rear seat-belt mounts.
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'C' pillar trims revealed more wiring and the radio arial amplifier. There's also the wiring for the electric sunroof.
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Moving to the front half of the cabin, work starts to remove the centre console.

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Dashboard next.

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Near-side under-dash behind the glove box. note the metal bracket.
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Bracket removed.
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Instrument cluster removed.
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Off-side under-dash.
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The dashboard is secured at each end by a couple of star drive bolts and is clipped along the forward edge to the bulkhead. The are also a number of large electrical multiplugs in the nearside footwell that need disconnecting. Of course I discovered this after I got the dash out!

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That big heater box needs to go.

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Carpets and underfloor ventilation and fittings.

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The carpet has thick foam underlay built in.
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The floor mounted accelerator pedal s mounted on a column to bring it up to carpet level. 
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The headlining also came out.
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Piles

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Thought I'd better take some pictures of it all piled up before it went to the tip.
Now this is mainly the carpets and sound deadening material along with the dash, centre console, heater system and the head lining. It does not include the seats, the door cards, window mechanisms, glass, boot trim, external trim, sunroof or mirrors! And there's still more to come!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Project: Bratwurst - Rear Section

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The rear section is a bit like a continuation of the cabin area with some elements of the front section thrown in. Out goes all the boot trim and furniture (tool box, jack etc...) but there's also the rear bumper and other alterations that can be made.

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Rear Bumper\n
The rear end strip, like the front end, is starting off with the bumper. This also has the large cross member behind it but unlike the front, this one is made of thick fibre glass. It is also still fairly heavy and the metal mounting brackets are rather substantial.\n
But before it is removed it is receiving some preliminary treatment to the rear valance. It's been cut off! The valance serves two purposes other than cosmetic appearances. It does a reasonable job as an air brake acting on the air trying to escape from underneath the car and it also restricts access to the mounting brackets. With this in mind it took no great deal of thought before attacking it!
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This greatly improved access to the mounting brackets and considering the amount of dirt and debri that fell out of it has also contributed to the weight saving.
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The bumper mounts can be clearly seen now and were soon unbolted from the bodyshell with the following result.
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And out comes the cross member\n
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The body structure behind reveals a handy ledge of attaching the new bumper brackets to.
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Title

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Again small metal brackets are to be use to support the top edge of the bumper and stop it from sagging under it's own weight or trying to rotate about the side brackets. However, this time the aerodynamic loads will be trying to lift the rear bumper at speed (and tear it off). The removal of the rear valance section of the bumper earlier should greatly reduce this so I shall only bother with the upper brackets for this one.\n
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Here they are fitted. They are basically just bits of scrap sheet ally with slight fold in them to give them some rigidity. If you look closely you'll notice that they are mounted on rubber blocks. This is to bring them down to the correct height. I only used rubber as I had it to hand. Wooden off-cuts would have done just as well.

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", "_anchor": "gallery5-fm", "_isUserblock": true, "_cid": "sNVGio8elk", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" }, "H3": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Boot Lid
Hmmm, I'm sure we can do something with this, now where did I put the angry-grinder?

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", "_anchor": "gallery5-fn", "_isUserblock": true, "_cid": "sNVGiZVirt", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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Much lighter, but now also prone to folding in the middle if you try to slam it shut!

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-fo", "_isUserblock": true, "_cid": "sNVHdlAono", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-fk", "_isUserblock": true, "_cid": "sNVG4foBTP", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-fj", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} }, { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Project: Bratwurst - Electrics

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These BMW's all come with the same basic main wiring loom regardless of model. This means there's a lot of excess wiring for equipment that may not be fitted. As I'm removing just about everything there is now even more excess wiring! As much is being removed as possible which has resulted in a big mass of wires. I haven't taken that many pictures of this which is a shame as has actually turned out to be one of the biggest jobs on the car. Here's what I have taken.

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Under bonnet fuse box
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Stripping through the cabin
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Under rear seat fuse box
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And here is the bag of surplus wiring.
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It hit the scales at 13kg's.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Bratty Shell.html": { "settings": { "title": "Bratwurst Bodyshell", "order": 44, "meta_descr": "Project: Bratwurst BMW E34 Light Weight Racer - Body Shell" }, "components": [ { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Project: Bratwurst - Body Shell

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Once stripped of all surplus fittings, the bodyshell itself can undergo a bit of trimming. First to go is all the sound deadening adhesive pads used to stop the tin can type noises through the bodyshell. This was achieved with the aid of a hot air gun and a metal scraper.\n
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Next, all the now redundant brackets and studs that held various parts of the interior in place can be ground off.

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Rear seat bulkhead prior to be attacked with a holesaw!
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Here's how much was removed.
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All 10.3kg's of it!
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Rear bulkhead full of holes.
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", "_anchor": "gallery5-fy", "_isUserblock": true, "_cid": "sOd2vyEhNt", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-fx", "_isUserblock": true, "_cid": "sOd2hEz8zH", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-fw", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} }, { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Project: Bratwurst - Modifications

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Depending on available funds (not to be confused with remaining budget!) this section might be a bit brief! The initial and possibly most substantial modification of course is the weight loss program but others are planned. It just depends whether I can afford them or not.

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\n LEARN MORE\n LIVE DEMO\n
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Battery Relocation & Isolation Device

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To improve weight distribution I moved the battery from under the bonnet to the alternative location under the rear seat base. The bracketry was already there and there was even a convenient power junction box to wire in to.

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Original battery location.
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Note the black plastic junction box bolted to the strut tower.
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Battery tray unbolts revealing the support bracket.
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Which was cut off.
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All gone.
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The plastic junction box mounted to the strut tower is opened...
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\n ...and a new thick power cable is added.
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\n The new cable runs through an existing bulkhead bung into the cabin and then along the sill to the new battery location.
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Rear under-seat battery location ready to accept the battery.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Title

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The ingenious battery isolation device consists of a humble bulldog clip and a piece of string. You will notice I have used an old Ford square post type battery. Well as you can see from the pictures, the earth lead is simply held in place by the bulldog clip. This is attached to the rear door by a piece of string. In the event of an emergency the rear door is opened, pulling the bulldog clip from the battery post allowing the earth lead to safely fall clear of the battery thus disconnecting it from the vehicle. The magazine was so impressed by it that they awarded it 'best modification'.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Bucket Seats & Harnesses

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This potential modification was a bit of a win, I managed to purchase two old Corbeau bucket seats for £10! They were pretty tatty and hardly state of the art but for £10 they were a bargain and a lot more effective than my previous plan of gluing extra bits of foam to the existing seat to try and make my own bolsters!

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So I set about butchering the passenger seat to try to make some suitable seat rails.

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Passenger seat underside.
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Seat mounting frame.
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Rail portions freed from the frame.
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Slicing off the lower face of the seat rails.
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Finally, a pair of fixed rails.
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Back in position in the car ready for mounting the new seats to.
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Sadly that's as far the fitment of the bucket seats got.
The harness I was intending to use was an old aircraft flight crew seat harness I had managed to acquire. It had a nice feature in that the shoulder straps were on a recoiling inertia reel system like a normal seatbelt so you could still lean forward. Like a normal seat belt it would lock under a shock load and it could also be manually locked via a small lever on the end of a teleflex that would typical be mounted on the side of the seat base.

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Lockable recoiling aircraft flight crew harness.
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Recoil locking lever.
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This label is older than my wife!
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It would have looked the nuts!
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Induction / Turbo!

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The original idea here was to remove the air filter box and feed cold air straight from the front of the car into the airflow meter. This involved removing the internal intake trumpet from within the air filter housing, remounting it in place of one of the headlamp main beam units and connecting the two with some suitable ducting.

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I then got offered a used turbo for not a lot of money and started having silly ideas.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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I even got as far as picking up an ebay special exhaust manifold.

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\n But three things happened that put paid to the idea.
1) There is insufficient space on a right hand drive car for the exhaust pipe to exit past the block without fouling on the steering column.
2) I ran out of time.
3) I didn't have enough money for all the rest of it anyway.
So my boosted aspirations remained just a pipe dream.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-gm", "_isUserblock": true, "_cid": "sPU1HSjCzv", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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As this is a subject in itself it gets its own section.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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AJ-V6 Flywheels

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Like most modern domestic engines, the AJ-V6 uses a dual mass flywheel, the S-type variant weighing in at 12kg.
A normal single mass flywheel was available on the V6 Duratec powered Mondeo ST220 and I managed to get hold of one to see if it would fit. Whilst it will certainly bolt up to the crank there are some key differences that make it unsuitable when using the rear wheel drive gearbox.

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Left - Mondeo ST220
Right - Standard Jaguar S-type
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Note the removable spigot bearing carrier is still fitted to the S-type flywheel.
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Difference in thickness means the clutch assembly sits much closer to the engine on the Mondeo flywheel...
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So you would have to check the splines on the gearbox input/primary shaft extend far enough and you will likely need a spacer for the clutch release bearing.
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But the real stopper is the starter ring gear. Although the outer diameter is the same there are two issue with the teeth.
1) They are of a different pitch to the S-type (or most other similar) starter motor.
2) They don't have a chamfered 'lead-in' to guide engagement of the starter pinion.

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Mondeo left, S-Type right. Note subtle bevelled lead in on engagement side of S-type teeth.
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Mondeo left, S-type right.
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Title

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So why not just swap the ring gears over?
The problem here is that the internal diameter of the Mondeo ST220 ring gear is smaller than that of the S-type ring gear making the S-type ring gear effectively too big.

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Mondeo flywheel,
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Ring gear internal diameter 267mm
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S-Type flywheel
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Ring gear internal diameter 270mm
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\n \"Mobirise\"\n

www.TTVRacing.com

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Fortunately there is another option. UK based TTV Racing actually list a range of lightened flywheels purposely for the S-type version of this engine.
Click on the picture to be taken to their website.

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TTV Racing

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After saving up some pocket money I took the plunge and bought the TTV Racing single mass 'Lite' flywheel. At 6.1kg this is about half the weight of the standard 12 kg dual mass flywheel. Lighter flywheels are available from them but I want to retain some road manners.

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As delivered, looking all shiny and fast.
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The 'Lite' flywheel uses the standard S-Type clutch assembly.
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The spigot bearing carrier is machines as an integral part of the flywheel,as is the starter ring gear.
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\n \"Mobirise\"\n

\n A few items are required to fit the flywheel regardless of what you end up with:
Spigot Bearing - P/N: 410 0015 10 (LUK)
Bolts (8. off) - P/N: C2S5392 (Jaguar), 4 107 081 (Ford)
Rear crank seal - P/N: AJ89510 (Jaguar), 4 605 210 (Ford)
The rear crank seal isn't a necessity but unless your engine is freshly rebuilt it makes sense to whilst you are there. The genuine parts price is a bit steep but it is up to you if you want to take the risk on this item with a cheaper aftermarket item.

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", "_anchor": "image3-11o", "_isUserblock": true, "_cid": "tt1SbQ23xw", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "gallery5-11p", "_isUserblock": true, "_cid": "tt1X5A8snC", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-bs", "_isUserblock": true, "_cid": "sMylPthsgX", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-br", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} }, { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Bratty Front.html": { "settings": { "title": "Bratwurst Front", "order": 41, "meta_descr": "Project: Bratwurst Light Weight BMW E34 525i Racer - Front Section" }, "components": [ { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 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Project: Bratwurst - Front Section

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The front section is possibly the more awkward area to loose weight in. It has the heaviest single component in the car located in it, the engine. Not much can be removed from this to make it lighter and still function. There's little by way of trim or furnishings that can go either. But there are certainly a number of things that can be removed, reduced or replaced with lighter alternatives.\n

Front Bumper
The front bumper has a large metal cross-member behind it that needs to come out. This requires removal of the bumper first which entails removal of large amounts of front end trim (not all of which will be going back on). The front bumper was first to be attacked. The manual of course makes the job out to be much simpler than this!

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Pipework is the power steering oil cooler that has to be loosened to allow movement of it's connecting pipework that covers some of the bumpers mounting fasteners.
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Here the air filter box has been removed to reveal the nearside bumper bracket.
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Those rigid pipe lines go to the previously mentioned power steering oil cooler.
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And the off-side bracket in front of the battery tray.\n
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The bolts wouldn't shift and I couldn't get in there with my breaker bar. Well, not unless I go in through the head light aperture!
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "left" }, "H3": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Title

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With the bumper off and the metal work out it is immediately apparent that the plastic part itself is actually pretty rigid. Therefore, as a lot of the weight is in the metal mounting arms, the whole metal assembly will be ditched. You'll also note that the lower inserts have been removed. The middle section below the number plate had to be cut off to remove it. I'm hoping to fit a mesh and channel some more cooling air into the radiator. I just hope it doesn't upset the cars highly tuned aerodynamics!

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Here's the back of the front bumper showing the big metal girder within.
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The plastic covers are simply pinned onto the beam with plastic expanding rivets similar to some of the internal fixings.
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The plan is to ditch the beam and mounting irons completely.
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The bumper is re-attached with simple folded metal brackets whilst utilising the original side mounts
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Simple folded steel brackets pop-riveted to cut down front panel metalwork.
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Power steering oil cooler piping clearly visible here.
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Scrap sheet ally lower mounts.
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As said, the original side mounts are now supporting more of the bumpers weight (which has now been dramatically reduced). The three upper mounts along the top of the bumper also support a fair amount of the bumpers weight but also stop the bumper from sagging down as it naturally try's to rotate about the side mounts. The bottom plates aren't supporting any weight but are supporting against aerodynamic loads trying to push the bottom of the bumper under the car at speed.

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Sliding side mounts.
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Secured with self-tappers.
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Complete.
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Heater Blower Motor & Fans\n
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The heater blower motor & fan assembly is only being removed temporarily at the moment to aid in the removal of all the other parts that are no longer required. The present plan is to later refit the blower along with a limited amount of ducting to provide for windscreen demisting and cabin cooling (that didn't happen).

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When the heater and blowers go so do the heater control valves.

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Whilst the fan access bulkhead panel was removed I stripped the insulating padding from it. This made a huge difference to its weight.

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What these blurry images are trying to tell you is that the panel with the padding weighs 5lbs where as the panel with it all removed weighs only 2lbs.
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Battery Tray\n
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As mentioned elsewhere, the battery is to be relocated from the engine bay to the alternative location under the rear seat. This will allow the removal of the battery tray structure under the bonnet and free up a fair amount of space for any possible future turbo conversions. The windscreen washer bottle has also been removed in these shots.
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Wiper Mechanism\n
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The wiper mechanism is a fairly substantial unit in it's own right even with the motor removed.The main frame is alloy and very much over engineered for the limited use it's going to get. The assembly as shown in the pictures weighs in at 1.7kgs.\n
This is actually the mechanism from the old daily driver 518 as one of the spindle housings has worn. The original one from Bratwurst was used to replace it as it would prove more useful on a car I use on a daily basis as opposed to a car that may well never get driven in the rain again.

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And the final weight? 1.6kgs! Well worth all that effort! Most of the weight to be fair is in the steel operating bars and arms which I haven't touched. In the end, after the demise of the daily driver 518 I have refitted the slightly better original without bothering to repeat this procedure.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-ga", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} } ] }, "Bratty Budget.html": { "settings": { "title": "Bratwurst Budget", "order": 48, "meta_descr": "Project: Bratwurst Light Weight BMW E34 525i Race Car" }, "components": [ { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Project: Bratwurst - Budget

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\n As stated, this car was built to compete in the Practical Performance Car magazines £999 challenge.
As such, a record of expenses has been kept and is reproduced here.

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\n LEARN MORE\n LIVE DEMO\n
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\n Subtitle\n

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1991 BMW E34 525i

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£85

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\n Given to me for free but to keep in the spirit of the competition I took it to the local breakers for a valuation.
It weighed in at 1.48t which at the time gave it a value of £59.20
Plus £20 for the four alloy wheels.
Plus £5 charge for weighing it.

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Repairs

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\n £43

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Used radiator £25
Wheel balancing £17

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Materials for Modifications

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£100

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Acrylic sheet for windows £60
Plastic for door cards £20
Used bucket seats (not used) £10
Harnesses (not used) £???
Door Mirrors (not used) £10

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Total:

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£228

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Special Issue

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\n $39

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n $39

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n $39

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Special Issue

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\n $39

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\n Themes in the Mobirise website builder offer multiple blocks: intros, sliders, galleries,\n forms, articles, and so on. Start a project and click on the red plus buttons to see the\n blocks available for your theme.\n

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Well, the two that I had anyway. Everything else was secondhand cash in hand...

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "sPSGvhrEps", "_anchor": "menu1-h1", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Project: Bratwurst - The Sale of The Century!

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Sadly, due to the imminent loss of my storage space for her, Project Bratwurst went up on ebay on 1st July 2011.
Here are the details of the advert.

Listing info\n
Page views: 897\n
Duration: 10 days\n
Start time: 01 Jul, 2011 20:32:23 BST\n
Start price: £100.00\n
Final Sale Price: £205
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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-h4", "_isUserblock": true, "_cid": "sPUmrPZzMm", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n \"Mobirise\"\n

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Project Bratwurst!

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This is it, your once in a life time chance to own a legend* of the race track!\n
This is Project Bratwurst, my Practical Performance Car magazines, £999 challenge veteran.\n
You might find it hard to believe, but under all of those finely crafted modifications lies a humble 1991 BMW 525i. It has undergone extensive race inspired development* to get it to the standard you now see here.
\n
It has been lightened at great expense* and has had the suspension carefully tuned*. The engine has been looked at (quite literally, I’ve spent hours just standing there looking at it) and the aerodynamics have been tweaked.

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Now, after looking through some of the forums whilst developing this ‘thunder saloon’ I have noticed a growing trend when describing the spec of a car to say what it hasn’t got. Apparently, the ‘in’ phrase for this is to call it ‘delete’.\n
So, with that in mind, here are some of the fantastic things that this car hasn’t got:

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Electric Windows – Delete\n
Central Locking – Delete\n
Electric Mirrors - Delete\n
Carpet - Delete\n
Rear Seats - Delete\n
Headlining - Delete\n
Sun-Roof – Delete\n
Centre Console – Delete\n
Dashboard – Delete\n
Door Cards – Delete\n
Sound Deadening - Delete\n
Rear Screen Glass – Delete\n
Door Glass – Delete\n
Door Inner Skins – Delete\n
Boot Linings - Delete\n
Boot Spoiler – Delete\n
Wheel Arch Liners – Delete\n
Front Fog/Vanity Lights – Delete\n
Heater - Delete\n
Bangin Stereo, innit! – Delete

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Look at all those fantastic features this car no longer has! That’s a lot of upmarket comforts you won’t be getting for your money. Absolute bargain!

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Oh, and it no longer has an ashtray

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So what do you get?\n
Well, if the above isn’t enough, what you are getting is :\n
1991 BMW 525i SE Manual\n
2.5ltr M50 B25 non-vanos\n
For none BMW aficionados, that’s an iron block, alloy head, DOHC 24 valve straight six without the variable cam timing thingy (Vanos) that most engine builders seem to ‘Delete’ anyway.\n
This engine is alleged to have approx 189bhp @ 5900rpm and 184lbs/ft @ 4200rpm when new according to wikipedia. It is popular with engine tuners due to the inherent strength of the iron block and in places like Europe and America, where they let the passenger drive the car, they are popular for turbo conversions.\n
The engine itself has proven to be very reliable and never missed a beat at the event. It occasionally produces a cam follower tap which soon clears once the engine is loaded.\n
Due to the success of the weight-loss program, the car rose up 2.5” on its suspension pretty much topping it out. Obviously, standard lowering springs would still leave the car 1.5” higher than standard and make the suspension too stiff. Therefore, after months of research and careful selection* a pair of Mazda MX5 rear springs have been fitted to the rear of the car. The front springs have had approx 2 coils removed from them to level the car out.\n
The front tracking has been reset after the modifications and it now drives very nicely.\n
The brakes are standard but are now having to stop a lot less weight.\n
I have not re-weighed the car after ‘deleting’ most of it but I have removed 13kg of excess wiring and 10kg of anti-drum sheeting alone! The front and rear bumpers have both been gutted and remounted on lighter mounts but are still very much secure in place.\n
There has also been some lightening of a more organic nature. Some areas of the shell have been converted to iron-oxide. This process takes a very long time (in this case, about twenty years) and improves with maturity. The results are even lighter than carbon fibre! However, it has been rather localised to the jacking points and a few other select parts as is common with these particular vehicles and so, in order to try to restore the weight distribution, steel plates have been welded to the affected areas. This has been carried out to a standard that any self respecting five year old would be proud of!\n
The deleted door and rear glass has been replaced with 5mm clear plastic sheet that is both screwed and bonded in place. The door mirrors have also been deleted but a pair of light weight replacement door mirrors are included in the sale.\n
Also included are a pair of mint condition bucket seats. By mint, I mean the polo variety with the hole in it. In fact, there more like a couple of packets of polos. Or maybe a box of Cheerios. Either way, they are full of holes and have pulled stitching. They do however match the rest of the car rather well and come complete with two pairs of cut down BMW seat runners and some box section steel to make the mounting frames from.\n
Thanks to me being a plum and loosing the only key, it cannot be locked. Well, it can, but you won’t be able to get in it again unless you unscrew one of the windows. Also, the ignition barrel has now been butchered and the ignition switch detached to enable activation by a dumpy flat bladed screw-driver. I shall include the dumpy screw-driver in the sale. However, should you loose it you should easily be able to find a replacement at any branch of Halfords, B&Q etc…\n
Whilst on the subject of the electrics, this car won an award for ‘best modification’ in the 2010 PPC £999 challenge. This was for my ingenious battery isolation device. The battery will not be included in the sale (though this is not a ‘delete’ option, you will need one to start the car each time) but I will leave the patented* isolation device fitted.\n
The car will be sold with the wheels shown in the pictures (standard BMW Lattice alloys) but with worn out tyres fitted. I haven’t worn the tyres out myself, I’m simply keeping them as they fit my daily driver and have good tread on them.\n
There is a lot more information on this car in the build story on my website but I think that if I put the website address on this advert I will be in breach of ebay rules so I’m afraid you either have to contact me to ask for it or you’ll have to trawl the web in the hope that you get lucky\n
What it achieved\n
The event was held at Santapod Raceway where, despite my worst efforts on the standing quarter mile, it achieved:\n
14.96 Seconds @ 91mph.\n
That was with major traction problems in first gear with not much improvement in second gear and with a complete numpty behind the wheel who'd never raced before\n
What it needs\n
Improved traction! Either hunt out an LSD or, as I was planning to do, get the diff welded. The average price for this seems to be around the £30 mark and details are available on the popular tramp drifting website.\n
It’ll also need tyres and a few loose ends sorting such as a wiring the wiper switch back in, finishing the wiring for the ventilation fan and possibly some of the lighting wiring if you wanted to make it road legal again.\n
As for the missing lights, they could be re-instated with a bit of electrickery or, to keep the moody look, just run it on a daylight only MOT (yes they are available for cars).\n
Personally, if you want to rule the race track, taking it on a trailer is the way forward. Knowing you aren’t relying on it to get you home does wonders for your lap times!\n
It comes with a few odd spares and some part used tins of paint.\n
So why am I selling?\n
I really wish I could keep this, I have had loads of fun with it and want to develop it further but I have two other projects on the go and something has to give.\n
Legal stuff:\n
No Tax (Sorned but you will have to re-sorn on change of ownership)\n
No MOT\n
Will have to be trailered away (by law, all four wheels must be off the ground)\n
Registration document present.\n
And Finally:\n
You bid to buy, not to view. You are welcome to pay to come and view if you wish, or just come and view anyway prior to auction ending. The car is located on a secure military airbase and as such, viewing is limited to Saturday 9th and Sunday 10th July.\n
Cash on collection please. Vehicle to be removed within 14 days of auction end.\n
Starting bid is what I believe it is worth for scrap, it would make a good engine donor if nothing else. I’d quite like to swap the engine and box into an old Triumph 2000 saloon (might also fit a Stag as they are based on the same car).\n
Or you could use it in this years PPC £999 Challenge! You’ve got until 17th September to get it ready!\n
As said, loads more info available including lots of photos on request\n
Happy Bidding.

*Actually, that might not be correct.


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Questions & Answers\n
Q: Hello, I only wish I had the room for it, it was really fast at Santa Pod at last year's £999 challenge. Who ever gets this, is going to have a great time in it!! 03-Jul-11\n
A: Ta very much, just rub it in why don't you!

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Q: i am guessing this is you smiler with the car that spanked me in last years £999.... if you were closer i'd be buying it for the engine as its sweet as hell!!! 03-Jul-11\n
A: Yes it is, I'm guessing from the name that you are Bulletproof Bob from said challenge. I didn't realise it was you in the gimp suite strapped to the bonnet getting spanked.

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Q: The best item description I've ever seen by far! Good luck with the sale 02-Jul-11\n
A: Why thankyou very much. I try'd to keep it in the style of the car, a big bit of fun. Basicaly, if I get at least the £100 starting bid for it then it's not going to waste down the breakers. It would be an ideal engine donor if nothing else as everything is there, the engine and transmission can be seen working and everything else is stripped out so you can get to everything. I'd rather see it get some use than just weighed in and crushed.
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\n The Cars Fate!

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The car was collected by its new owner on saturday 16th July '11 and trailered away. It has been purchased for it's engine and transmission with the intention being to transplant them into an 80's Mazda. The plan is to eventually turbo-charge the engine, much as I was considering doing only in a more professional manner.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Project: Bratwurst - Suspension

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As stated elsewhere, the suspension is in need of some urgent attention. The weight loss program resulted in a 2.5\" suspension lift! Added to that is the fact that the rear suspension is now topped out with very little weight over the rear wheels resulting in a rather stiff set up. The plan is to lower the suspension all round and try to soften the rear.
I ran out of time to carry out this work before the event so it was done afterwards in preparation for the following years event. Sadly circumstances prevented me from attending that one and the car was sold but not before the suspension work was completed.
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As the rear needs attention the most, this will take precedence and will be tackled first. The front will then be altered to suit.

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", "_anchor": "content4-gp", "_isUserblock": true, "_cid": "sPU5nCzNBk", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Rear Suspension

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The plan for the rear suspension was to find some alternative springs of the correct diameter, preferably from a small car. I had a rummage around a few local scrap yards and a moot around on ebay and then struck gold at work of all places. Whilst having a clear out of an old store room a set of four car springs were unearthed. It turned out that they were removed from a colleagues Mazda MX5 when he upgraded to a set of adjustable coil-overs. They looked about the right diameter and the length appeared promising so an exchange of paper beer tokens took place and I gave them a go.\n
As can be seen in the pictures below, they are quite a close match, being ever so slightly larger in diameter and about 3\" shorter than the originals.

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Holes for retaining straps drilled through top plate.
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Similar holes drilled through lower saddle plate.
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Metal straps.
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Looks like it's launching!
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Front Suspension

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The front, which still has the weight of the engine acting on it and so is still compliant, will be lowered in the age old method of spring chopping. Not the most elegant solution but if done carefully it should hopefully both lower and stiffen the front.\n
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The strut top mounts were un-bolted from the strut towers on the inner wings and the springs were clamped with a pair of spring compressors. The strut could then be lowered and pulled outwards allowing access for the springs to be cut in-situ. For gods sake don't try this at home. I am a proven idiot! (you should have figured that out by now). I should have removed the springs for cutting.
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The springs were cut each side a bit at a time and the suspension re-assembled until the correct height (i.e. level with the rear) was achieved. A total of one and two thirds of a coil were removed.

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Cuts were obviously made above the clamps but even so, not my finest moment.
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", "_anchor": "gallery5-gr", "_isUserblock": true, "_cid": "sPU6OlmoL9", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 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The Result

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As can be seen, the car is at a much healthier looking height.

