martymexico
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/23 16:56:08
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Hi, have you thought about Orange for the wheel centres...looks good on white.....just a thort !!!! [:D
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/23 21:18:51
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Ah, that's a thought.
Orange is my favourite colour on an RS but as it's factory white then that's the decision made so it may be a nice compromise.
Somehow me thinks I have time to procrastinate [:I]
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martymexico
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/23 23:46:33
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That gearbox mount looks it can hold up the Blackpool Tower !
I'd think about grafting an Escort mount to celica if possible ?
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/24 00:02:08
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Yes, I'm looking at doing something like a WCXmember set-up in reverse. Having the bushes on either side of the mount that locate through brackets welded to the tunnel. I think Phil has done something similar on his Cortina (see below - thanks). The original manual trans mounts had to come out to make room. 
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darnoldrs
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/24 19:16:33
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You need to get your self a auto tunnel. Heaps of room in it then and you can use the flore mounting points as tehy are wider apart also.[%]
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/02/24 21:51:09
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Hi Dave.
The donor car had an auto tunnel and to be honest for the minor massaging the hassle of installing the auto tunnel was over kill. Plus I would not have used this cross member as it looks like CRAP!!
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/01/03 21:52:59
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Small update. Brought a pair of Audi 90 rotors from Upullit the other day. I went there just to find one to use as a dummy to get the correct calliper placement etc but managed to find a car with 2 new discs so well chuffed @ $56 for the two  Took the axles to work today and machined approximately 3mm off the diameter of the axle flange to enable the rotor hat to slide over. This needed to be a close fit as the centre hole on the rotor is 67mm apposed to the 63mm hub on the axle. This would ensure the rotor is positioned concentrically. After doing this I trial fitted the rotors onto the axles with the original R31 brackets and found that (as mensioned earlier) the callipers are positioned perfectly for the offset of the Audi rotor. Pity the original R31 rotor has a diameter of 260mm - 15mm larger than the 245mm Audi item. If the R31 rotor is used I'm sure the original calliper brackets can be used as the rotors have a similar offset. I did contemplate using the R31 rotor but I favoured the Audi rotor due to the already 4 x 108 PCD (and the fact I picked these up cheaply!). I have drawn up a simple bracket from 10mm plate which should make a simple conversion. I will upload images later as I forgot the camera [:I]
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/03 21:51:21
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Had some items arrive during the last week. Managed to pick up a new Raceline light weight steel flywheel and an AP HD clutch from the UK. This will solve my starter motor problem as it's machined to suit the Zetec RWD configuration and retain the original Pinto starter    I'm just consulting the local clutch specialist as the clutch set-up was less than ideal using the Pinto clutch and the Dellow conversion to the Celica box. When it was in the old car there was very little adjustment to allow decent clutch travel. The thrust bearing seemed to be riding the clutch all the time but there was barely enough travel in the pedal to engage reverse. It seems there may need to be some "tweeking" made to the cover or the lever pivot etc to get the correct reliable long term operation. 
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Dave
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/03/14 05:18:31
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Paul.
How the rear disk conversion coming along?,got any photos,Im contemplating puting rear disks on my car now.
Cheers
Dave
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/03/14 09:26:59
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Hi Dave.
I have partially assembled the discs and callipers onto the housing ausing the original R31 brckets but as mentioned do not suit the smaller Audi rotors.
I have drawn up a suitable bracket and will make a prototype out of thin plate to see how it all matches up. Looking at getting them eventually laser cut from 10mm plate and bolting to the inner side of the housing flange. I intend to drill out the threaded holes in the housing flange (where the bracket will be secured) to a 10mm clearance and tap the bracket holes. I'm not confident that the original 8mm (I think) bolts are up to the task.
Hopefully will have it dummied up over the next few weeks.
Also need to progress with the pedal box fabrication. I have patterns of the required additional sheet metal and looking at the brake pedal modifications now.
Will place pics here when more progress is made.
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Dave
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/03/14 11:55:46
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OK,so the audi rotors are a no go then,I was going to go for r31 rotors and calipers my self and just fabricate/machine every thing around them to suit,so long as it all fits inside 15" wheels im happy.
Whens the car getting painted???
Dave
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/03/14 23:13:32
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Dave
Not sure if you miss-understood but I'm using the Audi rotors as they are less work to fit. Either way you need to make (or at least modify) the bracket but at least you don't need to touch the rotors when using the Audi items.
Paint - not sure but will need to finish the rust sections. Hoping towards mid year to be in the panel shop.
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/04/16 22:33:25
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OK, another mediocre update [:I] Purchased another set of rims to get some decent outers. Found it will be cheaper to do it this way instead of paying to get the others refurbished. Anyway, I now have a set of 15x7 and 15x7.5 which should be ideal considering the offest of my centres will currently have 24P on the front and 18P on the rear. I now have an array of inners and outers plus 7 Porsche centres which I have started listing on Ebay! 
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martymexico
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/04/17 01:07:07
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Hi, good hearing that progress is hapenning on your car Paul,
rear disk setups are personal preference, size, calliper etc and what can mate up with what the easiest !
I have gone the Volvo 244 solid front disk for my rears and 1990+ Peugeot 405Mi16 rear callipers, only cause they have handbrake levers, attached to the housing with 'butterfly wing' shaped 10mm bkts welded on (axles out as heat will destroy brgs). i did this arrangement on my mk2 some 10yrs ago and its been very reliable .
Marty
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/04/21 17:56:52
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OK, I managed to pick up a cheap set of later model FD (Series 6) callipers. Basically identicle to the FC (Series 3,4) items but have a more modern appearance (which i prefer). The only real improvement I can see is more material around the inside ends of the callipers adjacent to the brake pad recesses. Piston sizing (36mm) and mounts etc are identicle although there must have been alterations to the hub mounting points to accomodate the increased rotor size (276 - 294) between the FC and FD models.  Below are the 2 callipers placed on the 283mm Peugeot rotor used with the conversion.  The older set (RHS) will more than likely be the set sold with my brake upgrade package here http://classic-ford.org/forum/topic.asp?TOPIC_ID=17894
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