fiestaturbo.com

[FezzR]

andy you remember the conversation about the cambelt cover?

id try and keep the HT leads up as high as you can too, especially no 1 which looks to be sagging and nearly resting on the manifold, you be supprise how much a small distance makes too.
running 1 over the top of 2 and 2 of 3 should help and secure them together

where did you get the heat sleeves from in end?

[andyhardy]

andy you remember the conversation about the cambelt cover?

id try and keep the HT leads up as high as you can too, especially no 1 which looks to be sagging and nearly resting on the manifold, you be supprise how much a small distance makes too.
running 1 over the top of 2 and 2 of 3 should help and secure them together

where did you get the heat sleeves from in end?

I just knew you were going to bring the cambelt cover up!

I'm about to start work on strengthening braces for the cam/phase sensor that is used with the Cossie management setups. Unfortunately the bracket that it is sat in is a bit weak and so when going over bumps the sensor 'bounces' and goes off track. Having tested the waveform created by the sensor, you only have to move the sensor about 0.5mm before the sensor does not produce a waveform. This is a problem because removing the signal from the ECU causes the tickover to go crazy and causes all sorts of jiggery-pokery with the way the car runs! Soooo - because of these extra strengthening braces I'm going to have to modify the cambelt cover more than it already has been for the extra strengthening braces. There is also the small matter of having to drive to Grove Garage to get the cambelt cover back as well!

Yep - will re-route number 1 like you said as I wasn't very happy with the way it was drooping so low either, I'll get onto that tomorrow at some point

As for the heat sleeves - I got them from a company called rally-nuts.com based in Cornwall I believe, link here:

rallynuts.com - cool it thermotec wire sleeves

I'm really looking forward to Wednesday now - all I need is a new loom relay socket to replace the dodgy one I have on my ECU loom and solder up some connections and gap and install new spark plugs to finally say the car is complete

Once I've made sure it's all running OK I'm going to contact Stu at MSD about getting my coil pack driver installed as Andy B has kindly donated me a Fiesta CVH coil pack with bracket - no more distributor cap woes! (although I will have bought my new thick HT leads for nothing! )

Cheers,

Andy

[andyhardy]

Here's a short vid clip of the car in action for those that haven't seen the other vids (which have now been taken down).

You'll need to have DivX codecs installed on your computer to be able to see the video.

FRST overtake video

Cheers,

Andy

[Stoned]

Nice one Andy, that video is what it's all about

I love the chatter

[FezzR]

after all this you gonna ditch the distributor, if i was you (well i wouldnt have had the distributor in the first place) but just leave it for now. enjoy it
then when shows are over youll have a nice list of stuff you wanna do, but at least youve had time to have fun with it.

i know what you mean about the cam sensor, thats why they mount abs sensors in the wheel hub so that there not bouncing about on a bracket

[MarkRS2K]

cheers,


cool vid

[olivier]

Cheers guys!

I thought the same thing about the tyres when I saw them on it but was corrected by the guy doing me the Goodyear Eagle F1s - he looked at the compound on them and he went 'oooh - very nice! racing compounds'.

The guy wants the tyres back to get the compounds right on his new set (the motorsport shell 3 door track day car he uses! ).

We're firing up the engine tomorrow evening! Hope it all goes OK - will have to take a vid clip of it.

Cheers,

Andy

What's the size of tyres please ?

[royalwithcheez]

Whilst the car sits in the garage I have it plugged into this little baby

My dads got one of them on his honda firestorm, he keeps forgetting its on there and nearly goes off with it still attatched

[Max M4X WW]

What is it?

[royalwithcheez]

Its an optimate, basically a battery conditioner/charger so it doesnt run down when you dont use it alot. Useful if youve got stuff for fun which doesnt leave the garage alot/has the alarm on alot/whatever else.

[Max M4X WW]

Ah cool Thought it would be something like that.

[royalwithcheez]

Yeah yeah Nah theyre pretty cool, i thought they were pretty much just a motorbike thing, but a battery's a battery i guess.

And you cars looking proper tidy Max, never got the chance to say that yet

[Max M4X WW]

Thanks, But the arches are falling off.