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\n Title

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It's looking pretty level too! The front end has also stiffened up as a result of the springs now having less active coils to soak up movement. The back is still a bit too stiff but at least the balance has been evened out a bit now.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-gt", "_isUserblock": true, "_cid": "sPUbeQyQup", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n \"Mobirise\"\n

\n Text

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-gc", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "Escort Upgrades.html": { "settings": { "title": "Escort Upgrades", "order": 14, "meta_descr": "Ford Escort Mk3 & 4 Info and Mods" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Mk3/4 Upgrades

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Welcome to the Ford Escort MK3&4 survival and improvement website!

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-hi", "_isUserblock": true, "_cid": "sPUxCliJnE", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n \"Mobirise\"\n

\n My own project car and the subject of this part of the website.

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\n Introduction

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\n
Hello and welcome to the site. This was originally a website in its own right and was set up as a result of hours (by that I mean years) of bashing my knuckles whilst working on my own vehicle and trying to fit parts to it from other later cars. I had been building and modifying my own mk3 Escort for quite some time and incorporated into it many of the updated features of later cars. I therefore discovered first hand the many problems and pitfalls that lie behind even the simplest of upgrades and know how to overcome them. As there appeared to be a lot of interest in these subjects, I have decided to set up this site so that anyone else planning similar conversions can learn from my experiences and hopefully help solve a few headaches. (what a hero!)

However, this was some time ago now (best part of twenty years ago!) so a lot of the alternative parts will now be scarce. Due to the rising values of original Mk3 Escorts you may not want to modify your car now. I have also seemingly lost a large number of the original images some time in the past so some sections are rather thin on photos for which I apologise.
But this site still provides an interesting nostalgic trip to what we were doing to these cars at the turn of the century.

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Brakes

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\n Raiding the Ford parts bin.

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\n More Ford parts bin raiding and why the M3 Escort was better.

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\n Ford Escort Mk3 SG2000i

\n

\n The start of this section of my website, my own project car, the Hairdresser Chariot itself, the mighty SG2000i
SG200i? Yes, like the RS1600i but with my initials (as I built it) and the new engine size.
Click on the image below to be taken to the exciting back story.

\n
\n LEARN MORE\n LIVE DEMO\n
\n
\n
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", "_anchor": "content4-si", "_isUserblock": true, "_cid": "sQ4WeHyQSc", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Engines

\n

\n The mk3 & 4 Escort came with four different types of engine fitted, three petrol and one diesel.\n
\n
The three petrol engines fitted are:\n
OHV (in 1.1 and 1.3 ltr sizes)
HCS (replacing the OHV in 1989)
CVH (in 1.3, 1.4 & 1.6 ltr sizes with both carb, mechanical and electronic fuel injection and turbocharged)

I'm afraid I have no details for the diesel version. Sorry.
\n
\n

\n
\n LEARN MORE\n LIVE DEMO\n
\n
\n
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", "_anchor": "content4-ho", "_isUserblock": true, "_cid": "sPUEr5antE", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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OHV & HCS

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\n Over Head Valve & High Compression Swirl

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\n CVH

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\n Compound Valve-angle, Hemispherical head

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\n Engine Swaps!

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\n When it comes to engine swaps the first limitation is your own abilities. Swapping to an engine from higher up the range such as an RS turbo swap is going to be a lot easier than fitting an engine that never saw service in these Escorts. Fitting an engine from a different manufacturer carries with it even more obstacles to overcome but it is not unachievable. I know of one Escort that was successfully converted to Rover K-Series power!
The easiest and most cost effective engine swap for something that was never fitted to the Escort is probably the Ford Zetec from the later Escorts and the Mondeos.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-hs", "_isUserblock": true, "_cid": "sPUKT9TsH0", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n This is covered in its own section on the main site. The guide is based on the conversion I carried out on my own Mk3 Escort Cabriolet so everything you need to know should be covered in there.Click the picture to be taken to it.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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Escort Upgrades - CVH Breather System

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During the production run of the 1.6 MFi CVH engine a number of revisions where carried out to the crankcase ventilation system. These modifications were carried out to try to combat problems with stalling and rough idleing that was being caused by oil contamination of the throttle housing from the crankcase venting system.\n
\n
Before carrying out this modification you need to make sure the rest of the breather system is in good order. The breather hose from the front of the airbox to the rear drivers side of the cylinder head rocker cover must be checked for blockage as must the breather hose at the back of the block on the near side running from the bottom of the crank case to the rocker cover. These two apertures in the rocker cover themselves must be checked clear of blockage as they are often full of crud. The connection at the base of the block is also prone to guming up and must be clear. There is however a baffle behind this aperture so care must be taken.

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\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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On the MK3 cars, there were two versions of the breather system with the second version being introduced to try to overcome these problems but they weren't completely eradicated until a redisgned throttle assembly was introduced with the MK4 cars.\n
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Rather than mess about explaining the earlier versions I'll go straight to the latest spec, especially as parts aren't going to be in numerous supply down the local scrapyard.\n
First you need to source a throttle housing from a MK4 MFi car. This can be identified by a small idle adjustment screw on top of the housing with a tamper proof cap as opposed to the large thumb wheel adjuster mounted under the throttle housing on the earlier version.Clean up the throttle housing and check all passages are free from blockage. Fit this in place of your existing throttle housing. This does of course mean you'll probably have to adjust the idle screw.
Whilst you're there, retrieve the hose connector from the drivers side of the plenum chamber and the hose coming from it. You'll also want the small length of pipe connected to it ant the three way plastic adaptor as shown.
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Plenum connection, three-way adaptor and pipes.
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You'll find a blanking plug on the drivers side of the plenum chamber that you'll need to remove and insert the newly aquired hose connector. Discard the Filter and replace with the plastic adapter. You may have a small pipe running from the filter you have just removed across the front of the plenum chamber to a 'T' piece. Remove this pipe, the 'T' piece and the short pipe connecting the 'T' piece to the throttle housing end of the plenum chamber and discard. Connect the now free floating small diameter pipe directly to the plenum chamber.

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You should now have a set up similar to that shown below. The MK4 throttle housing and the near side plenum brether plumbed via a large diameter pipe to the auxiliary air device as normal and via a small diameter pipe directly to the over run fuel shut off valve (cylindrical unit on back of air filter lid). The drivers side plenum chamber breather should be attached to the new adapter in place of the filter which should in turn be connected to the rocker cover and via a long length of hose to the front of the air filter lid/fuel distributor unit.

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Basically, the nearside plenum chamber breather is taken out of the breather circuit and used solely as a tapping for the running of the engine (auxiliary air device and overrun fuel shut off valve). A new tapping is made into the drivers side of the plenum via the new hose connector which takes over the role of crankcase venting. The new throttle housing moves the idle air passage from the bottom of the housing where it it prone to blockage from contaminants to the top of the housing.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Range Rover P38 DSE

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Dispelling the myth?

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\n Text

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\n Title

\n

Ah, that stanchion of unreliability, the second generation Range Rover. But are they really as bad as the hype would have you believe? After being so pleasantly surprised by how great a car the much maligned Rover 75 is I decided to take the plunge in 2017 and find out for myself. As this is in the 'Active' projects section I obviously still have it and it has been in daily use.
Sure it has needed attention, it's a quarter of a century old! But are they really that bad as rumour would have you believe?

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\n Repairs

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\n The following sections show the rectification work I have had to carry out on the vehicle during my ownership.
Bare in mind that at this age these vehicles have spent many many years at the mercy of their owners own abilities and in some cases dubious garages that hide their own ineptitude behind the vehicles poor reputation.

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\n Electrics

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\n These vehicles are packed with 90's technology. Here are a few tips to give you a fighting chance.

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\n Upgrades

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\n Sensible improvements to ensure the longevity of your P38 and a few choice upgrades enhance it.

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\n Alloy Radiator

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Upgrading the standard fitment radiator to an all alloy aftermarket item.

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\n Finally

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\n Information and technical support is key to owning a complex older vehicle. Here is a link to the best technical forum out there for the Range Rover P38.

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www.RangeRovers.pub

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\n Unlimited Sites\n

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n The Black Pudding

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\n Made from the bits nobody wants.

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\n Title

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I bought this '79 Reliant Scimitar SE6A from a good friend of mine. It was the first known GM V6 conversion using the 3.0ltr engine and 5 speed manual gearbox from an ex-Police motorway patrol Vauxhall Omega. The whole build was recorded in a diary on the Scimitar & Sabre Owners Club Forum. It was built to compete in the 2009 Practical Performance Car magazines £999 challenge, the £999 being the maximum allowable budget to buy and modify a car to compete in a drag race and a handling course. It was a very successful conversion putting in a strong performance, earning itself a feature in the magazine and spawned a number of similar conversions. Details of his work are reproduced in a linked section below.

A while after the competition Nathans attention moved on to other things and the car spent some time sat dormant until he offered it to me for a price he knew I wouldn't be able to refuse. It was actually supposed to be a project for my son to get involved in but being only eight the draw of his mates and his games machine was too strong so progress was rather pedestrian.

Fast forward five years and one house move and it has now come to the point where it either gets some serious effort put into it or I'll end up sweeping it up into a skip! So despite already having a Scimitar project on the go, it looks like I'll be requiring a second toolkit!

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\n 3.0ltr GM V6 conversion

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\n The original builders online diary from the Scimitar & Sabre Owners Club forum.

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The Resurrection

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\n The car has been off the road for a decade, spending much of that time parked on grass. It also leaks. So as you can imagine, it is in a bit of a state. Some work has been started in the past but the whole car needs stripping, repairing and rebuilding. I shall attempt to record progress in the following sections.

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The Starting Point

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\n Any adverts are youtubes' doing and beyond my control. I certainly don't see any revenue from them!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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1971 Reliant Scimitar SE5

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\n Under Construction

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\n LEARN MORE\n LIVE DEMO\n
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\n Title

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\n This is my favourite project. My aim is to make this old sports car go as fast as I can for as little as I realistically can. I had so much enjoyment with 'Project: Bratwurst' (see 'Past Projects' section of this website) that I wanted to build something else following the same ethos. But in order to be able to achieve this that heavy old Essex lump had to go! Hence the Jag V6 conversion.
The rest of the car needs work including a number of common repairs which I have detailed within the sections below so if you have a Scimitar that is suffering the more common ailments then take a look as you may find some useful info in there to help you.

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Live Action Video

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First though, here is a video walk around of the general state of the car. This video will be updated and replaced from time to time.

Recorded on shaky old technology with appalling sound reproduction...
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\n Any adverts are youtubes' doing and beyond my control. I certainly don't see any revenue from them!

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\n The Work!

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The work, including general repairs that may be of interest to other owners, has been broken down into major sections accessed through the links below.

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\n Chassis

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\n Suspension & Steering

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\n Strip & Refurbish

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\n Brakes

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\n Engine & Transmission

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Jaguar S-type sourced 3.0ltr AJ-V6 and manual 5-speed gearbox

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\n Bringing the wiring up to date

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n OHV & HCS

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The mk3 Escort was available with two sizes of the OHV (Over Head Valve) engine, 1.1ltr and 1.3ltr. This is a pushrod engine (as opposed to an overhead cam engine) and both sizes shared the same bore size, the extra displacement of the 1.3 being achieved by using a longer stroke crankshaft. The larger 1.3 also used a five main bearing crank whereas the smaller 1.1 used a three main bearing crank\n
It is basically the same OHV engine as was fitted to earlier rear wheel drive (RWD) Escorts, some Cortina's and the Fiesta. In fact it's descendent saw use as the 'Valencia' in the Ford Ka.\n
The earlier Escort and Cortina OHV engines will not fit the front wheel drive mk3 Escort (or Fiesta) as the blocks are slightly different. This is due to the front wheel drive Escorts transverse engine mounting. The later FWD blocks have a mounting bolster incorporated into the block near the crank shaft pulley end to accommodate the right hand engine mount. Due to the inline configuration of the earlier RWD cars, this mounting point does not exist.\n
In 1986, with the introduction of the mk4 Escort, revisions were made to the two OHV engines. The valve timing was changed on both to give shorter opening durations to both inlet and exhaust valves and the 1.1 ltr engine had it's valves reduced in size. Keep this in mind when sourcing parts from mk4 cars down the breakers as the camshafts will be different to give the smaller cam duration and although the parts will probably fit (I haven't try'd it myself) you will loose performance.\n
The OHV engine was fitted to the mk4 Escort up until 1989 when it was replaced with the High Compression Swirl (HCS) engine. This is a lean burn development of the OHV engine and although it is similar in appearance and construction to the OHV engine there are a number of changes involved. The main difference is in the design of the cylinder head.\n
The inlet ports and combustion chamber have been redesigned to induce a high degree of swirl into the incoming gas flow as it enters the chamber to give improved mixing. The inlet and exhaust ports and valves have also been moved around. They now adopt a mirrored arrangement where by the two centre cylinders (2&3) now have there inlet valves next to each other. This means that the inlet and exhaust manifolds from the HCS engine will not fit the OHV engine as the ports will not match up. It also means that the camshaft cannot be swapped either as the inlet and exhaust valve lobes will be in the wrong positions.\n
Another new feature of the HCS engine was the adoption of a solid state ignition system. Instead of a conventional distributor, the HCS engine uses Fords DIS (Distributor-less Ignition System) system. This is a simple computer controlled ignition system that uses three sensors on the engine to determine when and where to fire a spark.\n
Finally, the HCS engine also uses a different carburetor to account for the differing fueling characteristics\n
Other than those differences mentioned, the HCS engine can be regarded in the same way as the OHV engine.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Compound Valve-angle, Hemispherical combustion chamber

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The CVH engine was introduced with the new mk3 Escort in 1980 and saw service through to the early mk5 Escort. It was also fitted to the Equivalent Orion's and the Fiesta from mk2 guise A redeveloped version also found it's way into the Sierra. Initially it was available in three capacities, 1.1ltr, 1.3ltr & 1.6ltr. Later 1.4ltr and 1.8ltr versions joined the line up but these differed a bit from the original engines as will be explained.

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The Engine\n
The engine is of single over head cam, eight valve design and consists of a conventional iron block with a five main bearing crank (some older small engines such as the OHV engine only used three main bearing crank) and an alloy cylinder head.The cam shaft is driven by a conventional toothed belt which also drives the water pump and the cam shaft operates the valves via hydraulic followers (with one exception, the RS 1600i uses shimmed solid followers) and rockers.

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All engines were designed to run on leaded petrol up until October 1985 when Ford fitted hardened valve seats to the cylinder heads to allow the engines to run on unleaded. This of course is right at the end of the mk3 Escorts production run so the majority of the mk3 Escorts out there will have left the factory with leaded petrol heads fitted. All mk4 Escorts however should be safe for unleaded petrol.\n
In 1986 a lean burn version of the engine was introduced which featured a modified cylinder head chamber. Instead of being of hemispherical design it used a heart shaped combustion chamber. The idea behind it was that it would push the combustible mixture towards the spark plug. To account for the reduced capacity caused by the intrusion into the cylinder head chamber to create the heart shape, the pistons were modified to bring capacity back up to the correct amount. This of course means that if you were to fit a standard hemi head to a lean burn bottom end you'd end up with a slight increase in capacity but a lower compression ratio and vice versa if you fitted a lean burn head to a standard bottom end. The 1.4 ltr version replaced the 1.3ltr engine in this year too.\n
As previously mentioned, the Sierra also used the CVH engine and came in both 1.6ltr and 1.8ltr sizes. However, don't get excited about plans to fit a 1.8ltr CVH from a Sierra into your Escort. The engines are very different from the CVH we are used to. They underwent many changes to be made suitable for the rear wheel drive application including new mount locations on the blocks and repositioning of the distributor etc.. They didn't have fantastic performance and have been all but ignored by the aftermarket tuning industry so there's not much that can be done to improve them. If you want bigger capacity beyond the existing transverse CVH range then you need to look for an alternative engine.

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Induction - Carburettors\n
Most of the engines in the mk3 Escort were Carburettor fed with Bosch mechanical fuel injection being fitted to some of the top spec models. Two types of carburettor were used, Fords own variable venturi (VV) carburettor and a Weber dual venturi (2V) 32/34 DFT carburettor. The fitments were as follows:\n
Ford VV Carburettor\n
1.1ltr..........81SF-9510-KAA\n
1.3ltr..........81SF-9510-KCA\n
1.6ltr..........81SF-9510-KFA\n
Weber 2V 32/34 DFT Carburettor\n
1.6ltr (certain models only).....81SF-9510-AA\n
If you wish to fit the Weber 2V carburettor in place of a Ford VV on your engine then you'll also need the corresponding inlet manifold as the base flange is different. As far as I am aware the mechanical fuel pump is common to all carburettor fed engines.\n
Later engines including engines fitted to the Fiesta range used different variations of Weber DFTM and TDL carburettors.

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The first production fuel injected CVH engines used the try'd and tested Bosch K-jetronic mechanical fuel injection (MFi) system. This is a continuous injection system using an airflow sensing plate mounted on a pivot to meter the rate of fuel flowing through to the injectors. Although fairly agricultural in operation it has proven to be a highly reliable system and can be found fitted to a multitude of different manufacturers cars including Ferrari! I have created a simple idiots guide as to how this system works that can be accessed further down this page.\n
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There were two more fuel injection systems fitted to the CVH throughout it's life, Central Fuel Injection (CFi) and Electronic Fuel Injection (EFi) covered shortly. Both are electronic systems with many similarities in the way that they operate. However, the CFi system uses a single fuel injector mounted in what looks very much like a modified carburettor mounted on a conventional inlet manifold. I haven't covered the CFi system in any detail on this site as it was never fitted to any production mk3 or 4 Escort and retro fitting this system to any car would be a ludicrous waste of time and money.

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Induction - Forced Induction\n
In 1984 Ford released the Escort RS Turbo. This as you probably already know and as the name suggests featured a turbo charged version of the CVH engine.It utilises a Garret T3 turbocharger and a modified version of the Bosch injection system designated KE-Jetronic which features additional electronic control.

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Induction - EFI - Electronic Fuel Injection
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The last year of mk4 Escort XR3i production saw the adoption of the EEC IV engine management system. Despite being named as EEC IV, it was actually the first production version, the previous three versions being development models. It was a bit rudimentary compared to todays systems with a separate ignition module but it still achieves the same end result. With after market remapping it has the capacity to be more tuneable than the Bosch K-jet system it replaced to get the best out of any engine modifications. Retro-fitment to a mk3 is possible but even if you do manage to find a donor car you will require so much from it (including fuel tank that requires its own mods) that for the end result it is a mammoth task that is just not worth it. You won't gain any extra power and it was criticised in its day for suffering flat spots. For the effort, just fit a Zetec.

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\n Bosch K-Jetronic MFi

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\n A simplified 'idiots' guide to the workings of the popular mechanical injection system.

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MFi Crankcase Breather System

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\n The crankcase breather system suffered from clogging issues and so saw a number of revisions. This section gives details of the best combination of parts.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Transmission

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\n Left - Mk3, Right Mk4

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\n The mk3 & 4 Escorts came fitted with either a manual or an automatic transmission. Early manual transmissions were four speed but the majority were 5 speed. The extra gear lives inside a bolt on extension on the end of the main casing as can be seen in the picture above (both are 5-speed transmissions).
I have no details of the automatic transmission, sorry.
The manual transmission uses the fully synchro-meshed Ford BC type gearbox. All models used the same basic gearbox but with variations to the final drive ratios.
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The sporty models final drive ratios were:\n
XR3i - 4.29:1\n
RS1600i - 3.84:1\n
S1 RS Turbo - 4.27:1\n
S2 RS Turbo - 3.82:1

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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There are differences between the mk3 & 4 gearbox cases though due to the revised method of gearbox mounting in the mk4 car.

The Mk3 gearbox uses a cast alloy arm bolted onto its forward face that attaches to a rubber mount on the LH forward suspension mounting plate and a bracket attached to the diff housing that attaches to a rear mount at the bulkhead. As can be seen in the photos below, the attachment point for the forward mounting of the Mk3 gearbox is not present on the revised Mk4 gearbox. Apparently some very early Mk4 gearbox still had the mounting platform in place on the casting though without the four holes drilled and tapped. These were probably end of line Mk3 units that were carried on into the new Mk4 production and with careful drilling and tapping could be used in the Mk3. I have not however seen any of these boxes myself so cannot say they definitely exist. If you do find one and decide to drill and tap the unused mount then be sure not to drill too deep or you'll puncture the casing.
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The Mk4 car's gearbox is supported by an additional bolt on cross-member running from front to back of the engine bay at the bellhousing position. This bolt on cross member, incorporating two rubber mounts and known as the gearbox cross member, is fixed in place to the shell by four bolts (two in the front cross member and two at the base of the bulkhead) and to the gearbox by lower bell housing bolts. Due to the fact that it locates onto the gearbox by utilizing the bell housing bolts it is possible to fit a Mk3 gearbox to a Mk4 car.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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A limited Slip Differential unit (LSD) was fitted to the top spec Series 1 & 2 RS Turbo cars to try to control wheel spin and improve traction. Fitment of these gearboxes is a good idea for high performance cars and there popularity and the fact that they were only fitted to one model makes them rather sought after so they command higher prices than the other gearboxes. However, there are no external physical differences between the LSD equipped gearbox and the standard gearbox. So how can you tell if the gearbox you are buying actually does have an LSD fitted? If the gearbox is still fitted to the car then jack the front end up so both front wheels are clear of the ground. Turn one of the wheels by hand and watch the opposite wheel. If it turns in the same direction then the gearbox has an LSD fitted. If it turns in the opposite direction then the gearbox has a standard differential gear fitted. Use the same method if the gearbox is removed from the car but still has the drive shafts or C.V. joints fitted.\n
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If the gearbox is on it's own with the drive shafts removed then you obviously aren't going to be able to turn anything. However, you can still check the LSD is present as you will now be able to see it.\n
If you look through the output/drive shaft holes in the diff housing of the gearbox you will see one of two possible things:\n
If you see a metal bar across the hole as shown in the view below then the gearbox has a standard open differential fitted (the bar can be at any angle as it rotates with the differential gear).
If you see no bar present but what looks like a thick washer deep inside then you have an LSD equipped gearbox!
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There are differences between the Series1 (Mk3) and Series2 (Mk4) RS Turbo gearboxes though that go beyond the mounting differences detailed above.\n
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The Series 1 RS Turbo was a proper homologation car with true motor sport routes and received the LSD as a result. The LSD unit could be harsh in operation and the final drive ratio was lower geared. The series 2 RS Turbo however was not a homologation car so it was toned down and re-tuned to be more civil for everyday driving. Therefore the LSD unit was altered to be smoother in operation and the final drive ratio was revised to give it longer motorway cruising legs. The other change was the way in which the crown wheel on the LSD unit was secured in place. On the Series 1 gearbox it is held onto the LSD by six bolts whereas on the Series 2 gearbox it is secured by eight bolts. Therefore the crown wheels cannot be swapped between the two LSD unit's. This means that if you whish to fit a Series 2 LSD to a Mk3 gearbox you also have to fit the crown wheel and final drive pinion. In the same way, if you wish to fit the Series 2 crown wheel and pinion to your Series 1 RS Turbo to get the higher gearing then you also need to use the Series 2 LSD unit.

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Apart from complete gearbox swaps for either 4 speed to 5 speed or for different stock ratios, there's not a lot that can be done transmission wise that I know of except for the fitting of a limited slip differential.\n
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Changing from a 4 speed to a 5 speed should as far as I know be a simple task of swapping the two complete gearboxes over. You will of course also have to swap across the gear selector linkage, though chances are your original 4 speed linkage is probably pretty worn out by now anyway. I don't know for definite but I seem to recall hearing somewhere that the gearbox and engine mounts might have been tweaked slightly when Ford started fitting 5 speed boxes to the Escort in order to move the whole engine and transmission assembly closer to the drivers wing. This would make sense as it would provide a little more clearance for the 5th gear housing of the 5 speed box. However, I have not yet had this confirmed. It is just something to bear in mind. If you do carry out such a conversion and discover that this is or is not the case then please do let me know so I can amend this page of the site.

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Fitting a limited slip differential gear to your gearbox might sound like a bit of a daunting task and many might argue that it would be easier to simply fit a gearbox from a Series 1 RS Turbo that comes with an LSD already fitted and bolts straight into a mk3 Escort.\n
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However, the Series1 RS Turbo has a relatively low geared final drive which isn't ideal for higher speed motorway cruising etc..\n
The Series2 RS Turbo had a higher geared final drive for more relaxed high speed driving making it the preferred choice. Unfortunately, as already covered in the compatibility section, being a mk4 car the Series2 RS Turbo's gearbox won't fit into the mk3 Escort.\n
There are two way around this problem. The first is to simply fit the mk3 gearbox outer casing to the Series2 RS Turbo gearbox allowing you to mount it into the mk3 shell, or remove the required innards from the Series2 RS Turbo's gearbox and fit them into your own mk3 gearbox.\n
The first option is the easiest option and will work fine as long as the donor gearbox is in good condition. However, many RS Turbo gearboxes have led a hard life and the gearbox is known to be the weak link in the performance Escort.\n
My original gearbox has been recently reconditioned when bought so I knew it's internals were good. I therefore opted to take the second option, keeping this known good gearbox and transferring the required internal parts to my good gearbox.\n
This was achieved in the following steps:
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Parts Required from the donor gearbox:
LSD assembly\n
Bare main-shaft with final drive gear (single piece unit)\n
New:\n
Gearbox rebuild kit (gaskets, seals, bearings and spring rings)

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As this is a rather complex in-depth job I have broken it down into more manageable chunks.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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The LSD has a tapered roller bearing on each end. These mate with the corresponding bearing races in the gearbox casing halves. As you are fitting the LSD to another gearbox, you will be mixing the bearings with other races which is not good practice. As the gearbox is totally stripped, now is the time to replace bearings with new. Problem is, the bearings on the LSD aren't very enthusiastic about being removed and there isn't enough space to get a bearing puller in underneath them.

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The only option is to destroy the bearing carrier and then carefully grinding the inner race off.
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The inner race should be ground through on two opposing sides to split it and relieve the clamping pressure it is imposing on the LSD.
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The new bearing can then be pushed into place.
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The other bearing may well need similar treatment to remove it. Or you might find that a bearing puller will do the trick as there is a bit more space to play with. However, you must take care not to damage the nylon speedo drive helical gear.

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Bearing and speedo drive helical gear removed.
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Nylon speedo gear in place.\n
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Tapered roller bearing being pushed into place.
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All ready to be installed (after cleaning and removing the black tape).\n
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\n Gearbox Rebuild

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Transmission Strip

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The first job is to liberate the Limited Slip Diff unit from the donor gearbox. The donor gearbox is dismantled as shown in the following sequence of instructions. However, the dismantling of the gearbox you are planning to use is exactly the same. As I have chosen to use the LSD and final drive from a Series 2 RS Turbo gearbox, that is the gearbox shown being dismantled. The procedure for striping Series1 RS Turbo gearbox is identical.

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\n Preparation\n
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The first job you need to do before you even contemplate dismantling a gearbox is to prepare a clean clear work area and clean the outside of the gearbox. You will also want containers and/or bags of some description to hold small parts and assembles etc.. I used disposable plastic cups and sandwich bags.\n
You will also need to drain as much oil out of the gearbox as possible. This is best achieved via the drive shaft output holes.\n
Don't forget to dispose of the gearbox oil properly by taking it in a suitable container to your local recycling center and not by simply pouring it down the nearest drain!

