Week 50 - The Build

 So, last time I'd been for a quick test drive and identified a number of issues to be addressed. 

First off was a binding rear stbd. brake. I don't really kmow how that happens on disk brakes but that probably just shows what I know! Anyway, I retracted the caliper pistons and it now seems OK.

Next thing was the front wheels ever so slightly founled the brake calipers. Maybe having the front brakes on front hubs from something else isn't supposed to fit. Solved this by fitting 5mm wheel spacers all round. They were 'universal fit' which means they dont fit anything properly. I made some annular spacers to fit correctly.

at least they centre on the hub now!

Next issue was that when driving the abs pump was doing its nut and the brakes werent that great. Had a go at bleeding the abs unit so we'll see how that went on the next test drive. Think I'm going to need to pressurise the system from the reservoir rather than applying a vacuum pump to each corner.

I also noticed the gaiter around the water pump drive shaft had a hole in it  resulting in the engine room being covered in grease!

Here it is off the shaft with my finger through the hole. And here is the shaft with the tripod removed

 

Next week its finishing off the interior!

Week 49 - The Build

Last week saw the last of the mechanical work completed. So the next job is road testing to see whats needs doing again!

Its been sat on a dolly since I first started so it was interesting to see how it sat on its wheels. All four touch the fround at the same time, so a good start. Next its road test time!!

Here are a couple of photos of it overlooking Caerphilly on a rather dull morning ...

and a couple of videos of it being driven...

This little drive revealed a number of issues that need further attention! Binding brakes for a starter.

Week 48 - The Build

 Its been a long week - again! I didn't do anything much leading up to Christmas until a few days into the New Year. 

Previously I'd managed to pull the port side drive shaft out of its socket and so had to dismantle loads of bits to get it back in. Well, thats all done and all seems in order in that regard at least.

The problem was caused by the suspension strut fouling the plate that covers the hole by the drive belt from the gearbox. The solution is to use a strut from a Mk7 Fiesta later than 2013. My donor is a 2009 model.The new model has a different spring and orientation and, with a bit of angle grinding to reshape the lower shroud, its all fits lovely.

Here are the two struts. The original strut on the right and the modified strut on the left. The area of interest is at the bottom of the spring. You can see the extra clearance.

Here it is with all the suspension and brakes back on. I've also bolted on a strap to restrain the brake pipe and cables.

Week 47 - The Build

 So, the time has come to fit the cover over the drive belt in the port quarter wheel arch. Been dreading this for somewhile. 

This is where the cover goes....

The first job is to get the suspension off....

and here it is all in place with a few self tappers and a mountain of PU sealant...

just need to get the suspension back on....

Couple of points of note here a) the cover fouls the drive belt and b) you cant get the suspension back on without the strut fouling the cover as well. Grr..

In the process of discovery I managed to pull the drive shaft out of the gearbox. This was very dissapointing.

Here you can see, but not touch, the problem inside the red circle.

As you see, half the known universe has been bolted on around the joint so it all has to come off. 

Managed to get the cover off using a selection od saws, wedges and a bit of brute force.

Here it is with everything off and the drive shaft back in. Phew! Now to put it all back together.

Next time its getting it all back together..  but first we have Christmas!!!

Week 46 - The Build

 I left it the other week with the cockpit sole cut in half. Well here it is again screwed back together in situ. the aft section needed to be raised so it didn't foul the various pipes and tubes that run below. Not super happy about the water drive cable but its miles too long and had to go somewhere. In retrospect I'd probably have routed it elsewhere - but hey.

 

Here it is with the cenre console installed....

 

Next is to trial fit the back seats. The squab is secured to the cockpit sole with no access to the underside. Thank goodness foe rivnuts!

Here is one side done!

And here are the back seats trial fitted.

During the dismantling of the Fiesta I must have felt over enthusiastic in the reomoval od the gear lever gaiter so its in four pieces where one bit would have been ideal.

The 'leather' bit needs to be reattached to the frame and clipped back into the console...

And trial fitted in the cockpit...

Next time I'm going to attach the cover over the drive belt on the port quarter wheel arch!

 

Week 45 - The Build

 I left it last week pondering the shield around the steering column. The gap between the column and the brake pedal is narrow so the shield needs to allow full travel of the brake pedal and full rotation of the steering column and be strong enough to resist a bit of a kicking.

Not so easy  - however using some plastic cups and a lot of masking tape I did manage to make what was a mould for some GRP. Difficult to see in the photo as the cups are transparent!

 

Anyway, here it is being glassed up...

.. it came out of the mould lovely and trimmed up with the angry grinder. The bad news is that it doesn't fit! The mould was quite fragile and I think the weight of the fibreglass must have distorted it!

Quite dissapointing really as it took a week to mess that up. I'm now wondering if I need one at all! A quick survey shows that most cars dont have one..

Onwards.

Week 44 - The Build

This week it's been more work on the interior. The cockpit sole is supplied as a single piece of grp. 

 

Can't think how this is supposed to go in as a single piece - too big for me anyway! Easy solution is to cut it in half!

It can always be glassed back together if required. Here they bits are in a trial fit.

 Still a few bits to be done before final fitting, including making a shield around the steering column down by the pedals. 

Here you can see how close to the pedals is the joint where the column joins the rack! It's almost possible to steer with a foot or even jam a shoe in there.

I'm hoping to make a glassfibre shield but need to improve my template making skills while lying upside down in the dark.