[royalwithcheez]

Oh dear, that doesn't sound too good Sillicone the baxtered on!

[Xr_Dub]

cheers,


cool vid

i swear i heard that in the vid, "cheers"

yeh cool vid andy

[andyhardy]

Yeah - that was my mate saying 'cheers' in that video as I overtook that line of cars

I took the car over to my Dad's today - it's still safe to drive with the AMAL valve disconnected I just have to go easy on the throttle and keep an eye on the boost gauge when driving

We gapped the spark plugs up and stuck them in, re-routed the HT leads and then soldered up all the connections that I'd temporarily re-connected when re-installing the engine loom. We also started machining some M10 threaded studs up for sorting out the alternator bracket which is now held in with 3 of the 4 studs it should be held onto the alternator spacer bracket with.

The only things left to finish the engine off now are the following:

- New relay socket for the ECU power relay (it works fine at the moment but we noticed the connectors were a bit dodgy when I checked the whole loom out)
- Alternator spacer bracket needs machining to countersink the head of a bolt through so that I can use a nyloc nut to hold the last of the 4 studs in place
- Cam/Phase sensor supporting braces to be machined up to stop the revs from chavifying the car in traffic

That's it! Everything else is purely cosmetic/ACT or carputer related

I've ordered a new AMAL valve to replace my exploded one as well - £55! Once that's on I can start using my car properly again

Cheers,

Andy

[FezzR]

seeing as you mentioned the ecu power relay, i pressume youve extrernally mounted your fan control relay too?

[heeman10]

55 quid?! That's so gay...should've gone used Andy, though I know exactly why you bought new, just one of those things, but they add up to ridiculous amounts

[andyhardy]

seeing as you mentioned the ecu power relay, i pressume youve extrernally mounted your fan control relay too?

Nope - not yet - I will do soon though!

Cheers,

Andy

[andyhardy]

55 quid?! That's so gay...should've gone used Andy, though I know exactly why you bought new, just one of those things, but they add up to ridiculous amounts

Yeah - but I have no car at the moment so I'm having to use the Turbo to get places. AMAL valve change is easier than 1.6 CVH engine change so I decided to bite the bullet and put a new one on - should get it tomorrow.

Cheers,

Andy

[olivier]

Cheers guys!

I thought the same thing about the tyres when I saw them on it but was corrected by the guy doing me the Goodyear Eagle F1s - he looked at the compound on them and he went 'oooh - very nice! racing compounds'.

The guy wants the tyres back to get the compounds right on his new set (the motorsport shell 3 door track day car he uses! ).

We're firing up the engine tomorrow evening! Hope it all goes OK - will have to take a vid clip of it.

Cheers,

Andy

What's the size of tyres please ?

???????? please

[andyhardy]

I can't remember mate - sorry!

I 'think' it was 215/40s but you'd probably be best to get 205/40s - the more shallow the tyre walls the better as well (Goodyear Eagle F1's would work I think).

Cheers,

Andy

[olivier]

I can't remember mate - sorry!

I 'think' it was 215/40s but you'd probably be best to get 205/40s - the more shallow the tyre walls the better as well (Goodyear Eagle F1's would work I think).

Cheers,

Andy

Thaks a lot

[olivier]

And 195, is it good or not ??

[andyhardy]

And 195, is it good or not ??

195 is possible - but you'll need to make sure that it has really good tough sidewalls to enable you to drive it safely, the wheels are 8" wide so you run the risk of rimming the tyre under hard cornering.

Cheers,

Andy

[olivier]

thank you very much

[Rhinopower]

whoa, that is quick, practically shat myself watching it!

[andyhardy]

whoa, that is quick, practically shat myself watching it!

I was taking it relatively easy too with short shifting - with the paddle clutch though it's much smoother to do flat-out gear changes though!

[heeman10]

You'll have to come out in mine Andy, it's just like a standard clutch. Lovely and light, smooth as anything Yours is the Alcon 6 paddle too isn't it?? Just ordered my Stage 1 CTS box

[andyhardy]

Yeah - mine's lovely and light and all that, but because of the mix of that and the Vibratechnics gearbox mounts the gearchanges are really designed to be done flat out or not at all, if you do it in between the car judders when you apply the clutch.