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Dismantling\n
Dismantling of both 4 and 5 speed gearboxes is very similar but in the case of the 4 speed gearbox ignore steps 3 to 6\n
The gearbox is dismantled as follows:
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1) Remove the selector shaft interlocking plunger assemblies

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The selector shaft interlocking plunger assemblies positions are arrowed above.
(4 speed gearbox has only one assembly fitted)\n
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The units themselves are simply a sprung loaded plunger that engages with notches cut into the selector shafts.

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2) Unbolt the end housing cover plate

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\n This is held in place by a row of 10mm bolts.

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It's removal reveals the fifth gear assembly
(except 4 speed gearboxes).

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3) Remove 5th gear selector pin from selector shaft

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This is achieved by undoing the clamp screw (arrowed) and pulling the unit off the shaft.

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\n The 5th gear selector pin assembly.

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4) Withdraw 5th gear complete with synchronizer clutch and selector fork

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\n Remove the circlip arrowed above to release the 5th gear assembly from the main shaft.

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\n The circlip is a single use item and must be replaced with new on re-assembly so should be discarded.

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\n The 5th gear assembly can now be withdrawn from the main shaft along with the selector fork which will come out with it's shaft still attached.

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\n Here you can see the synchronizer clutch still in place on the main shaft and the notches in the 5th gear selector shaft that the interlocking plunger assembly removed earlier engages into.

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\n The removed 5th gear wheel and selector fork complete with selector shaft.

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\n The synchronizer clutch is then simply withdrawn in the same manner by pulling it from the shaft.

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Removed complete with main-shaft 5th gear.

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5) Remove 5th gear driving gear from input shaft

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\n This gear is held in place with a snap ring. this is similar to a circlip except that it has no tangs with holes in to enable the use of circlip pliers.

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\n They can be very awkward to remove but the best method I found for this snap rings removal was to slide an old nail into one of the splines of the shaft to effectively lock the ring in position and stop it from rotating.

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\n Then the end can successfully be prised out with a thin bladed screwdriver. This snap ring is also a single use item and a new one will have to be fitted on re-assembly.

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\n The 5th gear driving gear can now be pulled from the input shaft. Although the gear on this gearbox came off quite easily, it may be necessary to use a puller to remove this gear.

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6) Detach the 5th gear casing

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\n The 5th gear casing is held onto the end of the gearbox by torx screws.

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Simply undo them all and prise the 5th gear casing away from the gearbox. There is a gasket between the casing and the main gearbox case so it might require a little effort to prise apart.

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7) Split the main gearbox casing

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\n The first thing you need to do in order to split the casing is to remove the two locking rings that locate the main and input shaft bearings.

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\n These two rings simply slide off with the aid of a screwdriver. They are reusable so need to be kept safe.

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\n There are 14 bolts to be undone in order to split the main casing including the three rear gearbox mount attaching studs.

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\n With careful use of a soft mallet tapping the sides of the casing, the casing can now be lifted clear. Again this may take some effort due to the gasket holding the two halves together.

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\n The gearbox internals are now revealed.

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\n The inside of the removed casing.

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8) Remove the magnetic debris disc

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\n This magnetic disc is located in the bottom of the differential gear casing and simply slides out of position.

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The disc acts as a makeshift filter be simply attracting metal particles to is as the various gears and components wear. This should be cleaned and stored carefully, it is rather fragile and if dropped will shatter on impact.

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9) Withdraw selector shaft guide sleeve (not 4-speed transmissions)

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\n The selector shaft guide sleeve is only a part of the selector shaft mechanism and not the entire shaft. It is the outer tube around the selector shaft and is secured in place with two circlip's.

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\n These two circlip's are fitted either side of the 1st/2nd selector fork as shown.

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\n They are easily removed with a pair of long nose pliers but be warned, they can cover great distances if simply allowed to spring away (guess how I know that!) Place a rag behind them as a simple way of preventing this from happening.

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\n The selector shaft guide sleeve can now be withdrawn.

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\n Leaving the selector forks and the fifth gear selector shaft in place.

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10) Remove the complete main and input shaft, reverse gear and selector forks

\n

\n The main and input shafts can now be removed by simply lifting them out of position. However, the selector forks and even the reverse gear will also come out with them as the whole lot comes out as one assembly.

\n
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", "_anchor": "image1-kv", "_isUserblock": true, "_cid": "sPYtA5IYDp", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n The whole assembly laid out.

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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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11) Remove the selector shaft and locking plate (not strictly necessary)

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The selector shaft is simply lifted clear.\n
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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n Selector shaft

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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n The locking plate (arrowed) is also simply lifted clear, though a certain amount of juggling may be required of the engaging linkages.

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", "_anchor": "image1-kz", "_isUserblock": true, "_cid": "sPYuCl751N", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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12) Remove the differential gear

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\n The differential is another easy lift out job.

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", "_anchor": "image1-l0", "_isUserblock": true, "_cid": "sPYuD4Q43x", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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Leaving little else in the casing other than various bearings, seals and the rest of the selector mechanism.

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", "_anchor": "image1-l2", "_isUserblock": true, "_cid": "sPYwJQm4dX", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle DIV": { "text-align": "left" }, ".mbr-section-subtitle": { "text-align": "center" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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If the gearbox you have just stripped is the gearbox you will be using, then the internals and all the component parts should now be cleaned.\n
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\n
I have not dismantled my gearbox any further as there is no need to. So if you decide to go further don't expect to find any details of how to put it back together again on this site.

\n
\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-l3", "_isUserblock": true, "_cid": "sPYx2oR5b2", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-jt", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "Escort Trans Shafts.html": { "settings": { "title": "Escort Trans Shafts", "order": 21, "meta_descr": "Ford Escort Mk 3 & 4 Maintain & Modify Transmission" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Transmission Main & Input Shafts

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\n
\n LEARN MORE\n LIVE DEMO\n
\n
\n
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\n
", "_anchor": "content4-l7", "_isUserblock": true, "_cid": "sPYzKLDAuR", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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The main shaft is required for the rebuild as the final drive spur gear is integral with the shaft. Therefore the entire shaft needs to be transferred. As it's not good engineering practice to mix used gears, the cogs from the original box will be transferred to this shaft. This is done as follows:

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\n Main-Shaft - Strip

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1. Preparation

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\n To ease the job of dismantling, the shaft is temporarily repositioned in the old gearbox casing. This provides a sturdy mount to hold the shaft whilst it is being worked on.

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2. Remove the retaining snap ring

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\n The retaining snap ring can be removed with a pair of circlip pliers as shown but it can be rather fiddly as it isn't easy to get a good purchase as it is not of the conventional circlip design with two engagement holes.

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Once free from it's groove, the snap ring is slid up the shaft to remove.

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\n If not distorted, the snap ring could be reused, though I would recommend replacement as a matter of course as it is really not worth the risk.

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3. Remove the bearing

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\n Removal of the bearing will require the use of the bearings locking ring as removed during the gearbox strip and a bearing puller.

The locking ring is repositioned in the groove on the bearing.

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\n Then the puller is used to withdraw the bearing from the shaft, the legs of the puller locating on the bearing locking ring.

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4. Remove the 4th gear

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\n The 4th gear is drawn from the shaft (shown the other way around in the photo so that you can see the selector engagement teeth).

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\n Followed by it's synchronizer ring.

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5. Remove the 3rd/4th gear selector/synchromesh

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\n The selector/synchromesh unit is retained by a snap ring which must first be removed.

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\n Then the 3rd/4th gear selector/synchromesh can be withdrawn along with the 3rd gear synchronizer ring.
Be careful when extracting the selector/synchronizer ring not to pull the unit apart. The outer 'selector' ring slides up and down the center hub and if pulled too far will disengage. This will cause three small sprung loaded bars to fly out and will provide you with the fiddly task of trying to rebuild it.

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6. Remove the 3rd gear

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\n The 3rd gear is withdrawn from the main shaft.

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7. Remove the 2nd gear

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\n The 2nd gear is held in place with a split thrust washer arrangement as shown.
The outer ring is first lifted clear which then allows the two halves of the thrust washer to be withdrawn.

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\n The 2nd gear can then be withdrawn.

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8. Remove the 1st/2nd gear selector/synchromesh

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\n After removing the 2nd gear synchronizer ring you will have access to the 1st/2nd gear selector/synchronizer.
It is held in place with another snap ring.

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\n Remove the snap ring and withdraw the selector/synchronizer.

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9. Remove the 1st gear

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\n First remove the 1st gear synchronizer ring.
Then withdraw the 1st gear.

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10. Main shaft Strip Complete

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\n That's the main shaft completely stripped down. The final drive gear to the differential is an integral part of the shaft.

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\n Main-Shaft - Build

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\n Obviously all parts should be cleaned and inspected prior to assembly and the work area also needs to be clean.
Please note that a lot of the photos in this section are actually recycled strip photos so please ignore the dirty looking oil and general grubbiness in some of the pictures.

\n
\n LEARN MORE\n LIVE DEMO\n
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1. Preparation

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\n You will need various sizes of snap rings in order to rebuild the main shaft and these don't always come with rebuild kits. The snap rings are available from your local Ford dealership. However, each snap ring comes in numerous different sizes (approx 5 sizes for each snap ring). As the snap rings are no more than 75p each (at time of writing, bearing in mind this was the best part of two decades ago) then it would be prudent to get all the available sizes in one go and choose the most suitable when the time comes.

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As before, mount the shaft in the gearbox casing to give a good sturdy working platform.
The rebuild of the shaft is pretty much (to quote a well known workshop manual) the reverse of the dismantling procedure but I shall go through it anyway.

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2. Fit the 1st gear

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\n Slide the first gear onto the shaft, making sure you have the engagement teeth facing upwards!

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3. Fit the 1st/2nd gear selector/synchromesh

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\n First fit the synchronizer ring to the first gear, being careful to note which way up it goes. Also keep in mind the three channels indicated.

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\n Fit the selector/synchromesh. The three notches in the outer circumference of the synchronizer. ring must be lined up with the three sprung bars of the selector/synchromesh assembly.
Care should be taken not to push the outer selector ring out of position on the center hub.

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\n The selector/synchromesh is secured in place with a new snap ring.
Care must be taken not to distort or over stretch the new snap rings when fitting. As previously mentioned, each snap ring comes in a choice of sizes. I don't actually know the correct way of sizing the required snap ring. I simply try'd the edge of each ring in the groove for thickness and chose the closest fit with out gripping. I also went for the smallest internal diameter each time.

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\n The 2nd gear synchronizer. ring is then fitted into position remembering to line up the three notches with the three sprung loaded bars.

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4. Fit the 2nd gear

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\n The second gear is slid into place with the engagement teeth facing downwards.

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\n It is then secured in place with the split thrust washer. The tang on each half of the thrust washer locates in a hole in the shaft, the securing ring then placed over the two halves.

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5. Fit the 3rd gear

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\n The third gear is slid onto the shaft with the engagement teeth facing upwards.

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6. Fit the 3rd/4th gear selector/synchromesh

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\n The synchronizer. ring is fitted onto the 3rd gear followed by the 3rd/4th gear selector/synchromesh assembly, taking cars to line up the notches and sprung bars as before. Alternatively, the synchronizer. ring can be fitted to the selector/synchromesh first and then the assembly slid into position.

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\n Another snap ring is used to secure the assembly in position as before.

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7. Fit the 4th gear

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\n The 4th gear synchronizer. ring is fitted into the 3rd/4th gear selector/synchromesh.

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\n Followed by the 4th gear which is simply slid into place, making sure the engagement teeth are facing downwards.

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", "_anchor": "image1-m9", "_isUserblock": true, "_cid": "sPZ7D8bG83", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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8. Fit the ball bearing

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\n The bearing is pressed into place and retained with a snap ring.
Be careful to make sure you fit it the right way around. The groove in the outer race should be towards the top!

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", "_anchor": "image1-ma", "_isUserblock": true, "_cid": "sPZ7Ek0EXB", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle DIV": { "text-align": "left" }, ".mbr-section-subtitle": { "text-align": "center" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n That is the main-shaft complete.

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\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Input Shaft

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The input shaft is pretty much a one piece assembly, there is not a great deal you can do with it other than cleaning and replacing the bearings. So that is what is done.

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Here the input shaft can be seen all cleaned with one of its two bearings removed and the new replacement bearing waiting patiently to be pressed into place.
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Here the new bearing is in place. You'll notice that this bearing has an off-set groove around its outer edge, this must be positioned towards the end of the shaft. This groove is where the large retaining clip engages on fitment of the outer casing.\n
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That's both shafts ready for re-installation.

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-md", "_isUserblock": true, "_cid": "sPZdgdN7he", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-l5", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "Escort Trans Build.html": { "settings": { "title": "Escort Trans Build", "order": 22, "meta_descr": "Ford Escort Mk 3 & 4 Maintain & Modify - Transmission" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Transmission Build

\n

The first job of course is to clean out the gearbox casings; once this is done there are just a couple of things to do before reassembly can commence.

\n
\n LEARN MORE\n LIVE DEMO\n
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Casing Preparations

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\n 1) Install Main-Shaft Bearing

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\n The main-shaft bearing adjacent to the input shaft seal is replaced. This is staked in place by centre-punching the surrounding casing as can be seen clearer in some of the following photos.
The white plastic thing in the middle of the bearing is an oil slinger to improve lubrication. Make sure you refit it before fitting the new bearing!

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2) Install The Input Shaft Seal.

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\n Remove the old input shaft seal.

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\n The seal is simply pushed home.
Note the orientation of the seal.

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3) Install The Differential Bearings Outer Races

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The new outer races for the differential/output bearings now need to be fitted. The large portion of casing containing all the selector gear has it's race fitted first. This is just a case of gently tapping the old race out and tapping the new race into place using the old race to push it in square. The old race is withdrawn by tapping from the outside of the box in.\n
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\n Then the new race is pushed in place from the inside being careful to keep it square as you drive it in. This is where using the old race as a drift helps.
Drive it all the way in until it abuts against the shoulder. Don't forget to make sure that the wide part of the taper (thin edge of the race) is facing the inside of the gearbox.

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\n Next the other race is fitted on the opposite casing. This is a little different though as will become apparent on disassembly. This bearing is held off the edge of the casing by a pair of spring washers. This is to maintain a pre load on the diff bearings and prevent any end float.

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\n The two spring washers that provide the pre load. These are fitted into the casing ahead of the new bearing race.

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\n The new race fitted on top of the two spring washers that are visible behind the race. The race, which is a sliding fit, is now secured in place again with staking by taking a punch and lightly peening over the lip of the casing in two opposing sides. This is only to prevent the race from falling out during reassembly of the two casing halves after which it'll have no where to go as the diff bearing will hold it in place. So, bearing this in mind, don't over do it or the sliding race won't be able to slide up tight enough.

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4) Fit The Magnetic Debris Disc

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\n Simply slot into place, and watch it doesn't simply slide out again! You should have your casing sat somewhere sturdy now and not require to move it again until re-assembly is complete.

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\n Re-assembly

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With the flywheel end of the gearbox casing on a sturdy work top with the flywheel side face down, proceed as follows:

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\n LEARN MORE\n LIVE DEMO\n
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1) Install The Selector Shaft

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\n The selector shaft and its lock plate are installed first.

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2) Install The Differential

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\n This is followed by the installation of the LSD. I'm sure you can figure out which way around it goes; just take care not to damage the plastic speedo drive as you install it.

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3) Fit Reverse Gear

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Before the gear can be installed, ensure that the fork at the bottom of the selector arm is engaged on the spigot from the selector shaft.

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", "_anchor": "image1-my", "_isUserblock": true, "_cid": "sPZNl2bXuE", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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The reverse gear can then be slid down its shaft taking care to engage the pin of the selector arm into the groove on the reverse gear whilst taking care to ensure that the fork at the other end of the selector arm remains engaged on the spigot from the selector shaft.

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4) Install The Input Shaft, Main Shaft & Selector Gear

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\n First of all, yes this is the same photo from the strip down section. I don't appear to have one of the cleaned and rebuilt items ready to be fitted as I have either lost it or forgot to take one in the first place!
Either way, apart from the reverse gear that you have already fitted, this is what you are about to try to manhandle back into the gearbox casing. Only yours should look nice and clean.

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\n It is a bit of a juggling act with so much to align with only one pair of hands but it is easily achievable. Getting reverse gear to sit in place can be a bit of a pain. Take note from this picture where the selector forks locate.

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\n You will have to joggle the selector forks to guide them past the shift locking plate.

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5) Insert Selector Shaft Guide Sleeve (not on 4-speed transmissions)

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\n Feed the selector shaft guide sleeve over the selector shaft and slide down through the selector forks. There are grooves in the sleeve that correspond with the selector fork positions, make sure you insert it the correct way around.

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\n The 1st / 2nd gear selector fork is locked to the sleeve with circlips. The 3rd / 4th gear selector fork is free floating on the sleeve.

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6) Casings Re-Assembly

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\n The mating faces of the casings should be clean and free of all traces of old sealant, but you have already done that when you cleaned it.
The gearbox internals are given a light covering of gear oil prior to re-assembly of the casings.

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\n The new gasket is then laid in place on a bed of jointing compound/sealant (Blue Hylomar in this case).

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\n The mating face of the other half of the casing also needs to free from oil or grease, the internal faces are given a wipe round with a rag soaked in gear oil to provide a protective film against corrosion. The differential bearing outer race is also given a light smear.

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\n More jointing compound/sealant on the mating face of the housing ready for joining the two casing halves.

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\n The two halves of the casing can now be rejoined. This involves a bit more juggling to get the input, main and selector shafts aligned with there respective holes as the housings come together. The differential assy. should line itself up but take care with the magnetic debris disc.

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\n When fully home, the grooves in the input and main shaft bearings should be visible. And yes, this is another recycled 'strip' photo.

The casing bolts are now fitted and tightened to 15.5 - 19.9 lbf.ft. No particular sequence of tightening is given but I would recommend adopting the standard 'opposites' method.

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\n Finally, the retaining clips or 'snap rings' are fitted to the input and main shaft bearings. It may be necessary to lift the bearings slightly with a screwdriver to completely reveal the slot that they engage into.

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Note that the snap rings must be orientated in such a way that they don't impede on the fifth gear housing.
These clips or 'snap rings' are available in three thicknesses as shown below. The thickness that just fits the groove should be selected.\n
\n
Snap Ring Thicknesses
1.86 - 1.89 mm (0.073 - 0.074 in)\n
1.94 - 1.97 mm (0.076 - 0.077 in)\n
2.01 - 2.04 mm (0.079 - 0.080 in)

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\n Note for four speed transmissions now go straight to stage 10

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\n Text

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\n LEARN MORE\n LIVE DEMO\n
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7) 5th Gear Housing

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\n As before with the main casings, the mating faces need to be clean and free from oil or grease. The gasket is fitted to the main gearbox casing with jointing compound/sealant. Note that the gasket is purposely shaped so that it can only be fitted with the input and main shaft bearings snap rings sat in a particular orientation as shown in the photo above. There is actual a slight mistake in the
photo. The input shaft bearing snap ring (the upper one in the photo) is fitted upside down. The small cut out just visible at the top of the photo should be at the other end of the snap ring. This is to aid removal of the main shaft bearing snap ring on disassembly as its end is located into this cut out prior to removal.

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\n Another smear of jointing compound/sealant and the fifth gear housing is fitted. (8.5 - 10.7 lbf.ft)

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8) 5th Gear - Input Shaft

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The input shaft fifth fear is fitted first, the splines of the shaft need to be lubricated with grease before assembly. The Ford manual quotes Ford Spec (& Part Number) ESEA-M1C-1014-A.
The manual also states that it will be necessary to heat the fifth gear up to about 80degrees C and then driven onto the splines. However, mine was a simple push fit without any heat (note it is not shown fully home in position in the photo).

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\n A new snap ring secures it in position.

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9) 5th Gear - Main Shaft

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First another apology, in my ongoing incompetence I have either neglected to take the appropriate photos for this section or I have managed to loose them from the computer along the way. So I'm raiding the photos from the strip down section. Just imagine that the parts look all clean and shiny!\n
\nFirst the immaculately cleaned 5th gear is slid onto the lightly greased splines of the main shaft on the spotless gearbox. Honest!

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\n Assemble the cleaned 5th gear synchro onto it's equally shiny selector fork.

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\n The assembly is then lowered into the housing.

Note the engagement of the synchroniser fork spigot in the selector linkage fork.

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\n Lock it in place with the locking collar and a new circlip.

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\n Refit the fifth gear interlock unit to the fifth gear housing.

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\n You should now be at this stage.

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10) Fit 1st - 4th and reverse gear interlock pin

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\n Yes, it's another photo pillaged from the strip down section. It now needs to be refitted to the main gearbox casing ready for setting up the 5th gear selector mechanism. Apply some jointing compound/sealant to the threads first.

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\n Fitted.

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Note for four speed transmissions now go straight to stage 12

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\n LEARN MORE\n LIVE DEMO\n
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11) Install 5th Gear Selector Pin

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\n First the gearbox needs to be put into the 5th gear position. You achieve this by turning the selector shaft (where it exits the gearbox) clockwise as far as it will go and then pulling it out.
Here you can see a pair of self locking pliers doing the honours. Go gentle with it, you don't want to score the surface and damage the seal where is passes into the gearbox.

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\n The 5th gear selector fork is now pushed down to engage the 5th gear wheel.

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\n Now the 5th gear selector pin is slid into position on the selector shift rod ensuring that the pin engages with two guide prongs and the selector linkage fork. Do not tighten at this stage!

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Using a screwdriver in the slot in the end of the selector shift rod (upper arrow in the picture), turn the shift rod clockwise until it comes to a stop. Then tighten the clamp bolt on the selector pin (lower arrow) to fix the selector pin in position on the shift rod. The bolt should be secured with a thread locker such as loctite prior to assembly.\n
Please ignore the fitted gasket in this picture, although the gearbox looks nice and shiny it is in fact another strip down photo. This time though it's of the recently overhauled original mk3 gearbox. Also, the 5th gear wheel isn't engaged in this shot.

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12) End Cover Plate

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\n As before, ensure both mating faces are clean and free from oil and grease. Lightly lubricate the 5th gear assemblies with gear oil and then assemble with a new gasket and jointing compound/sealant.

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\n Fitted.

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\n That's the gearbox reassembly complete. Just remember to refill it with oil once it is back in the car!
Don't do it prior to fitment in the car as the oil will just run out of the open drive shaft connections.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Brakes

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The Escort uses a pretty standard set up of discs at the front and drums at the rear. It uses a dual circuit hydralic system which is diagonaly split across the wheel so that each part of the system operates one front caiper on one side of the car and a rear drum on the opposite. This is a safety feature so that if one system fails you still have braking on both sides of the car. This is achieved by using a dual master cylinder. This is basically two master cylinders sat in line in one body with each of the two parts plumbed into one front calliper and one rear drum.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Upgrades

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Master Cylinder
The mk3 Escort has never been famed for it's aw inspiring brakes. In fact, the feel of the brake pedal has come in for some criticism over the years. This can be improved on with one easy modification, change the master cylinder! The 1.6 engined mk4 Orion uses a larger master cylinder than the Escort. As this master cylinder is still of the same design and layout, it can be simply fitted in place of the Escorts original instantly giving a firmer pedal feel and inspiring a little more confidence. It also prepares the braking system for future upgrades such as those listed below. For information on how to fit the Orion master cylinder please refer to your maintenance manual and treat as an ordinary master cylinder.

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Orion 1.6 on the left, Series 2 RS Turbo on the right.
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Braided Brake Hoses
The other improvement is to the flexible brake hoses, they'll be a bit old and tired by now so replace them with a set of braided hoses. These have a metal braid outer sheath which prevents the hose from expanding like a balloon when brake pressure is applied. They are easily available from most stockists and are a direct replacement.

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\n Front Brakes
One of the Series 2 RS Turbo's redeeming features is it's improved brakes. This area was the subject of much criticism for the Series1 so when the new car was being planned, Ford decided to address this problem. The new car featured bigger front discs enlarged from 239mm to 260mm diameter. This was achieved by lifting the front discs and callipers straight from the Sierra XR 4x4 which is exactly what I did.

What You Need:
Sierra XR4x4 or Escort Series 2 RS Turbo:
Front Callipers (make sure you include the sliders)
New:
Series 2 RS Turbo Front Brake Discs
Series 2 RS Turbo Front Brake Pads

Calliper Overhaul Kit
I reconditioned the callipers before fitment by stripping, cleaning, checking for piston corrosion, painting and reassembling them with new seals. The new callipers and discs are a direct replacement so literally bolt straight on.

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Rear Brakes
It is possible to fit rear disc brakes to the rear of the Excort mk 3 & 4 with the addition of adapter brackets and various components from the Ford parts bins.
I never actually got around to carrying out the conversion to my car.It is really more of a cosmetic modification as the rear brakes only produce a relatively small amount of the overall braking effort and disc brakes are notorious for poor parking brake performance. Once you have the parts however, it is I believe a simple case of removing the old (including back plates) and bolting up the new components.

Parts Needed:\n
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Sierra XR4x4 or post '87 Granada Rear Callipers (including Carriers, see pic)
NEW\n
Sierra XR4x4 Rear Discs & Pads\n
Escort MK5/6 2.0ltr DOHC Hand Brake Cable\n
Lengthened Flexible Brake Hoses\n
Adaptor Brackets - The adaptor brackets are available through many of the specialists that advertise in the Ford enthusiast magazines.
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Anti-lock Brake System
An ABS system appeared as an optional extra during the Mk4 Escorts production run. It was a purely mechanical system that only really provided true ABS on the front brakes.\n
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The rear simply incorporated a variable pressure relief/reducing valve in line to each rear cylinder that was operated by the suspension travel. As the weight of the car moved forward under heavy braking and the rear suspension rose, the movement of the rear suspension arms would reduce the pressure going to the rear brakes as the weight on the rear wheels reduced thus hopefully preventing them from locking.\n
The front system comprised of mechanical maxaret units driven by belts from the inner CV joint of each drive shaft. The maxaret unit is basically an inertially operated pressure relief valve. Whilst the wheels, and so the driveshafts, are rotating; the centrifugal/inertial force holds a pressure relief valve closed. If a wheel locks up and the drive shaft suddenly stops rotating, the inertial force within the unit operates the pressure relief valve thus reducing the pressure at the brake calliper and so releasing the callipers grip on the brake disc. Well, that's the layman's terms of it anyway.\n
It could b retro-fitted if you can find a useable set but remember, brake fluid is hydroscopic (attracts and holds water) so if someone has been storing one in a box in there garage for the last ten years without it being properly sealed it will probably be corroded internally and not safe for road use.\n
However, a common upgrade for cars fitted with this system was to remove it and convert back to standard brakes. Apparently the pedal feel, which is pretty poor at best with a standard car, was even worse with the ABS system fitted.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "sPSGvhrEps", "_anchor": "menu1-oc", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Bodyshell & Electrics

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Bodyshell

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\n LEARN MORE\n LIVE DEMO\n
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Title

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Bodyshell
You won't be surprised to hear that the Mk 3 & 4 Escorts rust! The Orion shaped Mk4 was particularly bad for it. Apparently something to do with Spanish factories and a deal on cheap steel but that's not based on anything concrete so should be dismissed as hearsay.

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They suffer from the usual rust spots: Arches, sills,front and rear valence, below the head lamps, under the battery tray and under the fuse box. A common indication of rust under the battery tray or fuse box was damp carpets in the front foot wells as this is where the rain water would end up after it had come through the rust holes.

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Fusebox rust trap.
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Battery tray rust trap.
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Underside of battery tray area from within footwell.
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Body kits don't help matters. Not only do they form their own rust traps but they hide the rust so you don't know it is festering away under there until it is at an advanced state.

