My Twin Turbo

[capri v8 driver]

The interia switch normaly only reacts on a very fast shock like in a accedent, not on slower shocks like driving over a pothole.

I reckon I'll take it out  - my worry is to pull out and overtake someone , hit a pothole and have the engine stop while
I'm on the wrong side of the road . I'm guessing the engine would run lean as well briefly , while boosting -not good .

I have never seen it happing that a interia switch cuts out in driving conditions, not even on a track.

Lets say you are driving at full trottle at full boost and the interia switch cuts out, Yes the engine would start to run lean, for maybe a 1 sec, after that, there is not enough fuel any more to create a burning air / fuel mixture. If the mixture cant burn any more because there is no fuel: no more heat.

its has only gone off when I drop a spare tyre in the boot.

The spare wheel is a big weight next to the interia switch witch can cause a fast shock.

[Dave]

LOL!

I know people who have got halfway through a days banger racing before they have tripped. 

If it worries you Matt then remove it!

[T4T]

 


First hurdle overcome .

Dennis has finished the gearbox and I'm picking it up tomorrow !!
There was a long delay with the step off gears .

One step closer .
Really starting to feel the end of a long journey coming my way .

I also know my engine is underway . 

I smile to myself just thinking about the car now ! Is that sad or ok ? lol

Bodywork update too ,

Looking at modding the front crossmember for intercooler clearance but decided it would be stronger with a 60mm box section with 4mm thick walls instead .

I'll get some pics up soon .



Matt

[Lemon-Ade]

Nice one Matt  almost there now then!  I'm smiling with you mate, is that sad? lol

It will be worth the wait 

[TwinTurbo]

Yep I can't wait either to see the finished car in a good video


I need to crack on to complete my sapphire next year.

TT

[T4T]

Gearbox in my possession  

The input shaft needed lengthening to suit the cologne as the gearset is intended for cossies .
[attachment=1]
I have up-rated the centre viscous to 60NM which will tighten things up a little .
I've had alloy gear cradle bushes fitted ( had them about eight years   )
[attachment=2]

Laughably , these bushes were the major transmission upgrade (Cost) when my initial plans for the car were rattling around in my head ten years ago !
Where did I go wrong/right since then ?  

The breather/oil return plate leaves me with a problem , no reverse light switch .


So I'll have to fit a manually operated one in the dash . I think that's a small price to pay though , for what I hope will be a reliable gearbox .
[attachment=3]

I have a break down of all the costs in the invoice from Dennis so if anyone wants to know how much the step off gears are , PM me .
It wasn't actually too bad at all . MUCH cheaper than a crownwheel/pinion which was the saving grace , as I would have preferred to have the front diff .
Have an uprated release bearing as well for the clutch .

Gearbox done !  

Cheers
Matt





 

[TimoXr4i]

Cant you fit a microswitch just before the gearstick for reverse? If you use one with a long switching spoon, it will last a very long time, normally about 20.000 switches

[T4T]

Quite possibly Timo .

I'll worry about it when we come to do the installation into the car .

There are still a couple of minor things to deal with regarding the gearbox - not internally though - one of which being stiffening the gear lever itself to have a more positive change .


Matt

[Lemon-Ade]

Don't know if it helps but the t5 kit I got comes with one of these to make the coz box fit



I can measure it if you like ? Or there is a bolt on type but I couldn't find one at the time but the one above was on mine with no problems.

Agree with timo too easy job  

Cheers Ade

[T4T]

Hi Ade , thanks for that but Bara have already done it .

You just can't tell in the pic above - or in the flesh - that it is modded from how fixit manufacture them !

Have to say that Bara and D.o.m.e.'s reputations are well deserved and great people to deal with .

Cheers
Matt

[Lemon-Ade]

Result ! Ready to fit then.

[TimoXr4i]

I work with microswitches daily, just the ones you can switch 220 volts, just a few one whitch welds itself together after a few years of hard work in a damp environment. Im trying to find out if i can make a gear indicator for my gearbox with those microswitches, not that i really need it, but i think its quite cool haha.

Nice gearbox, im a bit jealous

[capri v8 driver]

Why not a revers gear switch on the selector rod that runs true the cradle?  You need to fabricate a location pin on the rod and you need to find the best position for the switch.