Saying that - I don't really care as I never built the car for around-town driving

You won't be disappointed with the gearbox mate

Cheers,

Andy

[andyhardy]

The AMAL valve finally arrived this morning so I got to fitting it to the car.

All works perfectly with regards to that now - about 8/10 psi on low boost and just on 20 on full

I've still got a misfire problem though which is bloody annoying - I'm going to wire in a seperate direct earth for the ignition amplifier though as I think the length of this on the loom is too long. Apparently it's a common problem with the Cossies - causing intermittent misfire when the earth breaks down on the ignition amp.



















I've also still got to get the extra supporting braces made up for the phase sensor - it's all been put on hold though whilst I try and sort the Escort engine out!

Cheers,

Andy

[heeman10]

What a lot of pics to show the fitting of the AMAL valve :lol: Misfire's annoying, I hope the added earth has the required effect. Sounds likely if Cosworth owners have the same issue Still not found an engine for the Escort?

[andyhardy]

New engine now fitted in the Escort, new tyres have been put on the front and it went through it's MOT yesterday. During the MOT I got a phonecall from my mate Simon asking if I could bring along the car to his workplace's garage workshop.

So no sooner had I got home with the Escort (with fresh MOT) I unplugged the Turbo from the battery optimiser and wheeled her out to see if she'd start. After a short bit of turning over the car fired up and I cruised* her over to Eastbourne, after a bit of popping and banging with misfire.

The reason the car is running so poorly at the moment is because after checking the ECU out with Jano Oddkidd's Pectel monitor around Bruntingthorpe circuit it was obvious that the cam/phase/anti-knock/det sensor (call it what you will) is losing the signal due to a weak bracket holding it in place. Unfortunately this kills the signal to the ECU telling it where TDC is and goes into what's called 'Limp Home Mode'. The way around this is to switch the ignition off and start it up again, but unfortunately there was more to the problem. On the way home that day it would appear that all the thrashing of the day doing quarter mile runs has caused at least one of the valves to overheat and 'stick' - causing the car to have a semi-misfiring cylinder. The reason for this diagnosis? Well - it's quite obvious that with the poor signal the cam sensor was sending that the valves could be running hot as the ECU is unable to adjust ignition to prevent detonation. All the ignition side of things has been checked and good sparks are being received that side - so hopefully it's just something in the head!

To rectify this problem under good advice from Jano Oddkidd I've decided to purchase a whole new cam sensor arrangement, including laser cut pulley (including machining down of my vernier pulley), nice thick stainless steel cam sensor bracket and the use of a standard Cosworth YB Crank Position Sensor (same type of sensor and produces the same signal output). As the vernier pulley had to come off, when removing it me and Simon could see that the current phase disc was not held in place on the camshaft or vernier pulley and could actually be moved with the vernier pulley in place! We removed the vernier pulley and put the standard one on from the Escort's old engine and left the cam sensor disconnected (nothing much else we could do at this stage). This discovery furthered our suspicions about the cause of the head damage, if the TDC signal to the ECU was being sent but was miles out it could cause all sorts of buggery inside the head and on the pistons.

I missed a delivery yesterday morning which is almost certainly my cam sensor bracket, phase disc and freshly machined vernier pulley from Jano, so I'll be picking that up on Monday and handing it over to Simon on Monday evening.

I've got a few more little errands to make collecting bits for the return of the turbo but I've also got a few more things planned for this week including getting the car stickered up in the multimediacar.co.uk logos

Motorised touchscreen will also be installed and the MOT has run out as of today meaning that's got to be done later this week as well!

Oh well - it's always a mad rush before shows, but even more so this time!

I'll get pictures of the various stages with the car

Cheers,

Andy

* driving like an absolute bag of turd!

[FezzR]

just hope the theory this time turns out to be reality and the fix fixes it once and for all.

[andyhardy]

Thanks mate - it's a real 'fingers crossed' moment!

All will be revealed when the head's taken off tomorrow!

Cheers,

Andy