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But the Escort is of conventional construction so usual bodywork repair principles apply.

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Electrics
There are a number of differences in the wiring looms between the Mk 3 & 4 cars. Although they are of similar general arrangement they use different connectors for a lot of the switch gear and additional equipment. Both cars had similar levels of additional equipment available but the mk4 gained options for heated windscreen, trip computer and on the Cabriolet model, a power roof.
Some of the higher spec Mk 3 cars had a fault computer that was dropped on the later mk4 cars.

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\n General loom routing in the vehicle

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\n All of the additional equipment requires it's own sub-loom, not forgetting the door feeding looms in the door pillars.

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\n Upgrades

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The electrical toys are largely transferable between cars, the only real issue being the changing of the electrical plugs used between mk3 & mk4 cars so you may have to replace some plugs with after market items. In my case, as part of the dashboard replacement detailed elsewhere on this site (link further down this page), I replace my entire mk3 loom with a mk4 version and fitted all of the available mk4 toys. As already mentioned, each of the additional equipment options requires its accompanying loom. I would suggest that you just fit all of it that you can get hold of, even if you don't have the working parts to go with it. At least then if you do manage to find the equipment you want to fit the wiring is already there for you.

As far as the bodyshell goes 'upgrades' are a subjective matter but here are some of the alterations I made to mine.

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\n Front Wheel Arch Liners

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\n Help improve your mk3 Escorts chances of survival by retro fitting the wheel arch liners from a mk4.
Also includes the bigger capacity mk4 windscreen washer bottle upgrade.

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\n Locks / De-Locking & Security

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\n Remove those dodgy 80's Ford locks and the thief's have nothing to pick. It also emphasises the fact you have an alarm system fitted.

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\n Door Mirrors

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\n Upgrading manual mk3 door mirrors to full electric mk4 units.

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\n Mk4 Dashboard Conversion

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\n How to fit the Mk4 dashboard into the Mk 3 properly.

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\n Power Roof

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\n The power roof was only available as an option on the Mk4.
Here I show you all you need to know to retro fit a power roof system to your manual hood.

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Mk3 to Mk4 Fuel Tank Swap

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Going EFi? Or want to retain one key for your Mk3 following a Mk4 Dashboard swap?

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Escort Upgrades - Wheel Arch Liners

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This is definitely a worthwhile modification and is pretty easy to perform as well. Obviously before carrying out this work though, you'll want to clean out the wheel arches of your car and make any necessary repairs as well as ensuring the stone-gaurd/underseal coating is in good order.

You will need:\n
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From MK4 Escort/Orion\n
One pair of wheel arch liners.\n
8 Plastic plug nuts (as found behind the liners)\n
NEW\n
10 Self tapping screw and large penny washers\n
Small section of steel\n
Heavy duty sealant or thick underseal

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The first task is to go to your local breakers and get the required parts. Any MK4 Escort/Orion will do, there all the same. Remove the self tapping screws and plastic turn clips that secure each liner in position and withdraw the liners. Once removed, you will see a number of white plastic discs about the size of a 10pence coin on the inner wings. These are the plastic 'Plug Nuts' that the self tapping screws go into. Leaver these out and retain them. You'll now need to remove the liners from another car in order to obtain more of these plug nuts as you'll be using these and self tapping screws in place of the plastic turn clips when you come to mount the liners into your MK3.\n
Back to your car. You will need to apply some form of heavy duty sealant to the inside of the return lip on the fold of the arches on the outer wings. This is because on the MK4 cars the return fold has a tang built in to locate the liner (as you'll see when you come to remove the liners from the donor cars). As this tang is missing from the MK3 wings, the liner will have a tendency to rub back and forth slightly and so chafe. The sealant will both act as a barrier and help grip the liner to reduce this movement.\n
Once the sealant or underseal has dried, fit the liner in place using the steering arm and drive shaft cut outs as a guide to positioning. Once you are happy with the fit, mark out the liners mounting hole positions on to the inner wing of your car with paint or similar. You will find that the top row of holes are sitting in space, don't worry about this, it's not going to cause any problems. You will however need to seal these holes up with something such as grommets to stop dirt and road spray from passing through them.\n
Remove the liner and with the exception of the lowest hole position below the steering arm, drill the centre of the marked hole positions with an 8mm drill. These holes now need opening up with a file to produce a rectangle hole of sufficient size to house the nut plugs. Prime and top coat the edges of the holes and once dry, push the nut plugs home with a smear of underseal for good measure. The last hole is to be drilled a suitable size to accept the self tapping screws. The reason that a nut plug is not used here is that it is in a stress location and a rectangular hole here will induce cracking. Re-install the liner and secure with the penny washers and self tappers, check for location.\n
The lower rear mounting hole is also sitting in space and for security of mounting, could really do with being attached to something. For this, a simple 'L' shaped bracket needs to be fabricated and welded onto the shell. The bracket should be bent to approximately the correct size and offered into position with the liner in place. Mark the bracket where the hole lines up. Drill and file this hole as before to accept a plug nut and attach in position. Then mark the shell where the bracket needs to be mounted. Thanks to the large size of the holes, you have a little movement to play with. Remove the liner and weld this newly manufactured bracket into position. You should find it lines up nicely with a large flat as shown below. Refit the liner giving the lower self tapper a good coat of grease to prevent corrosion and bobs your uncle!
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Mk4 Washer Bottle

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Whilst you are in the area and are drilling screw holes in the inner wing it is worth fitting the larger mk4 washer bottle. This sits in front of the arch liner with the filler neck protruding through a large hole behind the headlight. On my late Mk3 the large hole was already there, albeit blanked off, suggesting that they were gearing up for the mk4 when my car was produced.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Improved Security

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Door Barrels\n
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First of all, what are you hopping to achieve? If your planing on fitting later locks from a MK4 for extra security, then don't bother! These locks are not much improvement over the original MK3 cars locks once they get a little worn. It requires a great deal of skill to fit them as well as the locating holes need to be enlarged and this isn't simple a case of making a round hole bigger. The holes are specially shaped, like two size holes together, to locate the barrel and prevent it from rotating. A better alternative would be to fit a set of after market locks, though these do tend to be rather on the ugly side. If you really must have MK4 barrels fitted then it is probably going to be a whole lot easier to just fit MK4 doors to your car. For details of this see further down this page.

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De-Locking\n
The best bet is to fit central locking to the vehicle and an alarm with remote locking feature. The majority of car alarms now come with this feature and as most insurance companies are now asking for one to be fitted, especially to a modified Escort, you'll probably soon have one anyway. This means you can then remove the door barrels completely and weld up the holes with plates on the inside to 'De-Lock' your car. This provides a number of benefits, it's not just to make the car look pretty. If there aren't any door locks, then there's nothing for Mr Thief to try to force with his screw driver. Also, the absence of door locks immediately tells him that you have remote central locking that is more than likely operated by an alarm system. What you must make sure you do however is remove the part of the door lock mechanism that the door barrel was originally attached to. This just entails cutting off a lever. This prevents any coat hanger attempts from having anything to lift.

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Internal Locks (Door pins)\n
This basically deals with converting your MK3 from the use of the door pin type internal lock to the MK4 style all in one unit built into the inner door release handle itself. It is another relatively simple and worthwhile modification.

You will need:\n
MK4 Escort/Orion\n
Inner door handles\n
Door latch mechanisms\n
MK3 Escort\n
Extra pair of inner door handle operating rods

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The latch mechanisms need to be swapped over due to the revised operating lever set up. If you have de-locked your doors, cut off the now redundant barrel operating lever to help combat any coat hanger attempts on your car. You should be able to identify this lever when you remove the mechanism from the donor car. The mechanism will bolt straight into the MK3 doors. The handles will also fit the MK3 door and trims with no problems as they are of the same dimensions as the originals. However, the inner handles on the MK3 are mounted further forward than on the MK4 which is where the extra operating rods come in. You may need to make minor adjustments to them to fine tune the operation of the lock and release handle. You will also have to make an extra slot in the inner door skin to accommodate the extra rods guide, otherwise you'll encounter problems with the rod bowing rather than operating the latch mechanism.
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Title

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Doors\n
The front doors from a MK4 car complete can be directly swapped with MK3 doors as the pressings are almost identical. In fact, if you order a MK3 door from Ford now you will in fact get a MK4 door anyway! The door can be built back up to either MK3 spec or MK4 spec as all the holes for the various fittings are present. Except for one little problem. (can't make it too easy for you) Your MK3 barrel locks will fall straight through the holes in the MK4 skin. MK4 barrels are of a larger diameter so you'll have to upgrade to MK4 locks. I don't know for certain yet but the mk4 barrel might still fit into the MK3 steering column so you may be able to retain one key for everything. Alternatively, de-lock the doors!\n
Apart from that, the only time you'll hit trouble is if you wish to retain the MK3 interior door cars but want to fit the MK4 inner door opening handles as detailed above. The problem here is with the relocation of the inner handles on the MK4. The inner door skins on the MK4 doors incorporate a larger mounting slot for the inner handle to allow positioning for both applications. The problem is with the handles securing screw. The MK3 handle lives in the forward position and has it's securing screw at it's forward edge. The Mk4 handle lives in the rearmost position and has it's securing screw at it's rearmost edge. The problem with mounting the MK4 handle in the MK3 position to line up with the MK3 door card is that this securing screw is left floating in mid air. Therefore you need to give it something to screw into. The best way to do this is to weld a strip of metal in behind it as shown below. If you can't weld it, use rivets or similar.

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\n Escort Upgrades - Power Door Mirrors

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The door mirrors were revised for the mk4 version and made more rounded without the option of having body colour coded inserts. They were available in much the same flavours as the mk3 versions, i.e. manual adjustment, internal mechanical adjustment and full electric adjustment. On vehicles fitted with heated front screens the mirrors were also heated operating from the same switch.\n
The only benefit of fitting the mk4 door mirrors to your mk3 Escort other than cosmetic if you happen to prefer them is that you are more likely to find a pair of electric mk4 door mirrors than the equivalent mk3 item (most mk4 shaped Orion Ghia's had them fitted).
Don't forget you will also need the looms for them. This includes the door feeder looms if you don't already have them and the loom from behind the dashboard.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Fitting\n
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Sadly fitting the mk4 door mirrors isn't the straight bolt on job you'd expect it to be. Both mirrors are held in place with three bolts but Ford in there infinite wisdom decided it would be best to move the positions of these bolts on the mk4 version.\n
However, to make the job easier Ford do provide a drilling template with them. On removing the mk4 spec mirror from it's donor you will find a rubber pad sandwiched between the mirror and the door. Use this to mark the positions of the new holes on your mk3 door. Note that the holes on the outer skin need to be just large enough to allow the mounting legs to pass through but the holes on the inner skin must only be large enough for the shank of the mounting bolts to pass through.
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\n Needless to say, getting the electric versions to work will depend on what wiring loom you are using. 

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Mk3 to Mk4 Dashboard Conversion

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Before carrying out this conversion, what is the condition of the original dashboard? If it's good then you may want to reconsider doing this as MK3 dashboards in good condition with no splits or distortion are rather rare to say the least! Most by now have suffered the effects of twenty odd years of sunlight and have splits emanating from the heater vents and binnacle surround. It would be a shame to spoil a nice one and loose some of the cars originality. I changed mine as, being a convertible, the dash was absolutely shot and finding a replacement was turning out to be rather difficult. I therefore fitted the dash and wiring loom from a MK4 shape Orion that I scrapped for parts.\n
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If you are planning to go ahead with the MK4 dash conversion then I strongly recommend fitting the MK4 wiring loom as mentioned elsewhere on this site. This will make things a damn site easier and as you'll have the dashboards out of both cars, it won't be all that difficult to do. It also paves the way for a host of other future mods so at least go and have a look now.

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What you'll need
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You will need the following parts from a MK4 donor car:\n
Dashboard complete\n
Steering Column Outer Casing (tube with casting that all the switches bolt onto)\n
Steering Column Surrounds and switches/stalks\n
Steering Wheel (horn in wheel)\n
All heater ducting including windscreen demisting channels\n
Heater controls and fittings (or entire heater to make it easier)\n
Bracket above heater from bulkhead to dash\n
Brackets from base of heater to dash\n
2x Instrument cluster\n
Switch plugs from the MK4 loom (if you intend on retaining the MK3 vehicle loom)
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In order to remove the steering column (and dash, see your Haynes manual) from the donor car you will need it's ignition key as you need to extract the ignition barrel in order to remove it. Make sure you have it before commencing or you will be wasting your time.
The heater unit is the same part between the two MK's of vehicle but the bracketry and controls are different between the two. As I had an entire donor car on my drive, I simply swapped the entire unit over, but if you cannot do this then simply remove all bracketry and controls and make a note of where the go.\n

All MK4 Escorts/Orions come with the same plastic moulded dashboard in either grey or blue. The separate darker glove box surround and lid is covered with a vinyl skin on higher spec models and is the one to go for. This part can be fitted to any dashboard so if the plastic dash that it's fitted to has had unsightly holes drilled into it for a phone holder or alarm etc. then you can remove it and fit it to the dash from a lower spec car.\n

Preparation
Right then, starting with your car. If you haven't already done so, remove the steering column outer casing, dashboard (a bit obvious) and all heater ducting and controls. If the original dash is in good condition then store it safely and look after it, it's worth money!\n

You should now be left with a fairly bare bulkhead. Along the top of the bulkhead you'll find two angled brackets that the old dash clipped on to, these are no longer required and will obstruct the new dash. Simply cut them back close to the bulkhead as shown.

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The next job is to offer up the new dash into position. Now if you are carrying out this conversion to a cabriolet as I did, then you will find that the bottom corners of the dash foul on the revised kick panels that the front speakers mount into. Simply trim the corners of the dash away with a file till it fits. Don't forget to allow for the thickness of the trim panels if there not fitted.\n
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Get two friends to hold the dashboard in position in the car (use the side securing screw holes and the captive nuts in the 'A' posts as a guide to help) and with a bit of paint, mark the positions of the three top mounting holes onto the bulkhead. Remove the dash and drill 3 pilot holes through the bulkhead at these marked positions of a suitable size for self tapping screws large enough to secure the dash in place. (see above pic)

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Vent Ducts & Support Bracket
Refit the dash and secure in place with the mounting screws but don't over tighten the self tappers as it will be coming off again a few more times yet. Offer the pressed steel bracket into position above the heater unit and in position in the dash and mark out onto the bulkhead sound insulation the location of the mounting feet. Remove and cut away the insulation to reveal the bulkhead. Refit the bracket and mark out onto the bulkhead the position of the mounting holes. Whilst the dash is in place, offer up the two MK4 side air vents and mark the positions for there mounting hole onto the 'A' posts. Remove the dash and drill the marked hole positions. The side vent mounting holes need to be drilled to accept suitable self tappers but the pressed steel brackets holes in the bulkhead need to be drilled to the same size as those in the bracket. Secure the bracket to the bulkhead with nuts and bolts. You will need to gain access to the engine side of the bulk head and may have to remove the heater fan and shroud. Secure the side vents to the 'A' posts with self tappers and plumb them into the heater box.

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With the dashboard still removed from the vehicle, retrieve the windscreen demisting heater channels and cut off the lugs used for mounting them to the bulkhead. Obtain some small self tapping screws and drill 6 evenly spaced clearance holes on each of the channels for these screws to fit in to. Hold the channels in position on the inside of the dashboard and drill 6 corresponding pilot holes in the bulkhead of a suitable size for the self tappers. The dash is double skinned here so you wont have screw ends protruding through the top of the dash (unless you use long screws or drill too hard!) Screw the channels directly onto the dash and apply a bead of sealant around the seams and joins. Better than the original!

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Now you need to either build up the heater unit with your new controls and brackets or if you have the whole unit, swap it across. As I swapped the whole unit across on my car I have no pictures or tips for swapping the gear over onto a MK3 heater.\n
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Refit the dash and check that all is well.

Speedo Drive
The next job is the speedo drive. Due to the revised layout of the later instrument cluster, the speedo cable will no longer line up with the speedo and trying to make it fit will simply put too sharp a bend in it and it won't work. (trust me, I know!) Therefore, a new hole has to be made in the bulkhead to re-route it. This is where the extra instrument cluster comes in!\n
Strip the cluster down until you have the basic shell. Destroy the speedo but retain the drive connection and mounting casting. Remove the centre rotating portion from this. This is going to be your drill guide! With a bit of tactical abuse to the plastic casing with a hacksaw you should end up with something like this:
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Fit the 'modified' cluster to the dash with all four mounting screws to help ensure correct location and alignment. Insert a suitable diameter rod with a dab of paint on it's end through the speedo drive until it contacts the steering column support bracket. You should find that it contacts an area stamped with apart number. Remove the dash and drill a hole at this position. You'll then want to open the hole up into an oval as shown below.\n
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Refit the dash and re-insert the rod (with a fresh dab of paint) through the speedo drive and hopefully through the hole in the support bracket you've just drilled until it contacts the bulkhead. Remove the dash again and also the column support bracket. Drill another hole straight through the bulkhead of a suitable size for the speedo cable to pass through and a rubber grommet. Restore the paint finish to the holes edges and refit the support bracket.

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Now the speedo cable needs to receive a little attention. Remove the inner cable completely and at the middle of the outers straightest run, cut the outer in two. withdraw the instrument end of the outer and feed it back through the new holes in the support bracket and the bulkhead. Disconnect the other half of the cable so as to give you better access and rejoin the two halves by sliding a snug fitting piece of plastic tubing over the ends. To make the join look more professional, cover the join in a piece of heat shrink or failing that, black insulation tape.

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Final Assembly
If you are being sensible and have converted to the MK4 loom, then you are now pretty much ready for final assembly. If however you are still using the MK3 loom, then you will need to cut off all your plugs and solder on the plugs from the MK4 loom. You should find that all the colour coding is the same so it shouldn't cause a major headache.\n
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Before finally re-fitting the dash, paint the very top portion of the bulkhead (about an inch) with black paint to stop any unsightly body colour showing through and lay a strip of foam draught excluder along the edge as available from DIY stores for household windows. This is to replace the factory fitted stuff that stops any annoying rattles or squeaks. You will have to re-route the wiring loom across the bulkhead as in it's normal position it will now foul the windscreen demister channels. Simply hang them lower down the bulkhead on string attached to the original (but now flattened) loom retainers. This may sound like a bit of a bodge but it isn't, It's a method employed a lot in the aircraft industry.\n
Finally fit the dash (remembering the side screws in the 'A'posts), steering column, new cluster and all the wiring and speedo. Fit the steering column shrouds, apply some protective sealant to the protruding screw ends on the engine side of the bulkhead from the top three securing screws to prevent corrosion and fit the steering wheel and that's it. Job done!
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Power Roof

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\n LEARN MORE\n LIVE DEMO\n
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Title

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The power roof option for the cabriolet wasn't introduced until the later mk4 cars but it can be retro fitted to earlier cars with manual roofs. Here how.

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What you need:\n
The full hydraulic system - Pump unit & mount, Hoses (4. off), Rams (2. off), Ram mounting pins & clips (4. off upper & 2. off lower)\n
Switch\n
Relays\n
Thermal cut-out\n
Loom (or make your own as I did)
Pump cover / boot trim (optional)

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Hydraulic Components
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Ram Mounting Pins (on the left)
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Switch (same as Mk4 passenger door electric window switch with new graphics)
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Small silver rectangle to the bottom right is the thermal cut-out.
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The power roof system can be fitted to any Cabriolet and will work with the manual roof frame. Here's how to install it. First you need to remove all the rear trim panels, the rear bench seat and the boot carpet and near side trim. Then proceed as follows.

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Mount the Pump

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Position the pump with mounting bracket in place making sure that the pump is close enough to the boot wall to avoid the mounting bolt hole from fouling the chassis leg underneath but far away enough to allow clearance for the hydraulic pipes.\n
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\n When happy, mark the location of the mounting bracket onto the boot floor.

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\n Remove the pump and remove the mounting bracket from the pump. Position the bracket on the boot floor in the location marked out.

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\n Mark and drill the first mounting bolt hole as shown.

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\n Reposition the bracket and secure in place with a nut and bolt. use the bracket as a drill guide to drill the second hole. Then bolt in place. If you have sound deadening material stuck to the boot floor in this location as I have in the above pictures, then you have two choices. You can either cut away the sound deadening as required or pack underneath the rest of the mounts with rubber spacers as I have. You may need to position more packing under the front and rear rubber feet attached to the pumps frame.

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\n Pump mounted in position.

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\n Fit the Rams

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With the pump installed it's time to replace the roofs gas struts with the hydraulic rams.

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\n The operating rams fit in the same location as the original gas struts but there mounting pins are different.

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\n The original gas struts use ball joint mounts exactly the same as those used for the boot lid gas struts.
The hydraulic rams of the power roof however use pins and retaining clips.
It is worth making sure you use these clips as opposed to using bolts as you will get a slack fit with bolts which will soon result in ova-ling of the rams mounting holes and will also reduce the effective stroke of the ram as it takes up the slack.

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\n The pins simply screw into the roof mechanism frame and the cars shell in the same manner as the ball joint mounts.

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\n The longer pins are fitted to the shell at the base of the rams and the shorter pins are fitted to the roof frame.

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\n Before the rams as offered into position, the hydraulic hoses need to be attached. They should then be taped to the ram body to stop them from snagging and migrating from position once installed.To make life easier later on, it is a good idea to identify each pipe at the pump end at this stage to make final connection to the pump easier. The hoses positioning and routing is down to personal preference. My choice of routing deviated slightly from the diagram in the Haynes manual but has worked well enough for me. I elected to tape the hoses to my rams in such a way as they both exited pointing downwards.

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\n The Rams can then be slid onto there respective mounting pins and secured with the retaining clips. Be sure to make sure that the top hose connection on each ram is pointing inwards and towards the rear of the car. Otherwise the connections will foul on the interior trim panel or chafe any wiring you may wish to route through that area.

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\n Hoses

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\n The next job is to route the hydraulic hoses under the rear bench seat and through to the pump in the boot. The best way to explain this is to simply show you the pictures of my layout. Just be careful to avoid sharp bends and protect the hoses from sharp panel edges that could cause chaffing.

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\n The hoses have been secured to the shell with black tape. They have also been taped together to help keep them located. When under pressure the hoses don't appear to move a great deal anyway.

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\n The pipes can then be attached to the pump. This is where your carefull labeling from earlier comes into play. The connection is quite simple. The pump has a 'T' piece on each side of the pump body. One 'T' piece supplys pressure to open the roof, the other supplys pressure to close the roof. It does not matter which side you use for which so long as you attach both rams top hoses to one 'T' piece and both rams bottom hoses to the other 'T' piece.

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\n 'Open' Latch Removal

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\n If you are using a manual roof frame as I have done, then the roof frame mechanism latches that hold the roof in the open position must be removed. This is achieved by simply drilling off the ends of the pivots that the latches are mounted to and removing the latches.

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\n Electrics

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\n If you have the correct loom for the system then you'll have to figure this bit out for yourself as I didn't get one with my system. I had to make my own. I found an alleged copy of the Ford wiring diagram for the power roof but decided that it was way too over complicated for my needs so I devised my own system. The bonus with my system is that you don't need to have the ignition switched on to activate the roof so if your car is parked outside with the roof down and a freak shower comes along, you don't have to go fumbling around for keys before you can close the roof!
The 12 volt supplies come straight from the battery with inline fuses rated at 5 amps to the switch and 20 amps for the main power to the pump. Use suitably rated cable at a higher rating to the fuses to allow for current drain over the length of the cable

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The relays are mounted by the pump rather than being hidden away.

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", "_anchor": "image1-qr", "_isUserblock": true, "_cid": "sQ3Z1N9RLG", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The thermal cut-out is also located by the pump.

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\n The switch is normally mounted on the centre console on the passenger side of the gear stick.

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", "_anchor": "image1-qt", "_isUserblock": true, "_cid": "sQ3Z3f2GGU", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Boot Trim

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If you don't have the correct boot trim panel for the pump then you will have to cut a section out of your existing trim panel in order for it to fit around the pump. This is largely done by trial and error but you should end up with something like this.

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", "_anchor": "image1-qu", "_isUserblock": true, "_cid": "sQ3Z4fT2eX", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Which when installed should give adequate clearance for the pump and cooling.

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", "_anchor": "image1-qy", "_isUserblock": true, "_cid": "sQ43UxRpZ9", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n With all the electrics installed, you should end up with something along the lines of this.

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", "_anchor": "image1-qv", "_isUserblock": true, "_cid": "sQ3Z5hLUOA", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" }, ".mbr-section-subtitle DIV": { "text-align": "left" }, ".mbr-section-title": { "text-align": "center" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Completion

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The hydraulic system can now be replenished and bled as described in the Haynes manual (very easy) and after functioning the roof to check for oil leaks, the trim panels can be replaced. If whilst functioning the roof it is found that the roof operates in reverse to the selection made at the switch, simply swap the two wires round where they connect to the pump motor.\n
\n
You now have a nicely installed fully functioning power roof. Job done!

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-qz", "_isUserblock": true, "_cid": "sQ44kiohRt", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_anchor": "image3-q3", "_isUserblock": true, "_cid": "sQ3Ij4ZVxb", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-q2", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "Escort Body Tank.html": { "settings": { "title": "Escort Body Tank", "order": 30, "meta_descr": "Ford Escort Mk 3 & 4 Maintain & Modify - Fuel Tanks" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n

Escort Upgrades - Mk3 to Mk4 Fuel Tank

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\n You ay be wondering why you would want to bother swapping the fuel tank in your mk3 for a tank from a mk4 but there are a few possible reasons why you may be considering this:
1) You want to fit the EFi tank with its built in high pressure electric pump to supplement a Zetec conversion.
2) You have converted to a mk4 steering column as part of the mk4 dashboard conversion and want to use the same key for the filler cap but have found that the mk4 cap is not interchangeable and you have to fit the mk4 filler neck which is also different (as explained below) meaning you are now facing replacing the entire fuel tank with the mk4 version.
3) Your tank is rusty and you are looking at the mk4 as a possible alternative.

Well, although it does fit it is not quite a straight swap.

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\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Differences

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Although they share the same basic shape, there are numerous differences between the fuel tanks fitted to the various models of Mk3 & 4 Escort.\n
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The main differences are Carburettor fed engines and fuel injected engines, and Mk3 and Mk4 Cars.The carb fed Escorts use a mechanical fuel pump attached to the engine and take there fuel from a pipe welded to the forward face of the tank. Fuel injected cars however use an electric pump mounted behind the fuel tank and so there fuel feed pipe is on the rearward facing wall of the tank.\n
Then there's the differences between the Mk3 tank and the Mk4 tank.\n
Although they can both be physically fitted to either car there are differences that make complete instillation a little more involved than a straight swap.

The picture on the left show's the fuel tank from a fuel injected Mk3 Escort where as the picture on the right show's the equivilant tank for the Mk4.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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It can clearly be seen that the fuel level sender has been relocated on the Mk4 tank and is even of a different design with a bigger base plate. The other difference is the filler neck attachment.

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The Mk3 filler neck attachment is shown on the left and compises of a collar onto which a flexible pipe is attached via a jubilee clip. The Mk4 tank however uses a one piece plastic moulding for the filler neck which slots into a hole in the tank with a rubber bung as a seal.\n
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This of course means that should you wish to fit the mk4 fuel tank to your mk3 (as I have done) you will need to fit the corrosponding filler neck.

