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Helpful ReplyHot!Progress

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jpayne
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2013/10/19 13:24:24 (permalink)
0

Progress

no idea where the old thread has gone but I have news
One step forward a more expensive one backwards.
Ordered the tilton hydraulic throwout bearing for the T5 gearbox about 18 months ago knowing I still needed the correct thrust bearing. Ordered that during the week to discover when offered up to the piston/carrier that the bearing was right the carrier was wrong. Hadn't opened the box and discovered an incorrect part. Too long ago to chase up so ordered the new carrier/piston.
Anyhoo nothing cash wont fix.


Had the cosworth T5 bell housing modified to suit the bearing base which also replaces the input shaft bearing retainer. why it didn't fit I don't know but the bell housing hole needed opening up by about 5mm. Had the faces of the belhousing machined, 10 thou one side and 60 thou to get the faces parallel so now await the right part and I can mate the engine up to the gearbox.


JP
#1
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179 Replies Related Threads

    Mk2_2dr_2L
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    Re: Progress 2013/10/24 07:53:43 (permalink)
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    Looking good. So that's a tilton twin plate clutch you've got there?
    #2
    jpayne
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    Re: Progress 2013/10/24 19:03:18 (permalink)
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    AP 7.25 triple with sintered friction plates


    should hold the power!
     
    JP
    #3

    jpayne
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    Re: Progress 2013/11/17 23:15:20 (permalink)
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    So It gets worse before it gets better or so they say.
    Doors Off, for the first time since manufacture in 1971 I guess

    8mm pin punch and a dremel made light work of 3 of the roll pins. the 4th needed a bit of heat. and the doors surprisingly aren't that heavy, well compared to falcon and suzuki ones anyway.
    Front guards off, this was easy as they were already bolt on

    Engine and gearbox are out, driveshaft and exhaust removed, engine wiring and ECU out rear parcel shelf lining pulled out...bent it a bit, damn alloy. Will be welding a new steel bulkhead in so big loss

    Will hopefully be getting it onto  a rotisserie in the next few weeks for the following.
    List is really for me;
    New new front floors,
    6 link rear boxes,
    rear turrets.
    diff tunnel
    gearbox crossmember,
    new rear bulkhead
    Roll cage door bars, through to strut tops
    dash bar to hold steering column
    remove old and replace with new seat bars
    tidy general welding throughout
    modify dash to suit 6 dial dash
    tidy front bulkhead and transmission tunnel.
    engine chassis mount
    weld up about 50 holes
    manufacture new exhaust to suit turbo.
    rewire fuse box, relays and switched to passenger side floor mount tower incorporate new engine ECU
    Build up bilstein struts to be adjustable
    fit intercooler somewhere
    mount remote oul filter, cooler and new oil system
    All for this!



     
    Damn long list now I type it all out. Fortunately I have all parts except the intercooler

    Justin
    #4
    jpayne
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    Re: Progress 2013/11/24 13:54:04 (permalink)
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    No going back now!


    All glass out, all wiring removed from cabin, oh and the seat rails and side intrusion bars from the cage cut out!
    Never liked the cages side bars as they prevented the seat getting low enough. Well I cant see the bonnet and Im 6+ foot but I could go 50mm lower. What was good to see was I did get penetration in the welds...
    Looks like I should be able to clean most of the old welds and remaining stubs up pretty easily before the new lower bars go in. Looks like I was going to have to get the cage redone anyway due to the new regulations.
    Bought a sandblaster so going to strip the interior, engine bay and underside again! have ordered new front floors and mounting rails so they are getting done too.

    Cheers

    JP
    #5
    jpayne
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    Re: Progress 2013/12/21 17:50:35 (permalink)
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    slow progress with Christmas and work and heat



    more parts on their way including new seat rail boxes.
    have started the cut-it-out process, having unpicked the two wings of the tunnel stiffener to free up the floor space for cutting and welding soon. Post Christmas holiday period cant come soon enough. spare time and cash to spend!

