Working on the "Other" engine....

My other project is progressing well, to wit, the rebuilding of a dirt cheap 2007 Focus engine I found in a local scrappy. This engine is going to be putting ot somewhere between 230-240bhp

Here's the spec:

13:1 Cosworth Pistons
250HP Cosworth Cams
Hi-port head gas-flowed
Farndon Con-rods
VP2C Main- and Big-end Bearings
Keyed crankshaft
ARP cylinder head studs
ARP main bearing cradle studs
Lightweight crankshaft pulley and trigger wheel
Raceline sump
Raceline cam cover
Raceline water-rail
Lightweight flywheel
AP Racing clutch
Omex 600 ECU
48mm Jenvey Throttle bodies Standard Birkin bell housing and concentric clutch
T9 Box with SPC gearset (tall 1st gear)


So far I have had the crank keyed and the crank sprocket has been spark eroded to fit.
The OMEX 600 harness has arrived
All the gearbox bits are here I must just assemble the gearbox when I get a free Saturday.
The head has been gas-flowed by Van Der Linde developments and the cams have been cut from fresh billets.
I had to design the trigger wheel myself on a CAD program to fit the Cosworth crank pulley and get it laser cut in Durban.

So far the block has been fitted with the crankshaft and its associated cradle and bearings, and the pistons have been fitted. All the main moving bits have been torqued up.

I just ordered the cylinder head gasket today so I can fit the cylinder head sometime next week.

I must still order the Raceline stuff. That is going to be a wallet bender!

Home Stretch

So now I have to buckle down and finish her off.

What are the outstanding jobs?

From back to front :-

Fit the roll bar and boot, but first I must check the fuel gauge sender, because it is reading way over full
Fit the centre console
Fit the carpets
Fit the interior side panels
Fit the seats
Bend the gear lever to a more user friendly angle
Fit the gear knob
Fit the gear lever shroud
Fit the ECU rev limiter light to the Carbon fibre Console, and fit that
Fit the scuttle
Make a hole for the GPS antenna cable in the scuttle
Connect the wiper mechanism
Connect the ECU harness
Connect up the windscreen washer tubing and tie the washer motor into the harness
Install the side indicators
Connect the radiator overflow hoses
Bleed the brakes and clutch
Wheel alignment (rough)
And finally fit the steering wheel

Now of those jobs I can scratch off the side panels, centre console and indicators, because I did that this last weekend.

The worst job I face is the bonnet, because the cut-out for the air filters does not match the position of the filters on the car. To avoid any cutting I am going to have to resort to sock filters and do away with the oval paper filters. Then I am going to fabricate an airscoop to cover the aperture.

Watch this space!








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