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\n Fitting the Mk4 tank to the Mk3 Escort

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The mk4 tank is mounted in exactly the same way as the mk3 item with a couple of bolts and a strap. However, the mk4 filler neck isn't quite such a simple swap. It is of a larger diameter than the mk3 item and so the hole on the bodywork that the filler neck protrudes from needs to be opened up slightly. This is achieved with the use of a rotary grind stone and a sanding flap wheel in a power drill. There's also a supporting screw half way along the pipes length which will require a pilot hole to drilled into the cars structure in the area of the rear suspension. Because of it's location access with a domestic power drill is very difficult with the suspension still in place. I was fortunate enough to have access to a right angled air powered drill.

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I would have liked to have included photos of the filler neck fitted but I cannot find them so must assume that they have been lost. But it is not a difficult job and is pretty self explanatory when you come to do it.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Suspension & Steering

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Suspension
Nearly all suspension components from all the models of the MK3 and MK4 escorts and Orions are interchangeable as the setups are virtually the same with the following exceptions.

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Front strut tops on pre-may 1983 cars\n
Front Track Control Arms on pre-may 1983 1.1 litre cars\n
Front Track Control Arms between MK3 & MK4 (different lengths)\n
Front Anti-Roll bars between MK3's and MK4's\n
RS1600i & Series 1(MK3) RS Turbo Front Anti-Roll bars\n
MK3 & 4Rear Tie-bars (slightly different length and location)\n
Shock and Spring ratings

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The rear wishbones from some later (MK4) cars are also slightly modified with an additional bracket to which an anti-roll bar is attached, but these can still be fitted to earlier cars without an anti-roll bar fitted.
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Some of the angles of the suspension geometry were changed for the mk4 car such as the camber on the front wheels. This was achieved by lengthening the Track Control Arms, hence them being different. Another area that was changed was the location of the front mounting/pivot point of the rear suspension tie bars which resulted in these being of a different length also.\n
The front strut tops on pre-may 1983 cars have a different mounting using two retaining bolts for the top mount as opposed to later cars that have a reformed top mount on the inner wing and use the shock strut top bolt to hold it in place.
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The front track control arms (TCA's) on pre-may 1983 cars fitted with a 1.1 litre engine where of a pressed steel design with a separate replaceable ball joint at it's end. It also used a different tie-bar setup with no anti-roll bar fitted. These parts can be fitted in whole to other MK3 cars but there is little point in doing so. The standard suspension set up found on higher spec and later MK3 cars can be fitted to vehicles with this set up already in place (i.e. if your car is a pre may '83 1.1 litre model it is possible to bolt on the front anti-roll bar and TCA's from a MK3 XR3i).
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The next alteration is between the MK3 cars anti-roll bar and the MK4's. As far as I am aware the actual anti-roll bars themselves are the same but the mounting plates are different. The difference is in the number of and location of the plates mounting bolt holes. The MK3 cars plates are secured to the shell with four bolts on each plate, two securing it to the front cross member on each side of the car and two securing it to the respective inner wing. The MK4 car however has only three securing bolts with only one bolt locating in the inner wing.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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The front suspension fitted to the RS models of the MK3 Escort was modified somewhat in compliance with homologation rules as these cars were born out of motorsport applications. The set up comprises of separate tie-bars and anti-roll bars which is much better at maintaining correct suspension geometry's when under load (i.e. hard cornering) and it can all be bolted straight on to a MK3 car, but not so to a MK4 car due to the relocation of the mounting plates securing bolt holes. Instructions of how to fit this can be found on the relevant page of this section.

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RS1600i
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Series 1 RS Turbo
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The shock absorber and spring ratings differed according to the specification of the cars, the XR3 had a harder setting than standard Escorts and the XR3i was lower and stiffer still. The MK4 XR3i was actually fitted with a softer setting of shock absorbers and springs so fitting these to your MK3 would actually be a down grade. However, apart from the front struts of the pre-may '83 cars as already mentioned, it's all transferable. More information can be found in the relevant page of this section.\n
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The rear suspension is identical on all models (except MK3 & 4 Rear Tie-Bars) with the exception of those fitted with a rear anti-roll bar. In this case the rear wishbones have been modified with an extra bracket welded to them to facilitate attachment to the anti-roll bar. Other than the extra bracket, these wishbones are the same pressing as all other rear wishbones MK3 & 4 and so can safely be fitted to a car that does not have a rear anti-roll bar. For instructions on fitting a rear anti-roll bar to your vehicle see the relevant page of this section.
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Steering
There have been few changes to the steering system on the MK3 & 4 Escorts/Orions throughout the vehicles production life and none were ever fitted with power steering. However, those parts that did change are worth mentioning. They are:\n
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Steering column outer between MK3 and MK4 cars\n
Steering Rack on post September 1988 cars\n
The steering rack of pre-may 1983 cars is also slightly different but this only comes to light if you try to overhaul it. For all intents and purposes it is identical in operation and directly exchangeable for the post-may '83 rack.\n
The steering rack on post September 1988 cars is of a 'variable ratio' design to try to give greater response at high speeds and allow easier maneuvering when parking. It too is a direct swap for the original.\n
The steering column outer fitted to MK4 cars has a different top casting to those fitted to earlier cars to accommodate the new switch gear. The MK4 column will bolt into the MK3 but isn't a straight swap. You'll have to use MK4 switch gear which means swapping the electrical connectors on the wiring loom, and you'll also need to use the MK4 steering wheel for the horn and the MK4 column shrouds. I suspect you'll find that it will all foul the MK3 dashboard as well as the column apertures are of different sizes. However, if you are planing on a MK4 Dash conversion then you will need this part.\n
There is one other 'extra' to be found on Escort Cabriolets from January 1987 onwards. An additional steering column brace is fitted to these cars between the column and the drivers door post. This is intended to stiffen the column and reduce vibration. It can be fitted to any car and the bracket is still available from Ford dealers. It simply entails the drilling of a bolt hole in the door pillar, the position of which is determined by holding the brace in place and marking the position of the hole.
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Upgrades

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\n The mk3 & mk4 Escorts were well catered for in their day by the aftermarket tuning companies but there were also improvements to be made from the Ford parts bins depending on the spec of your car.

Bushes
I bought a set of budget poly-bushes for my car. After much difficulty in trying to achieve a satisfactory fit I relegated them to the dustbin and invested in a full compliment of Superflex poly-bushes instead. There was a rather large difference in price but it was definitely worth it. Remember, there is more to a poly-bush than just the polyurethane part itself; the steel sleeves are just as important and form the main load bearers between the suspension components. The cheaper efforts that I first try'd simply didn't bother using an outer sleeve which beggars belief! Instead they were designed to use sheer bulk to try to fill the gaps. Once the car was completed and back on the road (with lowered stiffer suspension to really work those bushes) the handling was superb (for a floppy bodied cabriolet anyway).

Springs & Dampers
There are various Spring & Shock packages available for the Mk3 & 4 Escorts and all are interchangeable with the exception of early front struts as described in the compatibility section.\n
One thing to bear in mind if your car is a cabriolet like mine, some manufacturers of suspension kits list the Cabriolet alongside the Orion variant. This is because they supply slightly higher rated rear springs for these two cars to allow for the increased weight at the back of these models.

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RS1600i / Series 1 RS Turbo Front Tie-Bar Assembly

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\n Proper motorsport pedigree suspension for the front of your mk3!

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\n Rear Anti-Roll Bar

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\n More common on Orions than Escorts so you probably haven't currently got one.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-rd", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "Escort Sus Front.html": { "settings": { "title": "Escort Sus Front", "order": 32, "meta_descr": "Ford Escort Mk 3 & 4 Maintain & Modify - Suspension" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Escort Upgrades - Front Tie-Bar Suspension

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This is one of those fantastic modifications that are so easy it's criminal! The picture show's the standard front suspension anti roll bar setup at the top (except pre-may '83 1.1 cars), and the seperate anti roll bar and tie-bar set up as found on the Series 1 RS Turbo underneath.

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Top - Standard
Bottom - Series 1 RS Turbo

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As you can see, the standard set up comprises of a rather bendy looking anti-roll bar that also acts as the tie-bar to locate the front Track Control Arms. Due to the shape of the bar, it allows a certain amount of movement of the TCA's away from there normal plane. This does have the benefit of providing a little extra comfort by soaking up more of the bumps and 'insulating' the driver a bit more from the road. However, it isn't so good as far as road holding performance is concerned! Under hard cornering it allows the front suspension geometry to get rather out of shape as the anti-roll bar flexis and gets pulled straight by the loads put onto it by the TCA's.\n
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The lower set up overcomes this by having separate rigid tie-bars that keep the TCA's fixed where they should be and only allowing them to move in one plane of motion so retaining correct geometry. This set up was used on the original racing version of the Series 1 RS Turbo to bring the handling of the car up to scratch for the demands of the race track. As the Series 1 RS Turbo is a proper homologation car, it had to retain this uprated suspension system. The Series 2 RS Turbo did away with this system as it was not a homologation car so went back to the cheaper standard set up as found on the MK4 XR3i.

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", "_anchor": "content4-rx", "_isUserblock": true, "_cid": "sQ4rgpRPOC", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n RS1600i

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The RS 1600i was also a race bred version of the MK3 Escort and came before the RS Turbo and has it's own tie-bar set up. There are differences between the two but they both achieve the same goal. The main differences are the RS 1600i version has a one piece cast alloy cross member that everything mounts onto and the front mounts of the tie-bars are of a different design. The shape of the anti-roll bar is also different and it is of a thicker section at 26mm diameter. I have only covered the RS Turbo set up here as that is what I have and is the more commonly available, but fitting both types is the same.

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To fit the bar you will need a complete unit if you can find one from any specialist breakers. You will also need 10mm longer mounting bolts for the iron plates as they are thicker than the pressed steel originals. It is then simply a case of unbolting your old bar and fitting this one in it's place. It really is that simple, well, almost. There is a couple of trouble spots. First of all, the clamps that hold the anti-roll bar to the tie-bar usually break when you try to dismantle them. This is due to corrosion between the aluminium clamps and the steel bolts passing through them this causes the clamps to swell and grip the bolts. As there only cheap castings they usually break under the force of trying to separate them and replacements are no longer available. This is not the end of the world, get your local engineering firm to make you some new ones giving them the originals as a pattern.
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The other bit that'll irritate you is trying to free the gearbox mount as this tends to suffer in a similar way and you won't be able to remove the mounting bolt. Chances are the replacement unit will still have this attached anyway but if not, then cut through the bolt between the arm and the rubber mount. You should then be able to punch the remainder of the bolt out of the arm. New mounts and bolts are still available from Ford.\n
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All you need do now is get the tie-bars set up at a suitably equipped garage and look forward to nice crisp handling. That is of course assuming that you have replaced your suspension bushes as well!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Escort Upgrades - Rear Anti-Roll Bar

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Again this section is a bit lacking in pictures I'm afraid.

What you need\n
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From a donor vehicle:\n
Rear Wishbones with mounting bracket attached\n
Rear Anti-roll bar of your choice\n
New:\n
Shackles (were still available from main dealers when I wrote this)\n
Attaching Bolts\n
Recommended - New Bushes, preferably polyurethane

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There are two different thicknesses of anti-roll bar available across the range of vehicles and whether or not your vehicle has one fitted, the mounting holes in the shell should I believe be present. The mounting holes are located in the cross member that the rear wishbones are attached to near the top where it meets the floor pan. It connects to the wishbones via shackles to brackets welded in place. If your car does not have a rear anti-roll bar fitted as standard then these brackets won't be present. It should not be too hard to track down a pair of wishbones with these brackets fitted as they where fitted to a number of different Escorts and Orions MK3 & 4 and as stated in the compatibility section are all interchangeable.

The Orion has the thinnest Anti-Roll bar at 12mm and is what I fitted to my cabriolet as I didn't want to make it too stiff and promote the short comings in the shell. The available sizes are 12mm and 16mm and can be found on the higher spec Orions and RS Turbo's.\n
Fitting the anti-roll bar is almost a simple bolt on affair, there's just the small matter of the fuel tank getting in the way! I have managed to remove anti-roll bars from donor vehicles with a bit of brute force and ignorance without removing the fuel tank. I've even fitted it into position once as well but it took a lot of struggling and is much easier with the tank dropped. This isn't the most straight forward job in the world and if you do decide to lower it then you will have to empty it as you won't be able to hold it back up in position and align and do up the fixtures at the same time. Though you may get away with just undoing the tank strap and two off side bolts and get enough movement without having to disturb the plumbing. The bar attaches to the forward face of the rear suspension cross member by two bolts and is pretty self explanatory.
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The wishbones simply need swapping over for the bracket equipped versions which your manual will explain and then it's a simple case of popping on your new shackles. If you were a good mechanic you'd have bought a nice new set up poly bushes for the anti roll bar mounts and will have some left over molybdenum grease to help aid you push them into place. If when replacing the mounting bushes you found the metal 'P' clips were rather rusty and looked like they might crack, fear not as new replacements are still available at your Ford main dealers for no very much. In fact, I'd order a pair whilst ordering the new shackles.\n
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So assemble the bar with it's nice new bushes and 'P' clips and bolt in place. Then slide the shackles on to the ends of the bar and onto the rear wishbone brackets.\n
Job Done!\n
(apart from perhaps rehanging the tank if you lowered it!)
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n 1985 Ford Escort 'SG200i' Cabrio

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "DIV": { "text-align": "left" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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My own project car

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In the beginning\n
I bought this car in March of 2000 from a friend as a £330 shed. It had spent the last two years languishing in his parents front garden and it showed! I also know the previous owner to that. It was a daily driver for years belonging to another work colleague and I had always kind of admired it as I was a young apprentice at the time struggling to keep my MK1 Fiesta going. So to me this red convertible Escort was a bit upmarket. Not that it was all that pretty back then, the dash had already started to split, the roof was held together with a wide strip of black tape and the paint had faded to a pastel redish pink. He spent some money getting an expensive good quality roof fitted (which it wears to this day), a set of tyres and a new exhaust system for it. Then a month later his strapped for cash brother offered him his Astra GTE convertible for too cheap a price to refuse so the Escort had to go. Another lad from the same hangar bought it from him for the princely sum of £800 (just after I'd paid over £1000 for a 2.0ltr mk3 Granada!) and drove it around for the next two summer months until the MOT ran out. This is when it took up it's new duty as an unconventional green house where it helped cultivate all kinds of moulds and fungi.\n
Fast forward two and a half years on to early 2000 and after getting drunk and looking at an old car mag I get a silly idea pop into my head (which my equally pissed housemate then eggs me on with). Why don't I see if I can get him to flog me that old convertible shed! Then I can tool around in it for the summer and have some fun, then ditch it. Well, that was the plan.\n
I weaseled the car out of his ownership for a few hundred quid and had a fairly uneventful, if not entirely legal, two mile drive home. This was done with him following me 'just in case' (and more likely for his personal amusement!) and with the windows open to let out the smell. This drive home proved that few of the electrics worked and it was lacking a rear view mirror. However, the engine seemed OK and the brakes worked.\n
Whilst stripping it down and cleaning it up to prep it for an MoT another acquaintance offered to replace the rusty front panels for beer money if I sourced the panels. This seemed like a good idea to I bought the panels, cut the old ones off and he moved on. Great.\n
You can probably figure out the rest. A local bodywork specialist took on the job of repairing and respraying the shell and as it was the first time I had ever owned a shiny rust free car I got carried away and the whole project snow-balled.

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\n Final Spec

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Modifications Spec List\n
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Base Vehicle 1985 Ford Escort (MK3) 1.6i Cabriolet\n

Shell\n
Fully refurbished shell resprayed in two pack to original colour 'Rosso Red'\n
De-locked Doors\n
MK4 Front Wheel arch Liners\n
MK4 High Capacity Screen Wash Tank\n
MK4 Fuel Tank and Filler Neck\n
'87 Spec Cabrio Additional Steering Column Brace\n
RS 1600i Front Chin Spoiler\n
Hella Spot lamp Grill\n
Clear Front Indicators

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Suspension\n
All components stripped, blasted, keyphosed and powder coated\n
All bushes replaced with Superflex/Powerflex Polyurethane Suspension Bushes\n
Series 1 RS Turbo Adjustable Front Tie-Bar Suspension System\n
Orion Rear Anti-roll Bar (non fitted as standard)\n
Chassis Dynamics progressive lowering springs (-30mm)\n
AVO Adjustable (10 positions) Sports Shock Absorbers\n
(Above two part of AVO handling package specific to the Cabriolet)

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Brakes\n
Orion mk2 1.6i Master Cylinder (Larger Bore)\n
Sierra 4x4/Series 2 RS Turbo Front Calipers and Discs\n
Braided Brake Hoses

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Engine & Transmission\n
Rebuilt 2.0ltr Zetec ('96 Mondeo) modified with Escort 1.8 Zetec parts to fit
Gas flowed head, EGR removed
Mk 1 Focus inlet manifold & 2.0ltr throttle body
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Recon mk3 XR3i gearbox with Series 2 RS Turbo final drive ratio and limited slip differential

Electrics\n
'87 Orion 1.6i Ghia Wiring Loom\n
Central Locking\n
Electric Windows\n
Electric Mirrors\n
Heated Front Screen\n
Trip Computer\n
Solenoid Boot Release\n
Integrated Alarm System with remote engine start

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Interior\n
MK4 Dashboard and Steering Column\n
Dashboard, Sill Covers, Centre Console and Kick Panels coloured Black\n
MK4 Inner Door Latches\n
Series 2 RS Turbo Recarro Front Seats\n
 
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\n The cars fate

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\n The car finally past that MoT, just a lot later than planned. It was complete, but it needed a lot of finishing off work carrying out. The paint had got a bit flat and the seats never did get re-trimmed. Although I was happy with the car I had other projects on the go (the yellow Scimitar) not to mention a house and garden that needed a lot of work (they still do). So as it was likely the Escort was going to end up being parked up which would have done it no favours, I decided it would be best for it to find a new owner who could focus on it and make it really shine. So it went up for auction in 2017 on our favourite online auction site.

Below is a video I took of the car in preparation for the sale.

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\n Any adverts are youtubes' doing and beyond my control. I certainly don't see any revenue from them!

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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The Black Pudding

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\n The original build diary text and photos for the first known Omega GM V6 engine swap.

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The Black Pudding

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A while back I got a 1979 SE6a auto in special order black, this was bought with the soul intention of being entered into the Practical Performance Car magazines £999 challenge at Mallory Park at the end of May. I decided the car needed a little more power and would suit a more modern engine well. \n
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The cheapest power I could find was the 3.0L V6 Vauxhall Omega's, these have 210BHP and 200lbs/ft. The Vauxhall engine is a nice compact engine having a 54° V is only a little wider than the Essex. It's also exactly the same height and a little shorter, it's also lighter having aluminium heads. \n
A standard 3.0L Omega weighs 1550kg or 1.7ton yet with this engine it does 0 to 60 in 8 seconds and keeps going to 150mph!
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\n I managed to get myself an ex-police Omega estate for £270. The police spec comes with a more rare 5 speed manual box, this is a real bonus. It's a very short box with an easily adjustable gear linkage that can be made to fit the scim with little hassle. I am also amazed at how light this gear box is. I weighed it having single handedly lifted it out of the car through the engine bay. This box is only 40kg or 88lbs in old money. That's got to be a huge saving over the old auto.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Scimitars standard engine bay
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Omegas standard engine bay
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This is how much stuff I had to dig out to get to the front of the engine. Everything is labled with masking tape so I stand some chance of getting it all back together in the right order. \n

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The amount of electrics that will need transferring is immense. Again everything is labelled. Everything on top the engine is disconnected electrical loom’s. 
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Finally it gave up the engine. It took a whole day of stripping to get this far.
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Sat on the floor with gear box placed behind. 
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Again on the floor. It's a very compact engine and box.
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Just the electrical bits to remove from the car now.
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Next up. \n
Because of the amount of cooling this engine needs the spare wheel is going to have to reside in the boot. \n
The keys and immobiliser are going to be kept. An immobiliser is a nice thing to have on the Scim anyway. \n
There's also the compressor and vacuum air pumps to transfer, and if I want the omega speedo to work in the scim I'll need to transfer the abs computer and sensors. I've also got an ecu reader coming 

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Not quite as much to strip out like the Omega. 
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Engine bay clearing a bit now. 
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Space,,,,, Hopefully enough for Mr Omega to fit. 
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I new the front would lift a little, but I wasn't expecting this much.
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There's the little blighter.
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Just for some size comparison.
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Just for some size comparison.
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Now it's time for the real fun to start and make the Omega lump fit. From the look of it I'll have to sit the engine 2\" further back than the Essex to let the sump clear the chassis cross member. This is bound to result in a little fibre glass adjustment.

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Well here's the moment I've been waiting for, Will it fit???
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And the answer is...........
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YES
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And very nicely at that. \n

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It just looks right as well.
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It just looks right as well.
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This engine is far lighter than the Essex. Just look at the suspension, and that after jumping up and down on the front and pushing it around on my drive. 
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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t's sat in there with make shift engine and gearbox mounts now while I fabricate some to bolt it in properly. \n
No modification to the gearbox tunnel at the moment, I'll re-check but it's looking very promising indeed. \n
The sump is about an inch lower than the chassis and the whole engine is sitting about two inches further back than the Essex did.
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This is the LH engine mount, I also had to cut out some metal and weld a patch in on the chassis where the out rigger meets the chassis. I don't believe in just welding a patch over the top of the rust. 
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This is the gearbox rear mounts for both Scimitar and Omega. 
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And here is the finished modded mount. How simple is that! 
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Box fully mounted. 
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A view from underneath looking back from the front. I'm well chuffed with how that engine fits. 
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Next job was the gear stick. The standard Omega mount is so easy to adjust to whatever length you want.
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Simply cut out what you don't want.
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Then weld back together. It's kicked off to the left to clear the handbrake on the Scimitar.
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The gear linkage from underneath.
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And there we have it, one fully functional gearstick. It's sat about 2\" back from where the auto selector was positioned. It feels perfect here. \n
I had to cut a hole in front of the gear stick to allow clearance for the selector bracket. So thats a bit more fibre glassing I've got to do.
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A little more progress, I've built the exhaust, and what a pain in the butt that was.
I'm interested to find out how loud this will be as there's just one silencer at the end of each pipe. There’s space for an extra one if needed.

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The new left hand down pipe sat beside the old right hand one for a comparison.
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The pile of scrap bits of exhaust I accumulated over the weekend.
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The completed exhausts, I'm wondering if there's any extra power now I've removed the cats from the system.
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This is how it now looks after it has settled, completely level if you measure the chassis with a spirit level. The exhausts are hardly visible.
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And a view from the front, as you can see I bent the exhaust around the chassis and brought them back up toward's the cars floor.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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A bit more, I've been playing with the clutch.

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First job was to remove all the remaining fibreglass to make producing a new panel far easier.
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My local bakery had a refit last year and I saved all the stainless steel that was covering the walls from going in the skip. I've got sheets and sheets of it. It will make perfect heat shielding.
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Here it is cut and folded, also you will see the new clutch pedal assembly in place. Amazingly when I held it flat against the bulkhead the pedal was in exactly the correct place. How lucky is that!
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The clutch master cylinder from the Omega needed a quick modification to remove the captive studs and install a captive nut instead.
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For a little extra stability I welded a 3rd mount onto the pedal assembly, and also moved the mounting hole that drives the master cylinder to get the start position right with regard to the other pedals.
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All painted and ready to fit.
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The pedal assembly fully fixed in place.
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My gravity bleed kit, this is also now my temporary clutch master cylinder reservoir.
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The master cylinder fits perfectly beside the brake servo.
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Start of the sticky job. The whole panel will be fibre glassed to a similar thickness as the rest of the car.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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I've built the engine shroud and made a removable rear engine cover.

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The side panels are stainless steel.
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The centre part is 25mm box with 3mm wall thickness, I've drilled and tapped 24 M6 holes into it at 2\" between centres. This will house my removable panel. 
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With fibreglass and centre panel held in place with 12 of the 24 M6 stainless steel socket cap head screws.
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The angles took ages to work out, but it came together nice in the end, and it's solid.
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I had a spare half day today so decided to fit the radiator, I unbolted and removed the metalwork holding the bumper and front of the body in place. These will be replaced with modified ones.

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It fitted without even having to cut the fibreglass, though was tight. So I took about an inch out on the right and about half an inch on the left. The base of the rad fits perfectly between the power steering rack and the body / bumper supports.
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With the rad in this position the top and bottom hose's fitted perfectly.
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When I say fits perfectly I really mean that, just look at the bottom hose. I haven’t adjusted it or even rotated it. That’s exactly as it came off the Omega yet it bends around the suspension turret without touching a thing.
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The top hose is just as good and clears the bodywork as though it was a factory fitted part.
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The old and start of the new body / bumper mount.
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As the radiator fills the engine bay width wise there's no room for the RH support that runs from the suspension turret to the front of the nose. This was my solution to the problem. 
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And here it is in situ, I'm hoping it will give enough support to the nose and bumper. It's bolted right through the chassis.
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I then needed a bottle of inspiration and some help with a bit of lateral thinking for the next part.
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The left side was no problem at all as the radiator has a recess that fits around the original metal work. I just had to make the bottom support.
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All the parts ready for painting. 
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While everything was out the way, I degreased the front of the chassis and engine bay and gave it a thick coat of black.
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This is the original (bottom) and new (top) nose support. The original should have been a piece of angle but had completely rusted away. There was just one bit of the angle left that I was able to get measurements from to make my new one.
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Everything painted. \n

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And now in place.
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From above.
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The rad is also sitting nice and low. I still have to make the mounts for it so it will come up a few mm but not much.
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This is all to control the radiator.
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Making sense of it all.
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Completed, with ECU installed and connected as well.
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Starting to look \"Factory\" now.
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My chosen fuel pump, it's from a Mk2 Golf GTI, it's a pump, swirl pot and filter all in one tidy module. Not bad for a fiver!
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Here's it's new home, the standard Scimitar fuel pipes can be seen passing under the pump at the moment. So I just need to cut then and fit them.
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Bit of a jump but the radiator top mounts are made and bolted in place. The radiator is now fully fixed in it's new home. Also the water header tank is properly fixed with a few custom brackets. It's now ready to add water. A lot of the engine wiring is also in place and the whole thing is starting to look a lot more tidy.

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I just need to make a cowling that goes between the front of the engine bay and the radiator now.
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The new Continental timing belt complete with new tentioners. I'll now get to try my new cam timing and locking kit.
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Here is the old one with all the covers remove and the plenum balanced out the way.
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Belt removed with the locking set installed.
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Came up with an idea for cheap air ducting to the filter box. Gutter pipe, the pipe it's self came out of a skip and the 4 fittings if I need them all cost a fiver.  

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While on the subject of using cheap plumbing parts to get the Scimitar going. I used a bath waste seal to replace the perished original. B&Q £0.99 and you get 2 for that. 
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Its a perfect fit.
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I've really gone deep into the Omega now retrieving all the wiring I \"think\" I need. The dash had to come out.
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Really getting there now, one more wiring loom to add then a bit of finishing off. Hopefully it will spring into life then.
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", "_anchor": "gallery5-ui", "_isUserblock": true, "_cid": "sQhn447siT", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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I’ve done a quick check on the EML flash codes, came up with: \n
SAI - Not connected yet \n
EGR - I haven’t connected the flying saucer \n
AFS - not connected properly \n
Immobiliser - didn't have the key close enough on the first start up, that code should clear itself.\n
Well I've added a few relays to make the ECU happy, and it now runs without the EML flashing on and brings up no fault codes. Result! \n
Now I've got the induction piping sorted it runs even sweeter. That GM power steering pump runs the steering rack lovely as well, the pipes were even in the correct place and correct size to bolt straight on. \n
Most of the loom required goes with the engine, ecu included, there are only 3 connectors that link it to the car. Of those three connectors you will require about 12 wires plus the 4 big fuses in the engine bay. Off the top of my head they are: \n
Ignition Pos 2 \n
Ignition Pos 3 \n
Permanent live \n
RPM signal for gauge and immobiliser \n
Temp signal for gauge \n
Oil pressure signal for warning light \n
Battery charge light \n
EML signal for light \n
EML flash code wire \n
Immobiliser signal \n
Secondary air induction relay wire x2 (just to keep the ecu happy) \n
You will also require the immobiliser fixed around the ignition key switch and the key. \n
I may have missed a few, once it's complete I'll have to produce a more comprehensive guide.
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\n LEARN MORE\n LIVE DEMO\n
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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One new propshaft fitted and working.