    JP
    #6
    hak073
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    Re: Progress 2013/12/29 13:59:29 (permalink)
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    Hey JP. Excellent progress mate. Keep the pictures coming, its going to be very interesting seeing how your project goes. And tell me how you find some of that spare time and cash
    Also, I noticed the rear springs are out of the car now. Are you still interested in selling them?
    #7
    jpayne
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    Re: Progress 2013/12/29 20:46:12 (permalink)
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    Hak.
    I might hold onto them for a bit, someone made a very good point towards keeping the IP rear end. Already sold the shocks to the guy who bought most other parts in a 'bundle'.
    Will let you know if I re-change my mind
     
    Justin
    #8
    jpayne
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    Re: Progress 2013/12/31 13:56:31 (permalink)
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    FFS,
    Christmas holidays almost over and barely anything to report. How do I get myself so involved in others business!.

    Bigger holes cut. I like to call them exploratory but the reality is they are cutting my previous amateur mess out. Hope my new found patience and belief I have skill through Knowledge pays off. 6 months on its side to return to the same point I was a month ago would be um disappointing.

    All I can say is who did this!

    But nice new shapely bits

    Still after an Auto tunnel. Or I might re-repair this one or go aftermarket

    JP


    post edited by jpayne - 2013/12/31 16:13:19
    #9
    jpayne
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    Re: Progress 2014/01/04 23:52:03 (permalink)
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    Update seems pitiful but hey I also have two nice new ceiling fans installed, a new driveway, assembled the Christmas gift BBQ, welded in a drivers footrest to the subazuki and installed new speakers and amp in the ute!
    Slowly unpicking the mess. Spent 2.5 hours grinding of seam welds to help undo a previous repair

    After grinding away old welding I had to panel beat the front firewall 'tub' after it warped, has better shape than ever before. And lots of measuring before cutting. Im going to try and save this tunnel. Well the top anyway.


    JP
    #10
    jpayne
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    Re: Progress 2014/01/12 17:14:37 (permalink)
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    steel going back in.
    new front inner sill. decided to cut the roll cage foot out to get the the inner sill. at some point in the past it has been hit and was a bit crumpled. hammering, dollying and straightening. also plugged the chassis rail back together after old spot welds were removed. Also finally after 20 years of owning the car fixed the rust in the door aperture seam
    new bit welded in.

    Got fancy with the new metal bender, lots of measuring and checking and hey presto. good fit, Im happy with it too which is important.


    nice fit

    will trim up the rear floor and butt weld here I think,.
    5 hours of work. 1 x 150mm long 90 degree angle made and welded in,
    this 650x190 floor section and about 450mm of inner sill welded in.
    Oh and about 1kg of weld smoothed out!

    JP
    #11
    ronsmallford
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    Re: Progress 2014/01/12 17:31:18 (permalink)
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    Very interesting. Keep up the good work.

    "Horsepower loves the absense of weight" (from Elfin ad)
    "The car that reshapes your life".(Ford ad)
    #12
    jpayne
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    Re: Progress 2014/01/12 18:19:24 (permalink)
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    cheers mate. Hope too.
     
    JP
    #13
    martymexico
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    Re: Progress 2014/01/12 18:42:53 (permalink)
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    Nice to see some decent fab work going on there. I had the exact same corosion in my panelvan, I also remade both seat boxes from thicker metal reinforced, I put in tubes for wiring or brake line etc if required up near the tunnel sides.
    #14
    jpayne
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    Re: Progress 2014/01/12 18:47:56 (permalink)
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    cheers mate,
    I have to admit. this round of work is fixing my earlier attempt from the early 90's (always rushing young gun)
    But the car is worth something these days so worth the better attempt this time. Hoping to make it look right, be strong as best I can with the parts available and my current skills...oh and patience
     
    Justin
    #15
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