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Aug 17, 2023 12:19:56 GMT
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Bonded crank seal assy, mmmmm, not sure of that, if it lets go for any reason ByeBye engine, Ill ask my mate tonight about crank seals, I have a feeling you might need to use a later type sump to get the lip seal. Ill check. I'm hoping it could be big welded but need to have a chat with a friend of mine who can weld anything to anything, you're right about the sump - I have a 1200 sump that will fit to the 1500 but the change in housing will mean the sump will need modifying but I had considered modifying it anyway to get the oil capacity correct for the 1500 along with baffling it
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Aug 17, 2023 12:17:49 GMT
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I covered how to move the gearstick forward on a mx5 box in my thread (page 26) it's not difficult, the rx8 box is bigger so may require tunnel mods, a PCV system might help reduce the oil leaks too. Thanks for that, I've had a skim through and looks like a tidy solution to something I'd not thought about! I need to look at the PCV system as it's definitely not working the way I thought it should
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Aug 17, 2023 11:19:10 GMT
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I did manage to fit a type 9, 5 speed into a 105e without cutting the tunnel other than the hole elongation, it did require the judicious use of a scissor jack in various places and several assistances with the FBH, the down side of this IMHO it made nice quick 1760 into a slug, that bad, I sold the car, as for the rope seal issues, use a 1600 block, with the lip seal, better torque from the longer stroke, and retrofit the pre crossflow head, I have done it with factory parts, but I will need to check what parts I used, You can use Lotus flat tops but you will need to deck the block by about 250 thou, lots of people say no, but my mate still has a pre crosflow on a -250 decking and regularly revs it to 8k Thanks for the idea Ian, I hadn't thought of using a jack to massage the tunnel! I have just sold my 1600 block as I had been told by a few people I needed custom rods and pistons which seemed to cost thousands. I'm not revving the pants off it now so doubt I will in the future! I have my spare crank being crack tested and ground currently and I'll put it in the spare 1500 block I have and go from there. I'll find the photos but a chap made a crossflow style rear crank seal work on an early L block with the 4 bolt lotus crank so it can be done in theory. I don't want to make a new holder when I already have a crossflow one in my box of spares, I think if it's bored out to go over the 1500 crank end and a piece made to hold the oil seal in the right spot it could be welded or bonded together - once I have the crank back I'll explain it better! The rx8 box I have seems to be a popular choice at the moment as they're cheap and take more power than I'll ever make with a ford pushrod motor! the 2000e box I have has these ratios: 1st 2.972:1..2nd 1.97:1...3rd 1.4:1..4th 1:1 RX8 gearbox 2000e 1st - 3.760 2.972 2nd - 2.269 1.971 3rd - 1.645 1.4 4th - 1.187 1 5th - 1.000 6th - 0.843 So 1st in the 2000e is a little longer in the gears than the rx8 but that should help me off the line! I'd like to see what it's like with the 3.9 final drive but if it's a little too short geared dropping to 3.7 should even it up I think
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Aug 17, 2023 11:07:37 GMT
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There is a guy on YouTube- Dave’s Garage. He shows you how to make an adapter plate for a zetec to mx5 gear box. That should save you a few quid. You can also shorten the remote on that gear box and he shows you how to do that too if you need to. I watched that on the adaptor plate, I'll go back and watch the one on the gear selector
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Gearbox change on a mk1 are a pain as anything you fit will need tunnel mods. As my mk2 is a series 1 version, I’m in the same position as you. The series 2 had a bigger tunnel so the type 9 or mx5 box would go in a lot easier with only minor mods for gear stick and mounts. If you do change it perhaps the series 2 tunnel would be a good starting point, or perhaps you can just raise the top of the standard item. I did 165 miles in mine yesterday. Another gear would be great for cruising but on the smaller roads it’s no problem really. My engine leaks but not to bad. I think it consumes more than it leaks but mine is an old knacker. I think I’d built a nicer engine before swapping it out for a modern though. My number one mod would be the steering. If Reroford’s conversion to Escort rack was cheaper, it’d be on my Christmas list. They are tight! There's an article on retro fords site about fitting the mx5 gearbox to a zetec in a mk1 and its less intrusive than a type 9, I have an rx8 gearbox that's between the 2 in size and has similar ratios to my 2000e so will be similar but has an extra gear for motorway cruising which would be ideal. I don't seem to be consuming a lot of oil which is good, I have an idea to use a crossflow rear seal but modified to work with the 1500 crank. I've got the spares to build another 1500 but don't want to commit till I've fixed the bigger problems! I like the retro ford stuff but £2.5k for a rack conversion is a hard sell for me too!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Aug 14, 2023 13:37:17 GMT