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Looks lovely, made by Propshaft Services Heathrow. 
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Breath of relief, my drawings were correct, it fits lovely. \n
So now it moves under it's own power.
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I've been up to bodgery this week, the Scim was far to loud as every one said when I only put one silencer at the back. So I've used the old scim middle boxes as well.

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I cut the skin off the silencer.
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Then with some more of my scrap stainless steel made a new skin for it.
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While all this was going on I gave my dad a job as he was over and is far better at wood work than me. This is the new carpet support on the left and the old flaky one on the right, he made one for each side. 
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Other than that I've completed the engine bay electrics, made and mounted the battery, finish the bulkhead and painted all the fibre glassing that I had done, and welded a patch on the chassis.

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MOT tomorrow (Friday 15th) at 9 am, ooooohhh

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MOT tomorrow (Friday 15th) at 9 am, ooooohhh
The MOT station have apparently been preparing for my arrival ?????????? \n
I'm not sure if this is a good thing or bad thing. Just what prep do they need to do???


It passed first go with no advisory's \n
YAY \n

Oh forgot to add,,,, flippin heck it shifts. \n
A little acceleration test, keeping it about 3000rpm and it spins the wheels when you change to second and third. Scary stuff. \n
So I can happily report it's proper rapid. I used to think my VW Corrado G60 was quick, but this would leave it for dust. \n
Does anyone get the impression I'm just a little happy with it?

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2009 PPC £999 Challenge

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Well I'll be off to Mallory Park just after lunch, thought I'd give it a quick tart up with some polish and back to black. 

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I'm really looking forward to the challenge at Mallory. \n
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I'll let you all know what happened, on Sunday eve. \n
If anyone else is going to Mallory come over and say hi, the car will be in the paddock area or on the track all day.\n



Well, firstly I'm loving that car. \n
What a great weekend, what a lovely friendly atmosphere between all the £999 competitors. The challenge went a bit pair shaped, not on my part but on the set-up of the £999 challenge, they didn't allow enough time to do it properly between track sessions. \n
There were 39 entries in total, we didn't have time to do the standing 1/4 mile which was a shame as that was the only part I thought I'd have any chance at. Instead the handling test and 1/4 mile were combined into a partial lap of the track. \n
The auto test should have been called rally cross. It was held on a gravel area. So I thought it best to forget the handbrake and use my right foot instead. Probably no such a good idea, my best time was 54 second flat. putting me 34th. Oops. That's the drivers fault not the car. \n
On the sprint things were a bit more promising, I managed 5th out of 39, so she pulls well. \n
PPC staff decided to call it void and have invited us all back free of charge to do it properly again very soon. \n
I also had 15 min's of track time and that was great fun. I absolutely thrashed the be-jesus out of it. I didn't trust it on the corners at all so was taking them slow, but on the straight it was awesome and passed everything that got buy on the corners. Pulling cleanly away from a Porsche 944 was most amusing.  I was taking the long corner in 4th then flooring it as it was still around 3000rpm, it was pulling 130mph down the long straight in 4th. Oh and the noise it makes under load like that is lovely. \n
Anyway I thrashed it until the break fluid boiled. I guess I should have replaced that as I have no idea when it was last done. I had to give up then as that was a bit hairy. Needless to say the cars faster than I'm capable of driving. I also cooked the crank angle sensor on the last few laps and it was reluctant to rev above 3000rpm, so I need to get a new one of them too. It's fine unless you get the engine hot and work it hard when hot. They are prone to doing that apparently. \n
I need to give it to someone who knows what they are doing to test it properly for me. \n
As soon as I get some pics of it I'll post them on here. \n
I guess that's given it a good shake down, along with the 300 mile round trip to get there and back. \n
Oh also forgot to add, PPC magazine are going to do an article on it, I need to contact them again in the week. I also ended up having to go up in the commentary box and have an interview about it. How embarrassing is that. 
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I've spent so far £858, I can sell another £80 so that would give me £221 max remaining funds. \n
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A huge set of super sticky tyres on the back would be the best improvement for the £999 from what I can see of it. That or a miricle of an LSD for that money. A set of second hand adjustables would be good but it's traction in a straight line that's going to make it I think. \n
The three tests should be: \n
Auto test \n
Standing 1/4 mile \n
Sprint around a hair pin \n
All the times are added together and the lowest wins. So the most amount of time can be saved on a good auto test. That's the part I'm useless at, the auto test is more skill than car. Even the PPC Rolls Royce beat me on the auto test. Though I did beat the 750i V12 BMW and Jag V12. Never have there been so many out of place cars on one auto test.
The clever cars from what I can see of it are Nitroused metros and fiestas and the like. They have the advantage on the auto test then the nitrous comes in on the drag and for the brave also the sprint. As long as they can put the power down there away. \n
That track session yesterday really opened my eyes to what I've created! Nothing except single seaters passed it on the straights, though it was mainly chav-mobiles going round. The Porsche 944 made me laugh though, and a modded Cav that was really trying hard. 
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I've got my head buried into Lambda sensors at the moment trying to fathom which one is playing up. I know it's sensor 2 but trying to work out if that’s the left or right at the moment.\n
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I stuck my pc oscilloscope on both sensors at the same time in the end and instantly found the left hand one to be at fault, a steady 0.6V \n
All I had in the garage was an old one from a Vectra. Trouble was it had 4 wires while the one's on the V6 have 3. A quick google found the way to convert it into a 3 wire type. I fitted it and re-monitored it with the scope. Below is what it looked like, the original RH one is red channel 0 and the new LH one is green channel 1.
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It's slightly lower on voltage (0.1v) but the ECU seems happy with that, it also seems to switch more regularly so perhaps is a little more sensitive. \n
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The car now pulls even better and idles more smoothly, I thought it was smooth before. \n
The old one was stuck telling the ECU that it needed more fuel so when hot and really working the car was over fuelling hence being reluctant to rev over 3000 every so often. It should now be even more economical.
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Well I was expecting some teething problems with it, but none as annoying as yesterday when the clutch thrust bearing decided to start making one hell of a lot of noise. So now I have to take the gearbox back out and change that bearing. The most annoying thing is that a couple months ago I had the whole lot sat on the floor and it would have been so easy then.\n
So it's off the the Vauxhall garage to ask for a thrust bearing for a SE6a Scimitar.\n
Well at least I made that removable panel on the bulkhead to get to the top bell housing bolts, it's going to be useful that.\n
I've done almost 1000 miles in it now.\n
Well on Friday I took the gearbox out to find out that was making the huge racket whenever I pressed the clutch.\n
Firstly I was very pleased to find that it is is possible to change the clutch without even dropping the gearbox as you can let the whole gear box rest on the chassis cross member and just slide it back.\n
I pulled the clutch thrust bearing off to find there was nothing wrong with it, this meant I had to dig further. So the gearbox came out completely and then I took the clutch plate out to find the spigot bearing in the end of the crank shaft had collapsed.

Yesterday evening after work I refitted the complete gearbox, exhaust, prop shaft, lambda sensors, and gear stick. The gearbox is so light it makes this an easy job. 2 hours are plenty to refit it. 
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I got a new spigot bearing from my local Vauxhall dealers for the grand total of £3.06.
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The collapsed spigot bearing and the new one to the right.
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The clutch hydraulic hose is quick release and if done properly doesn't need bleeding on reassembly.
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Gearbox, lambda sensors, clutch, pressure plate, and a new thrust bearing just for good measure.
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The clutch plate has no springs in it as the V6 uses a duel mass flywheel.
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The gearbox back in and prop shaft connected, just the exhaust and lambda sensors left to connect in this pic.
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A test drive today shows all noise issues fixed so there's a result.

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What a lovely circuit Curborough is, we all had a great day there Friday despite the weather. The morning tipped it down but in the afternoon the sun came out and it was lovely. \n
We all done a drag race in the wet from the last corner back down the the finish line. My best was a 11.37 in the wet, the best for the day was a 10.24 set by a Skoda Rapid on NOS. Neil's SS1 turbo done a 10.93 \n
We all then started the sprint, which was a double lap of the circuit starting and finishing at the line. The front wheel drive lads were really struggling in the wet. The best I could do in the wet was about a 1.19.52, and most of that was sideways, I think I drifted the whole circuit.
It then rained so hard the circuit started to get some big puddles so we called it off for lunch, and managed to cram about 30 of us under one gazebo. In the afternoon the rain had stopped and the sun came out. On my first dry sprint I knocked 10 seconds of my best wet run and came in at 1.09.11, I couldn't get this much lower and done my best at 1.08.89, this put me back in 18th out of 24 runners. I think I need more practise at this, I've never really done anything like it before. Though less than half a second faster would have moved me up to 14th over all, it was that close between everyone. Neil managed a very competitive 1.02.98 to put him self 3rd over all, well done mate. Best time of the day was jointly set by an MX5 2.0L on nitrous and a Honda Prelude at 1.00.32 \n
I had a great day there and what a mixed bag of competitors, less than a grand motor sport is so much more fun. \n
It all went a bit pear shaped on the way home though, the fuel pump gave up on the M42. I think there must have been some rubbish in the tank that got stuck in the pick-up pipe. So my arrival home was on the back of an AA truck.

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Thought I'd better do a bit of tarting up for Curborough, so got the drivers electric window working with the help of an electric drill and some WD40. The brushes were all clogged up and everything needed a good clean to remove the carbon. I wasn't expecting it to look like a sardine tin though.

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I striped the door card off, and discovered one big heap of rust,,,, Thought these things were fibreglass??? 
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As usual one job leads to another far bigger one. Looks like I'll be breaking out my stainless steel stock and making a new door top. For Curborough it will be fiberglassed to stop the water getting in.
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The rest of the door support and top is in the bottom of here.
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The sardine tin motor with a big chunk of magnet missing? Well it works like this but I will be on the hunt for a new one.
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I was getting worried about the new rad as it was a bit vulnerable down there in the front so I've made this to replace the old rusty thing.

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Looks ok and doesn't affect engine temp so there’s a result.
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Back at it again, this time concentrating on the speedo. As some of you will be aware I've been using a GPS as my speedo, so yesterday I started to look at what was required to get a speed signal sorted. The first thing to do was establish what the signal was supposed to look like and how it was affected by the speed. \n
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To do this I used the Omega speedo as my Ginnie pig and found that the speed signal to the speedo is held at 12V, then taken to ground every time the Omega wheel sensor passes a tooth on the axle. \n
So I quickly rigged up a BC547C transistor to switch the speedo signal to ground then made a program and used my laptop to emulate the signal. Amazingly it worked first time and I could control the speedo from my laptop.
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Speed to frequency is as follows: \n
MPH.....HZ \n
10.......57 \n
20.......171 \n
30.......276 \n
40.......392 \n
50.......498 \n
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70.......713 \n
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100.....1044 \n
So it's linear that makes life much easier as when I make the signal conversion control box the maths needed in the processor will be simple. \n
I even clocked up 18 miles sat on the drive.
Next job is to mount up a sensor on the prop shaft and work out the conversion formula.
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While I wait for parts to complete the speedo, I've turned my interest to the heater, or lack of it at the moment. \n
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After the conversion there wasn't enough room for the heater to fit by about 1 1/2 inches. So I've started making a new stainless steel heater using the old matrix and operating principle's.

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First of the old heater stripped apart.
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This is what I've come up with, looks to nice to hide behind a dash.
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With the matrix sat in position.
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And this is how it will sit in the car, cold air from the existing fans will be fed into the lower rear of the heater, then a flap will either direct it through the heater matrix for hot, or around it for cold. A cowling on top will take the air to the windscreen demister and the punkah louvers.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Well, here we go again, the car and me have been hibernating over the winter months, starting to wake up again now.\n
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There's a few things on my list that I want to get right, firstly and most importantly as it annoys the heck out of me is the leaking sunroof, I think I've sourced the correct replacement rubber for it. After that the interior and heater need looking at, then respray time. Once the car is looking a bit more presentable I'll be happy spending time fitting the ABS and TC etc.\n
To fit the heater properly and investigate a small water leak I'm going to take the dash out completely, as it's very warped and cracked I doubt it will get re-fitted, I have other plans for that, I'm hoping it will look ok, more will be revealed as time goes on. I've set a deadline of having the car drivable again by the start of April as thats when I'll tax it again.\n
Until the sunroof rubber arrives and the nights get a little lighter I'm playing wiring again, with the dash out will be a prime opportunity so make all the electrics work correctly. I'm going to install the original Omega instrument console as a permanent thing. To that end I've started work on the \"Multi Function Display\" (Trip computer), I see no reason why this cant be fitted and made to work.
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I've labelled all 30 of the trip computer wires and tested them.
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Labels may look cryptic, but they tell me the entire route of the wire from source to ground.
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The trip computer not only gives MPG figures and the like it also links to the lamp test unit to report on any failed lights around the car, oil level and pressure, water level, screen wash level, etc. It's very thorough. The display may look odd in the pics as I only had an LED to illuminate it until I get four new lamp for the back light.
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There's even a built in stop watch, just what every budding autotest contestant needs. haha.
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I want to fix the omega instrument console permanently in the car along with its digital display and trip computer, to do this will require modifying the dash top a little, now as this is warped and cracked I wasn't to bothered. On looking at the rest of the dash I decided that was in a poor way and up to usual Reliant interior standard. To this end I've gone for a complete redesign but keeping the Reliant \"look\". I spent a good few hours down my local scrap yard with a tape measure and tool box. I've come away with a complete Vauxhall Corsa heater unit and the control panel with all linkages and associated wiring. I've also got a Rover 400 series fuse / relay box. While down there I noticed that Alfa Romeo 156 seats are very nice and also very narrow, they look about the same size as the SE6 ones, sadly no tilt mechanism though.
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Anyway, here's a quick pic of my plan with the heater sat temporarily on the passenger seat.

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I'll make up a steel dash skeleton then use 10mm square steel mesh to complete all the contours needed, then fibreglass, plastazote 3mm foam, and leatherette. It will be made in the same way as Reliant did, so a separate top panel, centre panel, and side panels. The main dash and side panels will be tan leatherette with black instrument panel and black centre panel. \n
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Once the dash is done I can get on with replacing the horrid carpet and generally tarting the interior up a bit.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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I'm at risk of breaking the sewing machine out!
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A 1.8 meter wide by 4 meter long roll of Tan Vinyl leatherette arrived today yay, don't you love the 70's haha. This should be enough for the dash, doors, and perhaps seat sides too.

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Looks perfect colour.
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Nice texture too.
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Oh, and I've done this too.
Can anyone spot the difference?
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I've got taking the dash out and labelling everything down to less than half an hour now. haha Oh, there's some other Vauxhall parts mixed in with that lot just for good measure.
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", "_anchor": "gallery5-vb", "_isUserblock": true, "_cid": "sQhG1ZOSZ9", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Heater No. 2 (Corsa)

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I've cut some plastic out of the heater to make it fit, some other parts needed adjustment.
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I had to shorten the centre vent tube to keep centre console back as far as is possible. My fiberglassing is coming along nicely as well, I've got bends of to a fine art now.
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And here it is sat in place, the gearstick will need it's start position changing again to give a little more clearance when in 1st, 3rd, and 5th. I should have about 1.5\" of clearance.\n

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This gives a current clearance idea, it's getting there.\n

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The controls are kicked over to the left to allow room for the instrument cluster and light switches, the stereo will sit above all this. It's starting to look \"right\" once again.
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Looks more like something from Tate Modern, but it is the new top to the Corsa blower.
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This should help make it a bit more obvious, the original Corsa top sat far to high.
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This then turned up, 1 gallon of fibreglass resin and hardener along with 10m of chopped strand fibreglass matting.
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The top of the heater now enclosed, I've only fiberglassed down to the original joint so the entire top can still be unclipped if you ever needed to get to the blower.
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The original removable bulkhead panel needed modding to buy me a little more space, I've also chopped it in half to aid heater installation and removal.
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", "_anchor": "gallery5-vd", "_isUserblock": true, "_cid": "sQhH1mBXdv", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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I de-activated the Omega steering wheel air bag. This was done because I've discovered a new trick.
The Omega steering wheel fits snugly on the standard Scimitar column. In this pic I've also fixed the Omega gauges, trip computer, and light cluster in place. I'm also very tempted to fit the Omega headlight and indicator stalk assembly, it has a variable speed wipe option that I'm sure I could get to work on the standard Scimitar wiper motor. Sitting in the driver's seat now is completely different, and having a modern chunky steering wheel makes it feel lovely. I will connect up those horn buttons too.
Not sure if you can make it out but I've started the metal framework for the dash top, I'm trying to keep it all flowing to make vinyl covering it as easy job as possible.\n
The heater is not far of completion, I need that fully plumbed in (both water and air) before I can make the dash. The instruments also had to be fixed in place to ensure that the heater ducting doesn't obstruct it. Fitting the instruments needed some planning to so that you can clearly see all the gauges through the steering wheel.

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I made a set of dash brackets that sat where I wanted the dash to go, then made the shape I wanted out of 6mm steel rod. To this frame I've tack welded rectangular wire mesh and formed all the curves I'm after.
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Another view so you can see the shape I was trying to achieve.
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As I was starting from scratch and I only had the thicker gauge fibreglass matting which doesn't form around bends to easily, I've \"wired\" the dry matting to the mesh backing.
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Then soaked the entire thing in fibreglass resin ensuring I got good penetration. You can just imagine the mess and smell.
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From the top side.
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Once it was set it was far easier to move and test for fit in the car.
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've started to add some expanding foam to the back to add extra rigidity and sound deadening to the entire thing.
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Start of the body filler stage, this has taken me all day to end up with something I was happy with.
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The finished part sat in the car to check angles and fit. Well chuffed with it, just needs covering now.
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It's ended up exactly as I wanted and should look great covered in tan vinyl. It's hard to get a photo to show the radius's and curves correctly, I've also sealed the dash in fibreglass resin now so that there is a good base for the contact adhesive and foam / tan vinyl.\n
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It was my first attempt, but to be fair I had a good fiddle around with the wire frame and mesh until I was happy with the shape, it's only once it's fiberglassed that your stuck with the shape. It took a whole day of body filling, then sanding, then body filling, then sanding, etc etc.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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I've made some of the heater mount brackets now and a stainless steel centre console that will be black rubber coated.\n
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On another note, the engine had gained a water leak at the end of last year, but as there was only 2 weeks tax left on it I just left it. Over winter all the coolant leaked out, I went out yesterday to fill it up and it came out the water pump shaft as quick as I could poor it in.

Thinking this will be expensive I went on ebay hunting for a new pump, I was well chuffed to find new ones for just £19.35 delivered. That's got to be as cheap as an Essex, if not cheaper. The only down side is I will now need to remove all the air ducting and cam belt cover to get at it. Time now to see just how serviceable I've made it.
On the immobiliser key fob front I've managed to remove the part that's mounted in the Omega key and heat shrunk it to the Scimitar key, so now the Omega immobiliser module is mounted around the ignition barrel and all works well. Perfect.

I've started making the centre console out of stainless steel sheet, it's folded and rolled this shape to follow the contour of the Corsa heater controls. I don't have a sheet metal roller only a folder so the radius was roughly created using a piece of scaffold pole on my lawn.
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It's not perfect yet but more fettling will see it looking fine.
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I then set about it with the angle grinder to make the Corsa heater controls fit thought it.
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From the side.
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It's to wide at the moment, I done that to be on the safe side. I will now cut about an inch and a half of the right hand side and then taper both sides down to line up with the edges of the transmission tunnel. My intention is to follow the same tapered profile as the side of the Corsa heater control.\n

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Some more views, the pasenger glove box will have an extra piece added to it to follow the profile of the dash top, the whole thing will then be covered in the same tan vinyl.
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t's close to the steering wheel at the moment, once trimmed back and tapered it will be fine. I've also thrown the stereo on top as this is me intended location for it. There will then be an extra separately made and covered bit of dash that extends out over all this, looking a bit like the original scimitar centre part. All the stainless steel will be sprayed with black rubber paint that has a nice feel and look to it. In the remaining panel to the right of the Corsa heater controls will sit the standard Scimitar headlight and fog light switches.
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Now trimmed and fitted, it's nice weather at the moment so I can't help but fiddle.
Switch hole's milled out.
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Sat in place and looking about right.
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I now have the rubber paint on order that should arrive over the next few days, I'm interested to see just how good a finish it produces.
I've managed to buy a full Scimitar leather interior for it in the same colours, and replace the leaking heater matrix that the Corsa heater had when I tested it. I've made a template for the sides of the centre console and a radiused part that keeps the lines of the Corsa vents right thought the dash therefore making it all look more complete. I've temporally fixed the leaking sunroof only to find the wiper's are letting water in now grrrrr. Still at least this is before I put a new carpet into it.
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", "_anchor": "content4-vh", "_isUserblock": true, "_cid": "sQhQbyLRWt", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "center", "color": "#000000" }, ".mbr-section-title": { "color": "#000000" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n The Sale

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Owing to lack of undercover space and currently time, I am offering for sale my SE6a Scimitar fitted with an Omega 3L 24V V6 and 5 speed manual gearbox. I guess you could consider this a rare opportunity, and I may yet change my mind and build a workshop for it. \n
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Viewing this is I'd say essential, as it's been off the road for 3 years sat on my drive, it still starts and runs fine, but this is in no way a completed project. From my brief look around it I'd say that for an MOT it would need some new tires and more than likely the lights sorting out again as I know how temperamental these can be. Also some finishing off the interior to make it drive-able. Body wise the sunroof leaks and the paint is crazed, the interior is shot,,, however, I have a complete spare cream and tan leather interior in the shed which goes with the car, you'd just need carpet and to sort the dash / center console. It has some custom dash I started and also the original that would bolt straight back in. The only thing requiring sorting would be the heater, as I sat the engine back as far as possible for handling.\n
This car for those that do not know, was built for the Practical Performance Car 999 challenge back in 2009, PPC magazine liked the car so much they ran a 6 page article on it in the October 2009 edition, it also seems to get the odd mention even now.\n
I'll also include the cam belt change tool kit that cost me £100 as the Omega Haynes manual (also included) states 40K miles or 4 years for the cam belt change period.

Price wise I am open to offers, or I keep it and finally get it finished, what it cost to build was no secret as it was in the 999 challenge so the total sum of the parts had to be under £1000.



Needless to say, it eventually found a new owner...
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Reliant Scimitar SE5 - A-Post Inserts

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\n This is a common ailment of these cars. As you are probably aware, the purpose of this steel insert is to take the load of the weight of the doors (approx 18kg) coming through the door hinges and spread it across a large area of the A-post and the adjoining kick panel.
Note that these inserts do not tie into any other structure or the chassis. They are standalone load spreaders.

An indication that they have rusted an require replacement is the billowing of the kick panel in that area between the mounting bolts. This being caused by the swelling of the rusted panel pushing the fibreglass out.

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The Repair

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Although the repair is intrusive, once you get into it it is not that complicated.\n
First of all you of course you need to remove the door and the door hinges.\n
Once done, proceed as follows.

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Title

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Gain Access
The hole in the kick panel is nowhere near big enough to effect the repair.
Access is gained via the front wheel well by cutting a hole as shown. The best tool for this is a DIY multi-tool as it gives a clean sharp cut with reduced spread of dust (don't forget your mask!). Be sure to leave enough of an edge around the hole to give something to bond to when replacing the removed section.

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Front left wheel well looking back.
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Outline of access hole cut with a DIY multi-tool.
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Portion removed.
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Metal insert now clearly accessible.
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Title

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Removing The Old Insert
Due to the fact that it has rusted, removal of the old metal work isn't as hard as you might imagine. The bond between it and the fibreglass will be very weak due to the surface rust of the metal. A few choice cuts through the outer layer with the multi-tool will allow you to effectively peel the fibreglass away from it.

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It will be possible to make out the outline of the old steel insert. Some cars inserts are better buried than others.
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Large holes in steelwork aid with bonding the insert to the GRP body.
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Fibreglass skin is cut around the extremities of the insert and then simply peeled clear.
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Once the outer covering of fibreglass has been peeled away it is possible to prise the insert out of position. The bond won't be that strong anymore thanks to the surface rust.
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Removed!
Note the bends in the top (far) end of the insert were caused during removal as the metal had become so thin.
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The 'surface rust' still stuck in place within the shell. Needless to say, this all needs cleaning off and rubbing down to prepare it to accept the new steelwork.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Title

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New Steel Insert
I will put my hand up here and admit to buying a ready made part. Someone on the owners forum had made up a batch of replacement inserts out of galvanised sheet steel so I bought a pair.
However, it is not a particularly complex shape and using the old one as a pattern (with the aid of a bit of Carboard Aided Design) you should be able to fabricate your own replacements. In fact you would be able to adjust them so you get the best possible fit for your car.

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RH Side insert removed with the tool that removed it, a DIY Multi-tool.
Note the welded in triangulation braces, you will need to include these.
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Replacement inserts. Square hinge cut-outs clearly visible.
Masking tape is because I am adding additional bolt holes on the kick-panel side.
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Drilling the additional bolt holes in two rows between the large holes. Despite being galvanized, the whole thing was painted after this to seal the exposed cut edges.
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Do NOT pre-drill the hinge holes as I have done. Do this after it has been fitted using the existing holes in the bodywork as a guide.
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Title

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Installation
After trial fitting to make sure you are happy with the way it fits, and having cleaned all surfaces to ensure a good bond, the new metalwork is bonded in place with resin. Use the large square hinge cutouts for alignment.

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New metalwork has had its mating faces painted with resin and is held in position as the resin sets.
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Spring clamps and screws through from inside through bolt holes into wooden blocks to ensure good bond with the kick panel.
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G-Clamps and wooden load spreaders to pull the metal work tight into the corner.
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Once the resin has had time to cure (I gave it a few days in the warm summer months) the various screws and clamps are removed and the internal faces covered over in a layer of fibreglass, effectively stitching it to the bodyshell.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Reliant Scimitar SE5 - Bodywork

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\n The Aim

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The vehicle is half a century old and so the bodywork is far from factory fresh and is in need of attention. This isn't going to be a restoration and I currently have no intention of entering the car into concourse events. However, I do want the bodywork to be sound and preferably last another few decades. Therefore I will undoubtedly be addressing some of the common issues that they suffer from and the repairs should be suitable whatever your intentions may be with your own car.
First job though is to strip everything out!

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\n The Big Strip

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Removing as much as I possible can from the body shell to aid in repairs and in lifting it clear of the chassis.

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\n Lifting the Bodyshell

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\n Separating the body from the chassis.

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\n Repairs & Modifications

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\n With the shell stripped it is time to assess and repair as necessary. See below for details of each repair and any modifications I carried out along the way.

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\n Rusted A-Post Inserts

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A common problem area given away by billowing of the kick panels.

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\n Rusted B-Pillar Hoop Fish Plates

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\n Another common rust area and MoT failure.

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\n Doors

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Replacing the rusted steel inserts.
Fabricating new light weight window frame & fitting acrylic windows.
Other weight reduction.

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\n \"Mobirise\"\n

\n Not Ready Yet

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\n Light Weight Nose Support Frame

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\n Ditching the heavy gauge steel plate for a light weight alloy frame.

