It is bolted to the hull at both sides;
then all the electrical plugs and heater hoses connected ..
All looking neat enough now!
As Amfey rises up frpm the Fiesta, the Fiesta is turning into a race car alongside!
First Easy job of the week was to refurbish the rear callipers. I'm using pre-not especially loved rear callipers from a Mk 1 focus estate. They are in good working order but very muck and rust encrusted.
They just needed a damn good wire brush and a couple of coats of hammerite.
Spent most of the rest of the week sorting out the heater hoses and dashboard fix. On the Fiesta the heater hoses attach to the heater matrix tails through the bulkhead. On Amfey they wont go through the bulkhead but do a 90 degree turn and come out in the footwell and then lead back to the engine room.
Using bits of hose from the Fiesta it wasn't possible to get a tight enough downward turn to the hose without having kinks.
The solutions available were to either cut more holes in the bulkhead or to adjust the heater matrix tails.
You can see the tails protruding from the front of the dashboard in the photo above. I cut about 2" off the tails and used premade 90 gegree elbow to lead the pipes down. I didnt take any photos so you'll just have to believe me! The elbows connect to more 19mm id hose back into the cockpit and these will connect to the preinstalled aluminium pipe that runs to the engine room.
This week has been amazing. Four jobs in progress. As ever nothing ever gets finished as everything is dependant on something else.
The first job was to finish getting the dashboard ready for installation. This was just a matter of drilling some (3) 10mm holes on the leading edge
Before the dashboard goes in I've screwed the plates over the forward bulkhead.
This should marginally slow the ingress of water when it starts to sink.
The next job thats been waiting awhile is to make a new hole for the fuel tank bund drain.I seem to have actually made the hole in the correct place and the right size. Thats not typical!
From under the bonnet...
and in the wheel arch
Like everything else it will all need masticing in later.
The next two big jobs are to get the dashboard and engine into the hull. To get the engine over the transom it will have to be about 1.5m off the ground. My engine crane wont go anything like as high as that so what we need is a gantry and a hoist.
The gantry comes in a box....
... and eventually all fits together.
I've got a chain hoist and thought I'd give it a bit of a test with the dashboard. This has a rather convenient tube running across its width so putting a strop through that and ...
... and before you know it the assemby is practically in the right place! Its beginning to look like a car now!
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.
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!!
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!
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.
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.
Got all the paperwork off to register it as a car now to test it as a boat!! Here are a couple of videos and some photos of it in action......
