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Discussion Starter · #1 ·
Hi all,

Just thought i'd add my pop to the garage.

Brought it as a half started project in December 2003 at the tender age of 19 and with very little knowledge of cars. It seemed a good base at the time so decided to rip it apart. Found the chassis was no good as all the crossmembers had been taken out. So started from scratch and made a new chassis out of 3x1 1/2 box. Escort rear on leafs, Herald/spitfire hybrid IFS with homemade uprights. Zetec engine with twin 40's and a home brewed dizzy drive (almost done).

As it arrived:





After a bit of graft:



And a bit more.





And More:



The stance:



Pedal linkage,



And repairs!









Firewall:



Widened flip front:







So there we are, my pop. Still alot of work left to do but we're getting there.
 

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looking very good , have you any more pictures of brake pedal linkage as thats what im sorting out at the moment, im using a mk1 fiesta servo and a xjs master cylinder mounted under the seat, with clevis pins mounted to it , also i will be making up my own pedal. nice work keep it up fella.
 

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The Pop

it looks great gtv,.. are u building it in the garden.. as that a task on its own .top effort m8:tup:
 

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Discussion Starter · #4 ·
looking very good , have you any more pictures of brake pedal linkage as thats what im sorting out at the moment, im using a mk1 fiesta servo and a xjs master cylinder mounted under the seat, with clevis pins mounted to it , also i will be making up my own pedal. nice work keep it up fella.
Ask and you wil recieve!

So I've use morris minor pedals with a triumph 2000 master cylinder (apparently similar to a Jag one?) with a homemade linkage.

The majority of the pedal linkage:



and the under seat servo.



it looks great gtv,.. are u building it in the garden.. as that a task on its own .top effort m8:tup:
Yeh building it in the great outdoors, which proves challenging at times! Oh well, slog on.
 

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looking good, i am especially interested in your build because its similar to what i'm doing, zetec, type 9 and a triumph front. how wide is your front track? looks like you done a great job on the front wings.
 

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great to see someone so young into hot rods and having ago at doing them selves so dont take this the wrong way but the geometry on the front suspension needs sorting before you get in too deep or you will suffer horrendous bump steer basically the rack needs to be dropped so that the arms are parallel to the wishbones
 

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Discussion Starter · #9 ·
Thanks for all the messages guys, much appreciated. The steering rack is paralell to the bottom wishbones, i think. Yeah it is. I think your looking at the picture of just the bear chassis. have a lookat the picture below with the engine weight as well.
 

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Discussion Starter · #10 ·
Right then, time for an update. Been beavering away.





Fitted bear claws to the drivers side (thanks to Blackpop for the guidence).





Shot of the inside.



As you can see, more work to be done.



To the engine. Right then, I'velost the six point pulley system and reverted to a simply three point by changing the water pump to a 1.8 version. This allows the pulley to work as i have it as it runs the other way round to the 2.0 waterpump. I've modified the alternator bracket to alow for the shorter pulley.

I've also made up the dizzy drive. Was going to copy Craig's but then came up with this solution. Basically a cog on the end of the camshaft which mates to the cog on the dizzy with a simple plate fixed both sides of the engine. Hopefully this'll work but it's still a bit trail and error. Also note how small the dizzy is. It's out of a mark 3 RS2000 escort (CVH) type.







That's all for now, will plod on.
 

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great build, how come you're not using the D.I.S.? Are you using throttle bodies, if so what type?
 

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Discussion Starter · #12 ·
I was looking at throttle bodies and found out that GXR-600 bike bodies are commonly used but decided against them and am now going to run twin 40's. Should give reasonale power and economy but still sound right (ok for a 4-pot!) Not sure what you mean by D.I.S though so hope that answers your question.

Also in awnswer to a previous question you had, it's standard Triumph Herald width. Now sits just inside the front arches. Also, I've been worried ever since I put the front suspension in that the wheels wouldn't sit in the arches properly but because of the way I widened the wings it's brought the wheels almost where i wanted them.
 

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D.I.S = distributorless ignition system or wasted spark coil pack thingys.
 

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Discussion Starter · #14 ·
Right, get ya. i've lost the coil pack and will have a ignition coil mounted on the bulkhead. There's no need for the coil pack now as the dizzy does that job.
 