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", "_anchor": "image1-x8", "_isUserblock": true, "_cid": "sQytnPkFFU", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@fullWidth)": { ".text-wrapper": { "padding": "1rem" } }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, "img": { "width": "100%" }, "@media (min-width: 992px)": { ".text-wrapper": { "padding": "2rem" } } }, "_name": "image1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Lowering the Floor

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\n Getting more head room by lowering the seats (by lowering the floor).

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "sPSGvhrEps", "_anchor": "menu1-wu", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Reliant Scimitar SE5 - Doors

\n

\n Text

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\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-wx", "_isUserblock": true, "_cid": "sQwKv1FDyB", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Text

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\n Title

\n

For a composite sports car the doors are surprisingly heavy. They can also get surprisingly rusty as the steel reinforcement inserts around the hinge mounts rot within the fibreglass. Read on to find out how to resolve both issues!

\n
\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-x6", "_isUserblock": true, "_cid": "sQy2LX18Fq", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n \"Mobirise\"\n

\n Damage to front edge of doors due to rusted metal inserts. The door check straps have pulled through and the fibreglass shell is cracking around the hinges.

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Door Strip

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First job of course is to strip the door down.

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Drivers (RH) door removed ready for stripping.
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Door card and furniture had already 'fallen off'.
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Approximate starting weight (without hinges): 18.7kg
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First item to be removed is the mirror to prevent damage. Simply remove the small grub screw in the base.
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The bracket can then be removed.
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Large metal plate at the bottom mounts the internal pull handle and the latch operating mechanism.
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The door capping trim (the black padded bit) comes off next.
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Lift it to reveal pop-rivets. Drill the heads off and tap the rivet bodies out.
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Now for the window winder mechanism.
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I didn't even bother trying.
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Just drill the heads off the plate mounting bolts. The bolt remains just pushed out afterwards.
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That just leaves the window and its frame.
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Window Frame Removal

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Possibly not strictly necessary if you just want to replace your rotten hinge plate but you are likely to want to refurbish the rest of the door anyway.

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Window frame mounting bolt locations. Those that don't simply shear off you will probably end up drilling out.
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Two at the base of the very front (one missing here).
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The heads of the two at the quarterlight position are accessed via slits in the rubber but should be captive anyway.
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The corresponding nuts (circled). They are likely to just snap off.
Those long studs in view are from the mirror and are not original.
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There are two hiding behind the rubber in the forward window runner.
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And two more in the rearward window runner.
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They might undo but more than likely you'll end up drilling and cutting.
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Finally, these two need removing. I had one pop-rivet and on screw so goodness knows what's supposed to be there.
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Simply slide it out.
Remember - the big piece of glass is loose and the frame is likely to spread!
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Window and frame.
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Door carcass.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Hinge Plate Replacement - Part 1 'Removal'

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A dirty messy job requiring patience and a good dust mask!

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If they haven't already fallen out, make sure that the two hinge bolt backing plates are removed. Save one to use as a drill guide later.
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For improved access part of this 'rib' needs to be cut free (and kept safe to refit later).
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It is secured to the door skin by a single strip of fiberglass.
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When cutting ensure you cut beyond where the window frame mounts so that you don't end up with a join there. The section peeled off the fibreglass strip.
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Excess of the fibreglass strip cut away.
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The problem area.
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Using my favourite precision tool, a DIY multi-tool.
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Slicing off the top cover.
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To reveal and empty space where the check strap mounted. The sheet metal insert has almost totally disintegrated by here.
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Pay careful attention to where I have cut the top off and make sure you are happy before cutting yours open.
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Bearing in mind how the door was constructed, the fibreglass sheet with the large hole is actually the closing sheet used to seal the original steel in from inside the door.
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Remove as much of it in one go as you can. It's bond to the remaining steel will be weak due to surface rust.
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Here you can see where the original steel sheet folded round the inside of the front of the door.
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Here you can just make out a surviving section from the upper hinge point that I have pulled loose.
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A closer view.
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Prising off the remains of the closing sheet of fibreglass.
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Once a section starts coming away it generally continues to peel off.
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Similar surviving but rotten section of metal from under the lower hinge point.
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All traces of the original steelwork and it's closing layer of fibreglass removed along with all debris.
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As these newly exposed surfaces will be the contact areas for the new steelwork they need to be cleaned and levelled to ensure a good contact and so good adhesion including up the sides of the hinge blocks.
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Lower hing block.
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Hinge Plate Replacement - Part 2 'Fabricate & Fit'

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I bought an off-cut of sheet stainless steel to make my new inserts from, hence the unpainted finish. I deviated from the original design slightly as I am not constrained by cot or time limitations of mass production. it uses slightly less steel but I believe it has improved location and stress transfer.
Please note that the multitude of holes aren't to make it lighter, they are to improve its bond into the door by allowing the resin to effectively stitch it into place.

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The finished article prior to fitment, just for reference.
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Flat sheet with one 90 degree fold down the forward edge. Note how it fits into extremities of the hinge recesses.
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The folded forward edge has been profiled to roughly follow the door profile but leaving a reasonable gap for glassing in. More later.
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Slid into place to allow for marking out of central void.
The forward edge is left at 1.5\" wide.
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The basic shape cut out. Note the two square tangs.
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The tangs are folded upwards to locate against the hinge block recesses once in position.
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In position with tangs making good contact.
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A view from inside showing the forward edge profile and the clearance from the outer skin to allow for the fibreglass to adhere.
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The crack damage is cut out of the front edge of the door shell.
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The cut edges are feathered to give a large contact area for the repair later.
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Lower hinge area.
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All of the bonding holes (but NOT the hinge bolt holes) have been drilled, along with some extra go-faster holes.
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The metalwork needs to be a good tight fit against the door shell.
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This may require some additional grinding of the door shell to remove high spots and maybe some trimming of the steelwork.
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Once happy, ensure all mating surfaces are clean and dry. Paint the mating faces with resin and assemble. Leave the clamps in place until the resin has cured.
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Two days later, the resin has cured and the clamps have been removed.
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A layer of fibreglass is now laid over the steelwork from the inside being sure to overlap the sides of the hinge blocks. The holes facilitate good penetration of the resin and promote any necessary gap-filling of unseen voids.
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Upper hinge.
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Lower hinge.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" }, "H4": { "text-align": "left" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Fabrication of Lightweight Window Assembly

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The glass and Chrome plated window account for a fair amount of the doors weight so I intend to replace them with acrylic sheet in an alloy frame. The new acrylic glazing will be fixed panels but with a sliding portion as typically found on proper race and rally cars.

For this I am using:
4mm thick Acrylic Sheet
Ally U-channel 2mm thick x 12mm x 20mm (external dimensions)
Ally H-channel 2mm thick x 12mm x 40mm (external dimensions)

First task is to make a template and form the single piece outer run of the alloy frame.

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Original frame complete with main glazing (to prevent bending) laid onto 8mm thick MDF board.
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To account for the 2mm thickness off the ally, the frame overhangs the board by 2mm.
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Note the original frame has an external seal. I will see how much mine flexis as I may have to incorporate something.
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The board after cutting, remembering to cut 2mm inside the line where required.
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Original frame repositioned to check.
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Profile looking good.
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The U channel is cut and bent around the former.
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The channel is cut every 1/2\" around the curve.
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Positioned into place.
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The rear part of the frame is marked where it contacts the door shell.
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Three mounting holes are drilled in the identified area.
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A corresponding clamping plate is fabricated from 5mm thick alloy that is tapped to accept the screws rather than fiddling with loose nuts.
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Secured in place.
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The front edge is then marked and drilled in a similar manner.
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Screwed in place.
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Clamping plate.
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The H section channel is held in position against the forward rib of the door shell.
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Making sure it extends a good 1.5\" above the top of the frame.
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Mark where the top of the forward rib ends.
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The H section needs to be trimmed down to this point by removing one side of it. A band saw is best for this.
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Set it so that only the legs of the 'H' section are cut off, leaving the centre spine at full thickness.
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The cut-out in the top of the door now needs extending to account for the material you have just removed from the lower portion of the H section.
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About 18mm was removed to start with.
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Then the H section was trial fitted and a little more removed to give a small amount of clearance.
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It should now fit flush against the forward rib. You might notice my straight bandsaw cut doesn't look that straight. Turns out that cheap bandsaws with plastic blade guides allow the blade to twist under load.
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The top of the H section needs marking out with the contour of the frame hoop.
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It is now cut to match the profile, with the exception of the centre spine.
There should have been a series of photos showing me gradually cutting it to shape but I got carried away and got on with it without taking photos.
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First cut down each side of the central spine to the marked line.
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Cut along the profile line until you reach the spine cut.
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Carefully cut down the sides of the spine. You will have to do the last bit with a file.
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The central 'tang' sticking out the top will be used to fix it to the frame 'hoop'
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This bit isn't very scientific but it seemed to work. An off-cut of the U channel was pushed up to the tang and the tang marked where the channel meets it.
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It was clamped in a vice at this mark and heat applied until it started to soften.
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It was then bent as shown. Use a long implement to push just above the vice so that the bend occurs in the right place. 
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A trial fit with the off-cut suggest success.
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Trial fitted.
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Looking good.
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Tang sat within the U channel frame hoop. This will be drilled and tapped and secured with screws.
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Four equidistant 4mm holes are drilled through the channel and the door shell.
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A clamping plate is fabricated from 5mm alloy and the four holes transferred to it but only drilled as 3.3mm diameter in preparation for tapping.
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They are then tapped to 4mm.
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Trial assembly.
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The clamping plate will foul the internal door shell and so will need cutting to fit to allow the screw holes to align.
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It was then peppered with lightening holes.
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Two 2.5 mm holes are drilled through the upper tang, these will later be tapped to 3mm.
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The H section is temporarily secured in position.
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Once happy that everything is aligned and the profile is correct, these 2.5mm holes are drilled through the C channel hoop.
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The H channel is removed and the two holes in the tang are tapped to 3mm.
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The corresponding holes in the C channel hoop are opened up to 3mm.
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Assembled.
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Assembled.
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Assembled.
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Next to be fabricated are the lower frame channels.
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When cutting the U channel to length be sure to leave generous overhangs either end.
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Mark out the cut lines for it to fit within the frame structure.
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Cut the sides away.
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Pretend action shot.
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Actual action shot, cutting the remains of the sides off to enable the 'tang' to slide within the channel of the frame. This is finished off with a file.
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Complete ready for heating and bending of the tangs.
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The bend point was marked out in the same way as before.
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Each end is then heated and bent as required.
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The main section is fabricated in the same way.
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The new sections are assembled into position and the existing frame structure marked to show their location. Note the main section sits lower than the quarterlight section. This is to ensure it sits within the open cavity to allow the forming of an effective weather seal later.
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Door Rebuild and Re-fitment.

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Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-wv", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "SE5 Body Nose Supp.html": { "settings": { "title": "SE5 Body Nose Supp", "order": 6, "meta_descr": "Reliant Scimitar SE5 Repair & Modify Nose Support Structure" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - 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Reliant Scimitar SE5 - Nose Support Structure

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\n LEARN MORE\n LIVE DEMO\n
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\n Complete bar Radiator Mounts

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Title

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The standard front support structure is a very heavy affair made from thick gauge steel plate. To be fair it is designed to support the weight of the spare wheel but as I have no intention of keeping the spare wheel under the bonnet and am wanting to fit a larger radiator as part of the Jaguar AJ-V6 engine conversion, I have fabricated my own light weight alternative.

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First job of course is to strip all the old stuff out.
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Original supporting steel work plus...
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...this crossmember which supported the front of the body via the two studs which passed through the body and acted as bumper mounts.
This is the first part that will be made.
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The alloy box-section replacement.
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The bolt holes for the bumper mounting bolts incorporate crush tubes with some movement available for alignment adjustment.
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This new cross-member needs to be tied in to the suspension tower and the front of the chassis leg.
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Attachment to the suspension tower is by a purpose made bracket.
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A suitable section of 1\" square alloy is cut to length.
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A hole is drilled and tapped into one end to take an eye-end.
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The rest is cut to shape to move the eye-end outboard to maximise space for a radiator later.
The two mounting holes are drilled to pick up on the strut brace mounting bolts.
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Bolted in position. Repeat for the other suspension tower.
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The start of the upper brace.
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The two parts are joined by plates (work in progress here).
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With a subtle fold being incorporated to keep the cross-member square to the front panel.
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All bolt holes use crush tubes.
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An eye-end is fitted to the underside of the bracket to take the lower support strut.
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That leaves the lower anchor point. I did try using the original support structure mounting hole as arrowed but that gave too shallow an angle to the support beam allowing too much flex resulting in the front sagging under weight.
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So I replaced the upper anti-roll bar mounting bolt on the very front face of the chassis leg...
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With this clevis/locknut/eye-end arrangement to give me the lower anchor point. At some point in the future this may get replace by a custom alloy roll bar clamp and bracket.
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This dramatically improved the angle and to structure is now well supported.
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To improve location with the bodyshell an additional length of square section is added to the top surface of the cross brace to take up the bumper mounting void and ribbed rubber matting is added to improve purchase and prevent chaffing.
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As fitted. Here you can se the bumper channel that the cross-member sits in.
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All parts duplicated on the opposite side.
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Completed and painted for corrosion protection.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Range Rover P38 - Electrics

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\n The P38 has a lot of electrical equipment fitted and has a reputation for electrical issues. This is 1990's technology comprising of lots of individual control modules and pre-dates the canbus systems commonly used today.
But there are some things to be aware of that can help keep the electrical gremlins at bay.

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www.batterymegastore.co.uk

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A Decent Battery

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The P38 is very sensitive to low voltage. A simple low voltage can make the BECM (Body Electronic Control Module, main computer located under the front RH seat) throw up all kinds of random faults such as gearbox warnings.\n
To prevent against this all seasoned P38 owners will tell you to fit the biggest battery you can. The Hankook MF31-1000 is the current (no pun intended) battery of choice and is available via the link below the picture.

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\n Better pictures to come.

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\n Mysterious Battery Drain - The RF Receiver

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\n There are plenty of complaints about the batteries in P38s going flat overnight, particularly if a smaller battery has been fitted. One common cause for this can be signals being picked up by the security system keeping the BECM constantly active. The frequency used by the remote signal from your key is close to that used by modern Wi-Fi. If you are parked in a strong Wi-Fi area the security system thinks it is being swamped by 'code grabbing' equipment and so wakes the BECM and immobilises the vehicle.
There is a filter in the system located near the RH C-pillar that Land Rover updated twice, once mid way through production and then again after production had ceased so only available over the parts counter. The latest version is supposed to be effective but is rather expensive. But enthusiasts from one of the forums (linked at the bottom of this page) have created their own for a lot less which I have fitted.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Failed Fusebox

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There have been issues with fuse boxes. This effects the earlier models as the fuse box was updated twice throughout the production run. On early cars the fuse box was prone to overheating around one of the fan relay mounts. This is very visible to see with the relay removed. But there is another common ailment that cannot be seen.
The fuse box is actually made up of two circuit boards, one stacked above the other within the casing. The upper circuit board holds all the relays and fuses. The lower circuit board holds the cable multi-plugs for the vehicle looms. These two boards are connected along their spine by a flexible link and are folded over like a book. They are joined by a row of solid links along two edges. The solder joints on these links have been known to crack, creating bad connections.
The second generation fuse boxes was improved against some of these maladies and is a direct replacement for the first generation fuse box.
The third generation fuse box saw more improvements but coincided with a redesign of the vehicle wiring loom and so these cannot be fitted to the earlier vehicles.

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The main fuse box. The black (should be yellow) relay at the bottom left tends to overheat.
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Someone had already had a go at fixing mine.
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All old solid links removed.
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Contacts cleared.
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Solid copper (as found in house-hold mains cable) is used to make new links.
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They are soldered in place and the ends cut flush.
Please excuse the poor soldering, this is a recycled photo from before the repair.
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\n Join a Decent Forum

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\n By far the best piece of advice I can give is that you join a decent forum. This invaluable tool can make all the difference to your ownership experience. Top of the list is the one linked below:

\n
\n LEARN MORE\n LIVE DEMO\n
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", "_anchor": "content4-xp", "_isUserblock": true, "_cid": "sQEki8MLUl", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-iconfont": { "display": "block", "font-size": "4rem", "color": "@primaryColor", "margin-bottom": "2rem" }, ".card-wrapper": { "min-height": "220px", "transition": "all 0.3s", "border-radius": "4px", "padding": "1rem", "background": "@cardColor", "display": "flex", "justify-content": "center", "align-items": "center", "margin-bottom": "2rem" } }, "_name": "features2", "_sourceTheme": "mobirise5", "_customHTML": "
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www.RangeRovers.pub

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\n Farcebook

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\n Unique Styles\n

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\n Unlimited Sites\n

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\n Text

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-xh", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "SE5 Eng.html": { "settings": { "title": "SE5 Eng & Trans", "order": 7, "meta_descr": "Reliant Scimitar Repair & Modify - Engine Swap" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - 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\n Reliant Scimitar SE5 - Engine & Transmission

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\n Jaguar S-type AJ-V6 engine and gearbox conversion.

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\n LEARN MORE\n LIVE DEMO\n
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\n Title

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Although the original Essex engine has a reputation for providing a lot of torque it is a very heavy unit with poor power output for its size and hardly becoming of a sports car.
Replacing it with a modern lightweight engine producing twice the power with better fuel economy, cleaner emissions and better reliability is a much better idea.
I sourced my engine and matching 5-speed manual gearbox from a Jaguar S-type (the modern re-dressed Lincoln as opposed to the proper classic Jaguar S-type) and if you are looking to carry out this conversion I strongly suggest you do the same as you will save yourself a lot of headaches over trying to convert the transverse mounted X-type or Ford Mondeo variant.

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The Jaguar AJ-V6

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\n The engine is covered on another section of this website. The link will take you to it where I cover details on preparing the engine for fitment.

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\n Mounting the Engine & Gearbox

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Positioning and fabrication of the engine and gearbox mounts.

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\n Cooling & Heater Systems

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\n Fuel System

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\n A modern fuel injected engine requires a modern pressurised fuel supply and the best way to achieve that is with an in-tank electric fuel pump.
This is covered elsewhere in the website, the link will take you straight to it.

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\n For this conversion I am going aftermarket engine management.

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-xy", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "AJ-V6 Acc Drive.html": { "settings": { "title": "AJ-V6 Acc Drive", "order": 54, "meta_descr": "Jaguar AJ-V6 Accessories Mounting & Drive" }, "components": [ { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, ".mbr-section-subtitle": { "text-align": "left" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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AJ-V6 Accessories and Drive

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\n \"Mobirise\"\n

\n My engine as I got it, minus power steering pump and air-con compressor.

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\n The accessories attached to the standard Jaguar AJ-V6 in S-type trim are all driven by a single multi-grove serpentine belt and include:
Alternator
Water Pump
Power Steering Pump
Air-con Compressor
How many of these you use and where you locate them will of course depend on your own application.
Of the above list, only the Alternator is the minimum required. The water pump is separate from the engine and as such could be replaced by an electric unit which I am considering doing myself in the future.

My resolutions to these components may not suite your particular application but their principles might help inspire your own work arounds.

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Alternator

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As it is the one accessory that you will require regardless of your application I will cover this one first.
In standard trim the alternator is mounted on the bottom RH side of the block. As with most modern engines the alternator is solid mounted with belt tension being achieved by a separate sprung tensioner.
The images below show its location and and rudimentary dimensions to help you assess whether you have enough space to retain it in its standard location. Do bare in mind the routing of the drive belt when making this decision.

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The fuzzy photo indicates approximately 8.5\" from crank pulley centre to alternator pulley centre and 10.5\" to the edge of the body.
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\n Title

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Relocation Options\n
For my application in the Scimitar the standard alternator position will foul on the chassis leg so I have had to relocate it. This means I am also going to have to think carefully about the routing of the accessories drive belt, but more on that later.\n
As the standard alternator is bolted straight to the block it is going to be easier to revert to a more traditional style alternator that bolts to a bracket. That will allow me to make my own bracket picking up on whatever convenient tapping's in the block that I can find in its new location. It also means I coul use it to tension the belt in the traditional manner.

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\n \"Mobirise\"\n

\n Lovely pair! Original on the left, replacement on the right.
Note direction of mounting bolt holes.

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The best location I found for the Scimitar was slightly higher up on the LH side of the block. Some people, notably those using an X-type sourced engine, have mounted the original alternator on a plate in front of the engine facing backwards. But I personally prefer my chosen solution.

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Title

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Fabricating the Mounting Brackets

Lower Bracket
There are a plethora of redundant mounting lugs on the side of the engine to which the new bracket could be bolted. I elected to use a section of thick walled box section steel as the basis for the mount, cutting it to shape after a bit of creative Cardboard Aided Design.

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Numerous useable mounting lugs.
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Establishing the distance from the front face of the pulley to the mounting lug.
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Using the front face of the crank pulley as a datum (via the straight edge box section attached to it)...
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...establishing where the corresponding face on the new bracket will need to be and so establishing where the bolt holes need to be drilled.
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Establishing the basic shape of the new bracket.
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Basic shape transferred to a section of box section steel.
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Basic new bracket cut out from box section and bolted to the block.
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The two lugs will be braced with an additional triangulating section welded in between them.
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Upper Bracket
The intensions is to use an adjustable mounting arm for the top mount to facilitate belt tensioning. To this effect, all that needed fabricating was a simple lug bracket in line with the alternators top mounting lug to attached it to.

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Two obvious contenders for the attachment bolts for the upper brackets.
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Off-cuts from box section used to fabricate a simple bracket. A straight edge was clamped to the alternator lug to set the lug on the new bracket square.
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Painted to make it look pretty.
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Mounting the Alternator
With both brackets complete the alternator can be fitted ready for establishing the route of the drive belt.

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Both brackets attached (lower bracket is still waiting for its internal bracing).
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Fitted.
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Belt run clearance check.
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Water Pump

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Unlike most conventional engines the water pump on the AJ-V6 is an external affair. The standard item in S-type trim is bolted onto the front of the timing cover and actually sits in front of the accessories drive belt. It should be noted that the pump pulley is smooth as it is driven by the back of the belt. If you are using the original water pump as I have here you need to account for this when planning the routing of the drive belt as it will require a reasonably large contact area to ensure good purchase.
The alternative that I will be looking into at a later date is to use and electric water pump. These are becoming increasingly common on mainstream production cars such as BMWs and have proven to be no less reliable than their traditional counterparts; failures usualy being the same sheared impellor shafts.

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Externally mounted water pump (ignore belt routing for now).
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Pump removed.
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Pump pulley/belt contact.
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Power Steering Pump & Air-con Compressor

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\n I'm afraid that as I have no need for either of these I have no information on them so cannot help you there. Sorry.

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\n LEARN MORE\n LIVE DEMO\n
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Accessories Drive Belt Selection, Routing & Tensioning

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Again this will be down to your particular application. If all you have to drive is the alternator then this will be very easy. In my case I have the Alternator and the Water Pump to be driven by the accessories drive belt. Care must be taken to ensure that the belt is in sufficient contact with each driven pulley (not idler pulleys) to transfer drive without slipping.

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The final belt routing. The idler pulleys are in the original locations but they are not necessarily standard items.
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Pulley A - If you can use the standard idler and its mounting then do so. On the Scimitar it fouled the steering column. Please see below for my resolution to this.
Pulley B - Standard pulley at standard position.
Pulley C - See next image.
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= 6, 'col-lg-6' : fullWidth && textWidth <= 5}\">\n
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\n Title

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\n Pulley C - This is the original smooth faced belt tensioner pulley removed from the sprung arm and bolted directly to the block where the tensioner arm was originally fitted. A metal sleeve was required to account for the larger internal bore of the pulleys bearing and a debris guard was cut down to fit under the bolt head.

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Pulley A
As mentioned, on the Scimitar the original pulley is too large and fouls on the steering column.
I purchased a second idler pulley 'B' and tried fitting that to the original bracket but it still fouls.
Therefore, using some of the left over rectangular section steel from the engine mount platforms I fabricated a new puley mounting bracket for the smaller pulley wheel moving it closer to the block.

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Fouling on steering column (Ignore the sheered off bolt in the mounting lug).
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Bracket made up from cut down rectangle section steel. Note the inclusion of the steel tube. This is to account for the sideways twisting loading that will be felt from the belt tension.
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As with Pulley C, a metal sleeve will be required to account for the large internal bore of the bearing race.
A spacer is also required to push the bearing forward so that it lines up with the belt run.
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\n Completion

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\n With everything fitted the belt is tensioned in the traditional manner via the alternator sliding bracket.

\n
\n LEARN MORE\n LIVE DEMO\n
\n
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", "_anchor": "content4-t5", "_isUserblock": true, "_cid": "sQg7ompteO", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Title

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The belt has good purchase around half of the crank pulley, half of the alternator pully and two thirds of the smooth water pump pulley.
Job done!

\n
\n LEARN MORE\n LIVE DEMO\n
\n
\n
\n
\n
", "_anchor": "content4-t6", "_isUserblock": true, "_cid": "sQg8I7uyN5", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Text

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\n

\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

\n
\n
\n
\n
", "_cid": "s48P1Icc8J", "_anchor": "footer3-sl", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "SE5 Eng Mount.html": { "settings": { "title": "SE5 Eng Mount", "order": 8, "meta_descr": "Reliant Scimitar SE5 Repair & Modify - AJ-V6 Engine & Gearbox Mounts" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - 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\n Scimitar SE5 AJ-V6 Conversion - Mounts

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\n Text

\n
\n LEARN MORE\n LIVE DEMO\n
\n
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\n
\n
", "_anchor": "content4-yd", "_isUserblock": true, "_cid": "sRksMO2qZw", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "@media (max-width: 991px)": { ".image-wrapper": { "margin-bottom": "1rem" } }, ".row": { "flex-direction": "row-reverse" }, "img": { "width": "100%" } }, "_name": "image3", "_sourceTheme": "mobirise5", "_customHTML": "
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0\">\n \n
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0\">\n
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\n
\n

\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

\n
\n
\n
\n
", "_cid": "s48P1Icc8J", "_anchor": "footer3-yb", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "SE5 Body Strip.html": { "settings": { "title": "SE5 Body Strip", "order": 3, "meta_descr": "Reliant Scimitar SE5 Repair & Modify - Bodyshell / Bodywork" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - 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\n Reliant Scimitar SE5 - Bodywork

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The Big Strip

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As I am hoping to make this car as light as possible I am removing pretty much all of the interior. Someone had already had a go at re-trimming my car in the past, no great surprise given its age, but it was in a very sorry state. It has also played home yo some furry friends in the past.
The photos start after the trim and carpets have been removed and I am part way through the highly rewarding job of removing the glue residue from the shell...

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Totally stripped including the entire wiring loom.
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Aftermarket and very much life expired front seats.
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Pedal box and remote servo.
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Bonnet hinge top cover has to be come off to reveal hidden pedal box mounting bolt.
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Drivers footwell. The access hatch at the top gives you access to the bonnet hinge as can be seen.
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Floor in work.
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It took a very long time to get this far...
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Almost there. Note the convenient speaker holes someone has added. They actually lead to the outside world somewhere within the rear wing as our cat used to climb through it.
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These cars are not big!
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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Range Rover P38 - Alloy Radiator

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There is nothing inherently wrong with the original radiator, but there have been a number of cases of the plastic top tank splitting which also happened to me. As my radiator had just been fitted when I bought the car four years previously I suspect that the quality of some aftermarket radiators may be questionable.\n
The standard radiators are not that expensive in the grand scheme of things but that doesn't help when yours does split and leaves you stranded somewhere (likely in heavy traffic when it will be under most strain). Therefore I bit the bullet and spent twice as much on an all alloy replacement.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Preparation and Installation

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The radiator I have used is made by Direnza and is almost a direct replacement; there is just a little easy preparation work to do first.