[T4T]

Certainly sounds like losing the std reverse switch is not the end of the world - not that it was anyway .

I'll get it sorted so it switches automatically then .

Thanks guys .


I'll sort some pics of the new front end up tomorrow as well .

Matt

[T4T]

Oh yeah

TT , since you mentioned video , anyone have advice / experience with in car cameras and their mounts ?

Something not too expensive but reasonably decent picture quality .

Matt

[Dave]

Good progress mate 


Hmmm I have known Fixit to supply proper V6 input shafts before.



Also it's possible to fit the breather to the original plastic cover, there is enough room.

[T4T]

Hi Dave
Oh well , it hasn't cost me anything to alter the input shaft so it's ok .
As for the breather/return , I just asked Dennis to give me connections for a cooler and improved breather
and it was up to him to supply the solution .
Apparently , this is what they used to do with the rally cars .

Matt

Are you getting closer with yours ?

[Dave]

Yeah it's STD to remove the sensor & to fit a plate for the breather etc on up rated boxes.

Lots of Cossies will have had it done, maybe worth asking on passion Ford for ideas on how they got the reverse lights to work.

Personally I would do another plate & fit the sensor to it.


My engine is still in bits, bogged down with other jobs.  

[T4T]

The intercooler and radiator are in .  
[attachment=1]
The car now has a 60x60x5mm front cross member with a screw in towing eye .  
[attachment=2]
I obviously didn't get my measurements quite right when I modified the intercooler .  
Now have to adjust headlight mounting .  
[attachment=3]
Brackets for intercooler are welded to the new cross member . Clearance to rad about 3mm !
[attachment=4]
Even with the huge std member removed clearance is tight .  
[attachment=5]


Matt

And yes , I do need to line the headlights up still .

[T4T]

Morning all .

Does anyone happen to have a photo of a sapphire cosworth washer bottle in situ in the car ?
I'm trying to make a little bit more space for the air filter and enclosure on the driver's side ,
and it seems to me they must use a different neck on the cossy because of the std filter box .
I can't find any on the net - not the most interesting part of the engine bay I suppose .

Thanks

Matt

[Dave]

I have got to look at this myself, I am thinking of using a Mk4 fiesta bottle & mounting it behind the wheel same as the Fiesta. Not mocked it up yet however.

Mk2 Cossie one.

[attachment=1]

Rs500 one.

[attachment=2]

[T4T]

Thanks for those pics , looks like the sapph cossy bottle will give a little more room to play with .
Next dilemma !
Sorry for all the questions by the way , I'm starting to realise how little I really know about cars !

When I thought about changing the transfer box gears for custom ratios and spoke to DOME some years ago , one of the
influential factors was how I intended using the car .
If gravel rallying as opposed to tarmac use , the gearing match wouldn't need to be so close .
But because I am tarmac use , obviously the gearing needed to be a very good match , so as to not burn out the centre viscous .

I calculated that with cw/pinion of 47/15 at the back and 47/13 at the front , transfer gears of 26/30 would be as near to perfect as makes no odds .
However I am no engineer , so I just supplied Dome with cw/pinion info front and rear and the rest was up to them !

What I have ended up with is a pair of gears in 29/33 flavour which by my calcs is within 1.5% of a match .
The reason given being that 26/30 are not practical to make .

Now I am sure what Dennis has done is fine , but the question is whether it would be better to get closer to an exact match by
playing with tyre sizes ?
I can do this with 215/40/17 front and 235/35/17 rear getting me to .1% different (although new wheels necessary for the rear as I have 7" )
or                      205/40/17 front and 225/35/17 rear getting me to .4% different ( I'm pretty sure I can put these on 7" rims )

Am I worrying overly and 1.5% is good enough to
A/  not cause an issue with the viscous
B/ not affect the handling adversely .

Opinions please .

Thanks
Matt

[Dave]

I would say 1% is safe & 1.5 is pushing it.

I remember working out the difference between new tyres & ones on the limit as 1% but can't find the notes.

Work it out & you will have your limit.

So the front works out to around 3.17, I agree I think you will have to correct it with the tyres as that sounds too much.

[T4T]

Thanks Dave

Calculating tyre wear

If I start with 215/40/17 I get 603mm diameter when new .

Assuming 8mm tread depth x2 then adjusting to 2mm is between 2-3% difference .