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Discussion Starter · #15 ·
Ok, here's a quick update. These are the latest pics I have taken in July so more work done since these. I have been working to try and get the body tidied up and all those small jobs done. These include the flip front which still needs quite a bit of work. I want the car to look, from the point of someone unknowing, stock (ish). Ok the flip front is comply against this, but when it's fixed in place it isn't really noticable.

So to progress of sorts.

Iver added the side and front grills as stock and have the front and side trims to fit after paint.





I've also glassed in some fibreglass inner wings for two reasons. Firstly to stop all the crap that will innevitable be thrown up off the road from going into the engine bay. Secondly they add strength to the flip front.





I've filled in the scallop vents a I know that they will only let water in!



Right to the bits I've redone. I still wasn't happy with the steering column as I hadn't really sorted it out just stuck in what was there when I got it. Anyway bit the bullet and ordered a stock herald column lower shaft and new rag joint. Anyway took it all apart and fitted the new bits and it fits! Finnaly something that works first time! The scary thing was that after taking the old shaft off I noticed that the old piece had been brass brased on:eek:



i also have remade the engine mounts as the first effort was very hard to tighten the bolts for the rubber bush up. Also made a plate for the old crank sensor as it's not needed now(2nd pic).





Lastly SHINY BITS! After many evenings with a dremel firstly and then varying size polishing mops I've finished polishing these damned things. The carbs where a pig and so was the inlet mainfold. Never again! Anyway the carbs clashed with the body work slightly and that's now resolved.

The exhaust I brought didn't come anywhere near fitting. I knew it would probably clash with the chassis but didn't expect it to foul on the bell housing! It is a exhaust specifically designed for a RWD zetec Mk1 & 2 escort using a type 9 so would expect it to at least work! I've made a spacer for the exhaust so it doesn't foal. Also having to rework the firewall for the exhaust but hey, still plodding on!





I'll take some more pics and get the build up to date ASAP!
 

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Which make of exhaust manifold did you purchase? as I have to get one soon and I want it to fit!
 

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Discussion Starter · #17 ·
Start rant. The manifold was from Ashley but brought it from a company called POTN and the service was terrible! They only deal via emails so damned near impossible to get a answer during busy periods. It wasn't the fact the it didn't fit, it's the fact that that they sent me a full system for a renault clio which was completely the opposite to what I actually ordered! Two months I waited for the right part, which didn't fit! Rant over.

Anyway, next time I would speak to retro ford as I think they do exhausts, or get one specially made.
 

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Discussion Starter · #20 ·
Hi all,

I ventured out in the rain yesterday to take some updated pics so here we go.

Right then. I've still been plodding on with the pop. I've spent some time working on the seatbelts. I'm using 3 point inertia belts as a safe option but have struggled with the mounting of them as I was trying to find a strong enough mounting point. This was my first attempt:



I wasn't happy with this though. It didn't work properly as there wasn't enough room between the roll and the pivot point and was binding. So I had another thought and then spent lots of time making the revised set up which I'm much happier with. So I've formed a plate to run over the inner arch with a mounting point on that for the roll. This plate is then welded to the between the rear window and the inner wing. This to is reinforced. All of this comes down to the boot floor where I have a chassis mounting point which I have also welded to the floor. I also have a plate welded at the other end to take the lap mounting point.





So after cutting a lump out of the bulkhead i needed to fill it again. This was a bitch of a job as it's in an awkward area and I was trying to get a curved shape to it. So this is what I'm came up with.



I have finished it now but I've too much stuff in the way to take a decent picture.

I've mounted the wiper motor. just got to fit the tube now, somehow!



I've also finished both sills. These were such a pain. I've carried the swage line from the doors into the sills. The drivers side was pretty easy as it fitted well in the first place. The passanger side I had to cut into about 12 peaces to get it to fit. Oh well....







I have also cut a great lump out the door and replaced it. I had a line of rust all the way along the door where the brace is on the inside. I tried to repair is before and the door just when ping. So had to go to more drastic measures!



I've also had some fun doing some more to the flip front. Just trying to get everything the same on both sides! I've also reworked to rear wheel arch as I wasn't happy with the wheel fit.

And finally this is how thr car looked as of 1:30 today!





 
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