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If you look closely at the moulded in 'pipe' along the top of the upper tank you can make out a split along it.
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The good news is that all of the holes, brackets and connections on the replacement alloy radiator appear to be in the correct place.
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The plastic fan shroud is designed to mate against the curve plastic top tank.
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The new alloy top tank it square section so the tangs on the shroud will need cutting off. This is simply a case of scoring along them with a sharp blade and the snapping them off.
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The shroud also needs cutting away to give some clearance around the hose connections.
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That is all the trimming of the shroud that is required.
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When slotting the radiator into position you will notice that the upper mounts are made to a much tighter tolerance than the moulded plastic originals. If your mounting frame has got a bit twisted over time you will want to straighten it first.
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The lower bolt holes did not quite line up on mine meaning I had to elongate the holes in the mounting frames slightly.
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Disappointingly the new radiator didn't come with bolts. The old radiator used different size bolts so I had to search the shed for some suitable replacements. 
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All fitted. You will notice that I actually trimmed slightly too much from the top edge of my fan shroud.\n
Warning!!!\n
As a result of this radiators greater efficiency that nice shiny surface becomes scolding hot! So if you open the bonnet after a journey do not casually lean on the slam panel as you will get burnt!
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Job done!
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So, does it make a difference? Is it worth the not inconsiderable extra cost (up to twice as much as the standard aftermarket replacements)?
Well, the viscous fan is kicking in more often as it absorbs the extra heat that this radiator it transferring from the coolant so that's a good indication that it is more effective. A year after fitting I have no complaints.

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www.RangeRovers.pub

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", "_anchor": "image3-yu", "_isUserblock": true, "_cid": "sT775QFOZC", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, ".row-links": { "width": "100%", "justify-content": "center" }, ".social-row": { "width": "100%", "justify-content": "center" }, ".media-container-row": { "flex-direction": "column", "justify-content": "center", "align-items": "center", ".foot-menu": { "list-style": "none", "display": "flex", "justify-content": "center", "flex-wrap": "wrap", "padding": "0", "margin-bottom": "0", "li": { "padding": "0 1rem 1rem 1rem", "p": { "margin": "0" } } }, ".social-list": { "padding-left": "0", "margin-bottom": "0", "list-style": "none", "display": "flex", "flex-wrap": "wrap", "justify-content": "flex-end", ".mbr-iconfont-social": { "font-size": "1.5rem", "color": "#ffffff" }, ".soc-item": { "margin": "0 .5rem" }, "a": { "margin": "0", "opacity": ".5", "transition": ".2s linear", "&:hover": { "opacity": "1" } }, "@media (max-width: 767px)": { "-webkit-justify-content": "center", "justify-content": "center" } }, ".row-copirayt": { "word-break": "break-word", "width": "100%", "p": { "width": "100%" } } } }, "_name": "footer3", "_customHTML": "
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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", "_cid": "s48P1Icc8J", "_anchor": "footer3-yt", "_sourceTheme": "mobirise5", "_protectedParams": [], "_global": true, "_once": "footers", "_params": {} } ] }, "SE5 Floor.html": { "settings": { "title": "SE5 Floor", "order": 5, "meta_descr": "Reliant Scimitar SE5 Repair & Modify Floor" }, "components": [ { "alias": false, "_styles": { "& when not (@sticky)": { ".navbar-dropdown": { "position": "relative !important" }, "& when (@transparent)": { ".navbar-dropdown": { "position": "absolute !important" } } }, "& when (@sticky)": { "z-index": "1000", "width": "100%", "& when not (@transparent)": { "position": "relative", "min-height": "60px" }, "nav.navbar": { "position": "fixed" } }, ".dropdown-item:before": { "font-family": "Moririse2 !important", "content": "\"\\e966\"", "display": "inline-block", "width": "0", "position": "absolute", "left": "1rem", "top": "0.5rem", "margin-right": "0.5rem", "line-height": "1", "font-size": "inherit", "vertical-align": "middle", "text-align": "center", "overflow": "hidden", "transform": "scale(0, 1)", "transition": "all 0.25s ease-in-out" }, ".dropdown-menu": { "padding": "0", "border-radius": "4px", "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)" }, ".dropdown-item": { "border-bottom": "1px solid #e6e6e6", "&:hover, &:focus": { "background": "@primaryColor !important", "color": "white !important" }, "&:first-child": { "border-top-left-radius": "4px", "border-top-right-radius": "4px" }, "&:last-child": { "border-bottom": "none", "border-bottom-left-radius": "4px", "border-bottom-right-radius": "4px" } }, ".nav-dropdown .link": { "padding": "0 0.3em !important", "margin": "0.667em 1em !important" }, ".nav-dropdown .link.dropdown-toggle::after": { "margin-left": "0.5rem", "margin-top": "0.2rem" }, ".nav-link": { "position": "relative" }, ".container": { "display": "flex", "margin": "auto" }, ".iconfont-wrapper": { "color": "@iconsColor !important", "font-size": "1.5rem", "padding-right": "0.5rem" }, ".navbar-caption": {}, ".navbar-nav": {}, ".dropdown-menu, .navbar.opened": { "background": "@menuBgColor !important" }, ".nav-item:focus, .nav-link:focus": { "outline": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "width": "auto", "transition": "all 0.25s ease-in-out", "&::after": { "right": "0.5rem" }, ".mbr-iconfont": { "margin-right": "0.5rem", "vertical-align": "sub", "&:before": { "display": "inline-block", "transform": "scale(1, 1)", "transition": "all 0.25s ease-in-out" } } }, ".collapsed": { ".dropdown-menu .dropdown-item:before": { "display": "none" }, ".dropdown .dropdown-menu .dropdown-item": { "padding": "0.235em 1.5em 0.235em 1.5em !important", "transition": "none", "margin": "0 !important" } }, ".navbar": { "min-height": "70px", "transition": "all 0.3s", "border-bottom": "1px solid transparent", "&:not(.navbar-short)": {}, "& when not (@transparent)": { "box-shadow": "0 1px 3px 0 rgba(0, 0, 0, 0.1)", "background": "@menuBgColor" }, "& when (@transparent)": { "background": "rgba(red(@menuBgColor), green(@menuBgColor), blue(@menuBgColor), @opacity)" }, "&.opened": { "transition": "all 0.3s" }, ".dropdown-item": { "padding": "0.5rem 1.8rem" }, ".navbar-logo img": { "width": "auto" }, ".navbar-collapse": { "justify-content": "flex-end", "z-index": "1" }, "&.collapsed": { "justify-content": "center", ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" }, "@media (min-width: 992px)": { "&:not(.navbar-short) .navbar-collapse when (@showLogo)": { "max-height": "~\"calc(98.5vh - @{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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", "_cid": "tgYg1udAxa", "_anchor": "menu1-zq", "_protectedParams": [], "_global": true, "_once": "menu", "_params": {} }, { "alias": false, "_styles": { "& when not (@fullScreen)": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)" }, "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" } }, "_name": "content4", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Reliant Scimitar SE5 - Floor

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\n LEARN MORE\n LIVE DEMO\n
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\n Title

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The SE5 is a small car and I struggle to fit my 6'1\" (was 6'2\" but I'm getting on a bit now) frame in it. Admittedly the original seats were long gone when I bought it but I had to either recline the seat too far back or tilt my head. Not ideal!

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", "_isUserblock": true, "_cid": "tgYg1xfHy8", "_anchor": "content4-zt", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Lowering the Floor

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The seat is mounted directly onto a raised section of floor, it is not actually attached to the chassis. So the plan is to cut out this raised section of floor, add a couple of outriggers from the main chassis rails to the outer sill rails for the seat to bolt to, and cover the hole with a new flat floor.

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After balancing the chosen replacement seat on the center outrigger I decided I needed to go lower.
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So with the aid of a cutting disc in the air grinder...
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...I trimmed an inch off the top.
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This revealed the internal structure.
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Next job is to make a new temporary false floor sturdy enough to place the seat on and take my weight.
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With the aid of cardboard, a plywood floor was made and supported from underneath with a bottle jack either end. The two lines indicate the position of the center outrigger.
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The seat it placed in position with the adjustable seat rails set to mid position. I then sat in the car and moved the seat back and forth on the plywood floor until I was happy with its position in relation to the pedals and steering wheel.
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Using the center outrigger as a datum, I now know where I need to fit the new seat mounting outriggers.
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Seat Mounting Outriggers

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\n Once the above had been carried out and the positions of the new seat mounting outriggers established the body was removed from the chassis to allow the chassis repairs to be carried out. The installation of the new seat mounting outriggers was incorporated into these repairs and are covered in the relevant part of the Chassis section of this site in this link.

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To be continued...

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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Reliant Scimitar SE5 - Lifting the Body

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@{logoSize}rem)\"" } } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "41%" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem", "text-align": "center" }, ".icons-menu": { "padding-left": "0", "padding-right": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "@media (max-width: 991px)": { ".nav-item .nav-link::before": { "display": "none" }, "&.opened": { ".dropdown-menu": { "top": "0" } }, ".dropdown-menu": { ".dropdown-submenu": { "left": "0 !important" }, ".dropdown-item:after": { "right": "auto" }, ".dropdown-toggle[data-toggle=\"dropdown-submenu\"]:after": { "margin-left": "0.5rem", "margin-top": "0.2rem", "border-top": "0.35em solid", "border-right": "0.35em solid transparent", "border-left": "0.35em solid transparent", "border-bottom": "0", "top": "40%" } }, ".navbar-logo": { "img": { "height": "3rem !important" } }, "ul.navbar-nav": { "li": { "margin": "auto" } }, ".dropdown-menu .dropdown-item": { "padding": "0.25rem 1.5rem !important", "text-align": "center" }, ".navbar-brand": { "flex-shrink": "initial", "flex-basis": "auto", "word-break": "break-word", "padding-right": "2rem" }, ".navbar-toggler": { "flex-basis": "auto" }, ".icons-menu": { "padding-left": "0", "padding-top": "0.5rem", "padding-bottom": "0.5rem" } }, "&.navbar-short": { "min-height": "60px", ".navbar-logo": { "img": { "height": "2.5rem !important" } }, ".navbar-brand": { "min-height": "60px", "padding": "0" } } }, ".navbar-brand": { "min-height": "70px", "flex-shrink": "0", "align-items": "center", "margin-right": "0", "padding": "10px 0", "transition": "all 0.3s", "word-break": "break-word", "z-index": "1", ".navbar-caption": { "line-height": "inherit !important" }, ".navbar-logo a": { "outline": "none" } }, ".dropdown-item.active, .dropdown-item:active": { "background-color": "transparent" }, ".navbar-expand-lg .navbar-nav .nav-link": { "padding": "0" }, ".nav-dropdown .link.dropdown-toggle": { "margin-right": "1.667em", "&[aria-expanded=\"true\"]": { "margin-right": "0", "padding": "0.667em 1.667em" } }, ".navbar.navbar-expand-lg .dropdown": { ".dropdown-menu": { "background": "@menuBgColor", ".dropdown-submenu": { "margin": "0", "left": "100%" } } }, ".navbar .dropdown.open > .dropdown-menu": { "display": "block" }, "ul.navbar-nav": { "flex-wrap": "wrap" }, ".navbar-buttons": { "text-align": "center", "min-width": "170px" }, "button.navbar-toggler": { "outline": "none", "width": "31px", "height": "20px", "cursor": "pointer", "transition": "all 0.2s", "position": "relative", "align-self": "center", ".hamburger span": { "position": "absolute", "right": "0", "width": "30px", "height": "2px", "border-right": "5px", "background-color": "@hamburgerColor", "&:nth-child(1)": { "top": "0", "transition": "all 0.2s" }, "&:nth-child(2)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(3)": { "top": "8px", "transition": "all 0.15s" }, "&:nth-child(4)": { "top": "16px", "transition": "all 0.2s" } } }, "nav.opened .hamburger span": { "&:nth-child(1)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" }, "&:nth-child(2)": { "transform": "rotate(45deg)", "transition": "all 0.25s" }, "&:nth-child(3)": { "transform": "rotate(-45deg)", "transition": "all 0.25s" }, "&:nth-child(4)": { "top": "8px", "width": "0", "opacity": "0", "right": "50%", "transition": "all 0.2s" } }, ".navbar-dropdown": { "padding": "0 1rem", "& when (@sticky)": { "position": "fixed" } }, "a.nav-link": { "display": "flex", "align-items": "center", "justify-content": "center" }, ".icons-menu": { "flex-wrap": "nowrap", "display": "flex", "justify-content": "center", "padding-left": "1rem", "padding-right": "1rem", "padding-top": "0.3rem", "text-align": "center" }, "@media screen and (~'-ms-high-contrast: active'), (~'-ms-high-contrast: none')": { ".navbar": { "height": "70px", "&.opened": { "height": "auto" } }, ".nav-item .nav-link:hover::before": { "width": "175%", "max-width": "calc(100% ~\"+\" 2rem)", "left": "-1rem" } } }, "_name": "menu1", "_sourceTheme": "mobirise5", "_customHTML": "
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\n Preparations

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You are going to be a bit disappointed with this bit as I stripped the body over a protracted period of time and am bound to miss something but as a rough guide here is what you definitely need to do:\n
Make the shell as light as possible by removing doors, bonnet, tailgate, all glass, seats, bumpers, heater.\n
Remove front body support structure and steering column.\n
Disconnect brake and clutch master cylinder pipes (I removed the cylinders).
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Disconnect the oil pressure gauge capillary pipe from the engine.
Disconnect handbrake cable including the retaining brackets within the transmission tunnel.\n
Remove fuel filler neck.\n
Disconnect electrics where they pass to the chassis (I removed the entire loom).\n
Remove all body to chassis bolts including seat belt anchorages and the body hoop fishplates at the base of the 'B' pillars.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Rear Valance

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On the SE5 and SE5A the rear valance tucks in under the rear chassis cross-member preventing a straight upwards lift. You have to raise the front of the car to a considerable angle to enable you to roll the chassis forward from under the suspended body with enough clearance for the chassis to pass under the rear seat foot wells.
I didn't fancy this much with the equipment and additional human resource (called Matt) that I had to hand. So instead I overcame this obstacle by removing the area of rear valance preventing a straight upwards lift.

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The squared 'bumper mount' protrusion houses the rear cross-member.
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A not very clear picture of the inside of the rear valance.
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The rear cross-member doesn't quite reach the ends of the channel.
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Using a DIY multi-tool I cut across the middle of the channel and the down to outboard of the exhaust cut-outs.
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The cuts are equidistant to the outer edges of the exhaust cut-outs. Sadly those exhaust cut-outs aren't quite so equidistant from the cars centre line.
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Removed revealing the full width of the rear cross-member.
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The intention is to refit this once the car is back together. I am as yet undecided if I am going to bond it back in or make it removable.
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The Lift

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A metal pole was initially fed through the front wheel arches in front of the chassis suspension towers to initially raise the body enough to pass a wooden fence post through.

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This initial movement revealed the forward outriggers and front end of the outer rails.
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Off-side front out-rigger with typical corrosion.
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Nearside outer rail was in a poor state and had been previously repairs with angle iron and mastic.
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Near-side forward out-rigger also corroded.
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Title

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The rear was lifted with the use of the engine crane and a suitable length of wood.

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I'm pretty sure you can figure out what's going on here.
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The wood has a tendency to move, hence the lashing tape.
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Using a collection of trestles the body was lifted in stages until high enough to clear the rolling chassis.
The rear was first raised enough to pass another fence post through the rear arches, resting on the rear wheels. The crane was then repositioned to the front to raise the front end, followed by returning to the back to raise that to match.

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Don't forget to keep the trestles clear of the wheels.
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Completion

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With the chassis out of the way the body was repositioned onto the trestles.
There then folowed a number of rather messy days with a bucket of neat car shampoo, a stiff floor scrubbing brush and a pressure washer. The drive looked lovely by the time I had finished!

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Rear footwells. The channel houses the rear suspension mounting tubes on the chassis.
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Looking back from under the front valance.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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\n Reliant Scimitar SE5 - Chassis

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\n The chassis is a pretty rugged affair and the main rails don't seem to generally suffer major corrosion issues (probably due to the extra protection offered by that leaky old Essex up front). But there are a number of areas that this protective oil mist doesn't quite reach and so do suffer from corrosion.

For details on removing the body refer to the bodyshell section.

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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Initial Assessment

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This particular chassis is in pretty good condition but it does exhibit a number of the usual symptoms commonly found.

Starting at the rear off-side (so that the photos flow in the correct order), here are some of the more common rust spots.

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Fuel tank rail requires a small in-fill repair.
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Outrigger is holed but not horrifically.
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Common rust point at the rear of the suspension tube diagonal brace. The brace is an open face C section so creates a dirt trap. Replacement parts are available and the main chassis rail appears sound.
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General view of the diagonal brace and another common rust spot, the seat belt mount.
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A closer view showing the rusted seat belt mount. You can see that the top of the outer side rail has rusted through revealing the additional bracing in this area. The rusted remains of the body hoop fish plate is also visible.
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Top of the front outrigger rusted through and further rust damage to the outer rail.
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Title

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Near-side, starting at the forward out-rigger (or what's left of it).

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Passenger side front outrigger is even worse.
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The join between it and the outer side rail has all but disintegrated.
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Passenger side seat belt mount was not as bad though.
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The body hoop fishplate is sound on the passenger side so no rusted remains stuck to the end of the suspension tube.
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The diagonal bracing has rusted though.
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Datums!

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Before chopping any metal out we need to preserve the datum positions of the main sections to be replaced. If the new outer rails are not located in the correct position the body will not fit back over them as they sit in a channel created by the recessed footwells and the outer sills.

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A piece of box section steel (the small bit resting on the chassis, not the big bit lying alongside) salvaged from an old desk (or a bed would do, so long as it is straight) is laid across the chassis adjacent to the front outriggers.
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Two pegs are welded to it at the correct distance...
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... to align with the corners of the outrigger to side rail joints.
This is then tack welded to the main chassis rails.
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The outer rail and front outrigger can then be cut from the chassis.
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Both sides removed. Note another salvaged box section has been tack welded towards the rear. This is so that the new side rails can be positioned in line with the main rails.
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Replacement Outer Rails

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Replacement outer rails are available from the two major parts suppliers. However, as I am lowering the floor in my car and fitting additional outriggers for the seat rails to bolt to, I am making my own from deeper 60mm x 40mm full box-section (the originals are 'C' section).

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The new outer rail box section is held up against the datum bars.
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It is butted up against the suspension tube...
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... and the centre of the tube is marked.
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A pilot hole is drilled at this height, but about 4\" along its length, all the way through both sides of the box section to ensure alignment. This is to give an overhang to the rear of the tube for a potential roll cage main hoop mounting.
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A 63mm hole saw to match the diameter of the suspension mounting tube is used on each side of the box section at the pilot hole location.
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The two cuts are joined curtesy of a cutting disc in the angry grinder.
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Slotted into place. Note the overhang both front and rear.
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A nice snug fit.
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", "_anchor": "gallery5-11i", "_isUserblock": true, "_cid": "tl28YWftt7", "_protectedParams": [], "_global": false, "_once": false, "_params": {} }, { "alias": false, "_styles": { "padding-top": "(@paddingTop * 1rem)", "padding-bottom": "(@paddingBottom * 1rem)", "& when (@bg-type = 'color')": { "background-color": "@bg-value" }, "& when (@bg-type = 'image')": { "background-image": "url(@bg-value)" }, "& when not (@spacing)": { ".row": { "margin-left": "0", "margin-right": "0" }, ".item": { "padding-left": "0", "padding-right": "0" } }, "& when (@spacing)": { ".item": { "padding-bottom": "2rem" } }, ".item-wrapper": { "& when (@autoSize)": { "& when not (@showItemSubtitle)": { "height": "100%" }, "& when (@showItemSubtitle)": { "height": "(@imageHeight * 100px)" }, "img": { "height": "100%", "object-fit": "cover" } }, "position": "relative", ".icon-wrapper": { "pointer-events": "none", "position": "absolute", "width": "60px", "height": "60px", "font-size": "22px", "left": "50%", "top": "50%", "display": "flex", "align-items": "center", "justify-content": "center", "border": "2px solid #ffffff", "border-radius": "50%", "opacity": "0", "color": "#ffffff", "transform": "translateX(-50%) translateY(-50%)", "background-color": "#1b1b1b", "transition": "0.2s" }, "&:hover": { ".icon-wrapper": { "opacity": "0.7" } } }, ".carousel-control, .close": { "background": "#1b1b1b" }, ".carousel-control-prev": { "margin-left": "2.5rem", "span": { "margin-right": "5px" } }, ".carousel-control-next": { "margin-right": "2.5rem", "span": { "margin-left": "5px" } }, ".close": { "position": "fixed", "opacity": "0.5", "font-size": "22px", "font-weight": "300", "width": "60px", "height": "60px", "border-radius": "50%", "color": "#fff", "top": "2.5rem", "right": "2.5rem", "border": "2px solid #fff", "text-shadow": "none", "z-index": "5", "transition": "opacity 0.3s ease", "font-family": "'Moririse2'", "align-items": "center", "justify-content": "center", "display": "flex", "&::before": { "content": "'\\e91a'" }, "&:hover": { "opacity": "1", "background": "#000", "color": "#fff" } }, ".carousel-control": { "display": "flex", "top": "50%", "width": "60px", "height": "60px", "margin-top": "-1.5rem", "font-size": "22px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "transition": "all 0.3s", "&.carousel-control-prev": { "left": "0", "margin-left": "2.5rem" }, "&.carousel-control-next": { "right": "0", "margin-right": "2.5rem" }, "@media (max-width: 767px)": { "top": "auto", "bottom": "1rem" } }, ".carousel-indicators": { "position": "absolute", "bottom": "0", "margin-bottom": "3px", "li": { "max-width": "15px", "height": "15px", "width": "15px", "max-height": "15px", "margin": "3px", "background-color": "rgba(0, 0, 0, 0.5)", "border": "2px solid #fff", "border-radius": "50%", "opacity": "0.5", "transition": "all 0.3s", "&.active, &:hover": { "opacity": "0.9" }, "&::after, &::before": { "content": "none" } }, "&.ie-fix": { "left": "50%", "display": "block", "width": "60%", "margin-left": "-30%", "text-align": "center" }, "@media (max-width: 768px)": { "display": "none !important" }, "@media (max-width: 991px)": { "margin-bottom": "3.625rem !important", "padding-left": "2.5rem", "padding-right": "2.5rem" }, "@media (max-width: 767px)": { "display": "none" } }, ".carousel-inner": { "display": "flex", "align-items": "center" }, ".carousel-inner > .active": { "display": "block" }, ".carousel-control.left": { "left": "0", "margin-left": "2.5rem" }, ".carousel-control.right": { "right": "0", "margin-right": "2.5rem" }, ".carousel-control:hover": { "background": "#1b1b1b", "color": "#fff", "opacity": "1" }, "@media (max-width: 768px)": { ".carousel-control, .carousel-indicators, .modal .close": { "position": "fixed" } }, "@media (max-width: 767px)": { ".mbr-slider .carousel-control": { "top": "auto", "bottom": "20px" }, ".mbr-slider > .container .carousel-control": { "margin-bottom": "0" } }, ".carousel-indicators .active, .carousel-indicators li": { "width": "7px", "height": "7px", "margin": "3px", "background": "#000000", "opacity": "0.5", "border": "4px solid #000000" }, ".carousel-indicators .active": { "background": "#fff" }, ".carousel-indicators li": { "max-width": "15px", "max-height": "15px", "border-radius": "50%" }, ".modal": { "padding-left": "0 !important", "position": "fixed", "overflow": "hidden", "padding-right": "0 !important" }, ".modal-dialog": { "margin": "0 auto", "max-width": "100%", "padding-left": "1rem", "padding-right": "1rem" }, ".modal-content": { "border-radius": "0", "border": "none", "background": "transparent" }, ".modal-body": { "padding": "0", "display": "flex", "align-items": "center", "img": { "width": "100%", "object-fit": "contain", "max-height": "~\"calc(100vh - 1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Replacement Front Outriggers

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As with the outer rails, replacement outriggers are available from the two major parts suppliers. However, as I have made my own outer rails from deeper box section, I need to fabricate my own front outriggers to suite.

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After taking a few key measurements a suitable piece of 1.5mm thick steel was cut.
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Again taking suitable measurements the basic shape is folded.
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The folder  was bought second hand from a popular online auction site for circa £50.
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Checking the fit over the outrigger support stub.
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The new outer rail is put in place and with the outrigger placed against the main chassis rail...
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... a line is drawn where the outer rail will meet the outrigger.
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The depth of the outer rail is also marked against the outrigger.
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the resultant notch it cut.
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Trial fit. You will notice that the new part is as deep as the main chassis rail. This was a mistake, it should be deeper by enough to allow for a lower flange to be folded.
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The outer rail is not against the datum peg. The outrigger requires further trimming to get the outer rail in the correct position.
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Further trimming and trial fitting was carried out until a good fit was achieved.
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The lower edges of the outrigger are trimmed off. In this shot I have trimmed too much off. I should have left more material to form a lower flange to give greater rigidity.
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The lower flange needs to be folded before the notch for the outer rail is cut out. Otherwise it will twist in this area as it is folded.
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Then the notch is cut out.
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The inner end needs the flange relieving to clear the inner support stub.
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In position fitting snuggly around the inner support stub.
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Check for fit.
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The location of the inner support stub is marked on the inside of the outrigger each side in felt pen.
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This is transferred to the outer face each side.
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A cardboard template is made of the each side of the support stub.
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These are transferred to the outer faces of the outrigger using the first line as a guide to positioning.
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The rest of the shape is transferred.
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1.75rem)\"" } }, ".carousel": { "width": "100%" }, ".modal-backdrop.in": { "opacity": "0.8" }, ".modal.fade .modal-dialog": { "transition": "margin-top 0.3s ease-out" }, ".modal.fade .modal-dialog, .modal.in .modal-dialog": { "transform": "none" }, ".mbr-gallery .item-wrapper": { "cursor": "pointer" }, "H6": { "text-align": "center" } }, "_name": "gallery5", "_sourceTheme": "mobirise5", "_customHTML": "
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Replacement Center Outriggers

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Due to the floor lowering the center outriggers need to be much shallower than the originals so again I am making my own.
The top of the steel box section I am using for the new seat rail mounting outriggers is 20mm tall.
The new outer rails are 60mm tall.
Therefore the centre outrigger needs to be lowered by 40mm so that it is in line with the new seat rail mounting outriggers.

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The inner support stub will require a fair bit of trimming to allow the the new outrigger to sit in its new lower position. First a straight edge is set across the main and outer chassis rails.
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The inner support stub is marked 50mm below this level. This allows clearance for both the thickness of the new outrigger and the bend radius of the sides. 
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Trimmed back with the trusty angry-grinder.
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The new center outrigger blank is folded.
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Check fit over the inner support stub.
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A nice sliding fit over the inner support stub.
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The main chassis rail needs to be clean so that it butts up against it.
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The total required length is measured (to the outer edge of the outer rail).
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Approx 530mm.
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The side are trimmed allowing an overhang for the lower flange to be folded, remembering to allow extra depth at the outer rail end so that it passes under the outer rail.
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Checking for fit before folding the lower flanges.
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Lower flanges folded.
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Rechecking the fit. The lower flanges will need light trimming at the main chassis rail end to clear the inner support stub.
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Finally the outer rail notch is marked out and cut.
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Trial assembley
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Note the inner support stub.
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\n The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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