Matt

[Dave]

Well I remember 1% for some reason lol!

Best if you base it on STD tyres.

So 195 60 14 = 590mm x pie = 1854mm for new.

& 590 - 14mm = 576mm x pie = 1810mm worn out.

I make it 2.4% max difference known to be O.K.

So your O.K as long as your careful with tyre wear as combined with the transmission difference it could be a problem.

There is info somewhere what Ford recommend but you can assume that upto 2.5% is O.K as it's proven.

[T4T]

Cheers Dave

As I thought , what Dennis has done is ok - I just need to keep an eye on things .

The car has been rolling on part worn 215/40's with adequate clearance .

BUT if I were to try different tyres to correct it the sizes above are very difficult to get .

I've been recommended Kumho Ecsta v70a tyres which I could get in 215/45/17 and 235/40/17 which would give an almost exact match
but obviously are on the large side in terms of diameter/circumference . There could well be clearance issues .

Next prob is 235's fitting on 7" rims - might be possible - as 17x8" superturismo wrc's are only available with 5x100 pcd .

I do have a helpful tyre place though , so might have a play and see what is possible !

I can only imagine running a wider rear tyre would be helpful with regards to grip and handling .

Matt

[TimoXr4i]

Wider tires make more grip, but be aware of aquaplaning, i had it while hitting a rain puddle in my 4i with my 235 rear tires, had 205 in front, lost grip on my right rear tire, and went 90 degrees to the left, i was driving just below 50 km an hour, but it was quite scary. Had 235 wide tires on 16 inch on my focus to, vredestein tyres, grip all the way, but also quite a bit noise, and they where pretty expensive too, but it drove like a dream, exept in rain, even as brand new tires it had some problems with very wet conditions, mostly on concrete asphalt mix roads!

Had them on 7 inch wide rims, later replaced the tires and rims for 6 inch wide 16 inch cougar rims, smaller tires, same grip, but far more less aquaplaning. My 4i current stands on 14 inch winter wheel, 195 wide, looks a bit sad tough...

[T4T]

Hi Timo
Good to know somebody has had 235's on 7" rims .
You don't happen to remember what offset you had on the wheels ?

I've got plenty of room to the coilover/inner wing at the back with et25 and 215/40 ,
just might be a squeeze to the wheel arch with 235's after geometry set up !
Likewise I think 215/45 at the front could be interesting with the arches !

I'll be running near to std ride height though , I'm not using the coilovers to drop it excessively , just a bit .

I'll try different tyre sizes to see if I can get them to fit and if not I'll stick to the 215/40's.
I sized the brakes to go under 16" wheels but then thought 17" so if I need to go up to 330 front discs I don't need to buy new wheels .

As for aquaplaning , I'll avoid being out in the car in weather like that , although the tyres are ok in the wet they don't like standing water .

Matt

[TimoXr4i]

No, i dont know the offset, didnt like the rims on my sierra, 15 inch is big enough for my 4i. Sold them ages ago, did have rubbing while full steering lock on front, suspention is set up on the hardest level, 40mm lowered.

The tyre guy fitted 13 inch tires on 14 inch steel to get a german look an a vw bora or such a crappy car, they can make a tyre fit!

Got a cossie brake setup, so no clearing poblems on my cossie wheels, i just dont like big rims on my sierra, but my cougar wheels painted white would look pretty okay, just 6 inches wide, but it just looks good.

a fellow dutch sierra driver owns a mk1 2.3 diesel, with... 18 inch spinners, bordeaux red car, black bumpers, spinners matching paint, but also narrow tires on a wide rim, i just dont like that!

[T4T]

Small update .

Everything is in slow mode at the mo .

Engine guy has requested that the car doesn't go there until beginning of Jan for fitting ( too damn busy ).

I'm too busy to spend any time on the car at the moment as my order books are too full and I'm in the middle of a move to new premises as well .
Very stressful and time consuming while still trying to be productive .

However , the bottom end has all been rebalanced and the block is now ready to be built up
Surprisingly , one of the JE pistons had not been reamed properly for the gudgeon pin ( obviously new supplied by JE ) .

Needless to say , my Christmas present to myself will have to be late .OH well .
Perhaps I was a little optimistic with my timescales but things are moving .

Matt