Week 10 - the Build

Busy week this week! 

First job was to fit a new clutch. Pretty staightforward with a clutch alighnment tool. I've also replaced the concentric release bearing.Not encountered one of these before but it a release bearing with the hydraulic cylinder andpipes built in.

Here is the CRB - the integral hydraulic pipes at a 2 o'clock leading to the outside of the bellhousing.

New clutch fitted with the old one dumped on the floor.

 While I was there I reconnected the gearbox. 

You can see the PTO pulley resting on the axle stand in the right of the photo. The rubber gloves protect the air inlet and an electical connection socket to the main loom.

Also this week I've started preparing the dashboard for installation.Three jobs here. 1) cut off the air con pipes. Shame really as I had hoped to get the air con back in action. In reality iot would be a monster job with very little benefit. Anyway its now all but impossible!

Job2) is to drill some holes on the front edge of the dashboard and the last job is to attached a couple of brackets at either side.

For a start this is the back of the dashboard with the air con pipes cut off together with a lump of bracket.

Time also to look at the driveshafts. These were supplied to Tim complete and returned dismantled but with the through hull seals fitted.

Laid out they look like this;

I'm sure they'll go back in fine, but probably not as they came out!!

Week 9 - the Build

A bit more action this week as my cable ties arrived. A bit of general loom tidying work and chafe protection on the brake pipes.

 The brake pipes from the master cylinder to the ABS unit and to the forward stbd. calliper needed securing so a bracket was made and the pipes secured to the underside of the scuttle.

In these photos you can also see the wiring loom secured to the bulkhead enroute to the stbd wing.This was all unravelled then reravelled with the extended washer bottle pump wire as the washer bottle swaps sides.

You can also see I've connected the brake vacuum hose to the servo. It reappears in the engine room.

One of the great mysteries of the week has been trying to work out what a plug on the offside front of the Fiesta is for. I hunted high and low on the engine any everywhere to no avail. Eventually worked out it was for the aircon pressure switch. Amfey wont have aircon!

Week 8 - the Build

 Another pretty uninspring but busy week just passed! Most of the work was what I'm going to call consolidation apart from replacing the stbd. aft lower suspension arm. 

The consolidation work included feeding the cable runs inside the car into split conduit and then feeding them into the side sills through to the engine room. I finally got the fuel tank to fit where I wanted it! The tank is from the Fiesta and sits in a fibreglass bund. The bund has a drain hole to the stbd. wheel arch. The hole supplied with the kit was too high so that has been filled and a new one will be drilled later. 

I did some more fiddling around with the wiring in the forepeak - probably more starting at it than actually doing anything.

The windscreen wiper assembly is mounted on the hull.

Week 7 - the Build

 I seem to spend a fairly normal amount of time on the boat this week but dont seem to have much to show for it! 

I've adjusted the stringers in the forepeak/bonnet to accomodate the fuel tank. This involved cutting about an inch off the stringers. The tank fits nicely now. The tank sits in a bund that drains to the stbd wheel arch but a consequence of lowering the bund is that the drain hole is now too high. I've filled the predrilled hole and will cut out a new one later. I also have prepared the fuel filler. This just involved cutting the Fiesta down so that there is just enough to slip some rubber hose over the end. I did dismantle the filler assembly to see if I could sandwich the deck with the two halves. I couldn't and it was a bugger to get it apart so that wasted a few hours. Just need to trim the rubber hoses to fit between the filler and the tank now.

While I was there I clipped down the brake and fuel lines in the forepeak so it's amost done there now. Just the front lights and hooter left apart from doing something with the radiator fan cable. Normally this is controlled by the engine temperature in the Fiesta but due to the enclosed engine room as a boat it needs to be on all the time. I need to find a connection that is live with the ignition on to operate a relay.

The windscreen wiper assembly lives inside the boat behind the dashboard as opposed to under the bonnet in the car. It also requires some modification to move the motor outboard a bit to clear the suspension turret. Thats all done and its installed now. 

The bad news of the week is that I've discovered one of the preinstalled rear lower suspension arm rubber gaitors is split. Grr! A job for next week will be to remove it and get a new one.

Only one photo this week and its a rather uninspiring photo of the mofified wiper assembly.