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Saturday I had booked to go to Bicester Heritage for the piston heads show - I fancied going to something different and wanted to take the Cortina which I still hadn't test driven, so Thursday I commuted to work in the Cortina as it was the first day we had some actual sun! The drive was nice and with the last few things fixed I felt confident to do another 200 miles or so! I got up early and made my way down the M1 to Silverstone which is where I usually stop for a coffee when we go to the in-laws, The Cortina had been doing well but the crank seal was doing its best to prevent the underside from rusting! A little further down the road and I arrived at Bicester, parking with some interesting if modern machinery. A walk around looking at various cars was fun with a few notable spots: The interior of the Alfa got me thinking about making some changes to the Cortina's interior It was a decent show, it lacked something I can't put my finger on but as lunchtime was approaching and the food stalls weren't doing it for me I decided to head towards home stopping off at Caffeine and Machine which I haven't done in the Cortina till now. Bagpuss seemed to be popular there A few more hours spent looking at some very cool things I got back home, lost some oil had some fun though! It has made me think about the future for the Cortina, I enjoy going out in it and want to do more than a 20 mile commute to work. the oil loss is a real problem not just for me but these engines as a whole with the rope seals being awful. I've spoken to several people both hobbyists and engine builders who have all said the same thing - they're hard to seal and to replace it the job requires removing the crank which I have tried to do by not removing it a few times but it's never been right. I can't keep dropping oil like this, I have one more idea to try and if that doesn't solve it I think I'll look at replacing the engine with something more modern (zetec or mx5). I want another gear even if I keep the original engine and have a gearbox ready to go but want to solve this problem first. That's why I've held off replacing the CROWN wheel and pinion as the engine/gearbox changes might mean the final drive ratio would be changed too so before committing I want to try a few things. Any suggestions would be gratefully received!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Aug 14, 2023 13:20:36 GMT
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Le Mans had taken its toll on the Cortina which I had expected although these issues weren't the ones I thought would be the problem! From early on into the trip (and too far to go home and fix it) the rocker cover decided to spray oil around like it had just won Monaco, dousing the engine bay/ underside/ anyone who followed behind. Needless to say when I was spraying people behind I didn't make many friends... I repaired it as best as I could in a campsite in France but when I got home I decided that I would fix the leak but also get the cover straightened up to help the gasket sit better but to also get it sandblasted and powder coated. To their credit the cover was pitted and they flattened the first coat then applied a second for no extra cost which was really good of them, I think it suits the Cortina and having a hardier finish on the rocker cover is far more important than a smooth finish with a paint that'll go soft when warm. I removed the diff again fearing the noises (like tints) was bearing related, the oil was clean fortunately and the chap who rebuilt it at Christmas took it back to have a look and check the lash etc. The bearings are apparently fine but it's looking like the CROWN wheel and pinion are responsible for the noise due to wear. I'll keep using it for now and look out for a second diff, possibly a casing so I could go LSD (if I'm making bigger changes why not?!) I don't want to rush out and change the ratio for reasons I'll come on to. The other issue was that the exhaust started to leak towards the end of the trip which I put down to a loaded lowered Cortina clipping a speed bump when finding some duty free with Broady - no major issue but time and heat stopped me from fixing it, When I started checking the exhaust I couldn't find a leak. In the end I had to run the engine whilst laying under the Cortina (not a great idea!) I had started at the back and found nothing till I got to the manifold, a few minor leaks where I had welded a different end on but that seemed too small to be making all the noise. I moved my hand up and felt a real gust of exhaust from cylinders 2 and 3 secondaries - the factory welds had split! When taking the manifold off I thought it was a small crack but no - the whole thing came off! Fortunately these welds aren't the prettiest so mine fit right in! I even found a pit that had turned into a pinhole! Finally the Cortina was just about repaired and ready to go on the road again but before that I needed to clean the oil off from underneath as it was annoying me - the underside should be white! With the driveway ruined I was told to put my toys away and pressure wash the drive then think about what I had done...
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Sold!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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And very well she did too! And far more practical than anything I took! Hi Nigel, Thank you for spending the time rereading this, your mk1 had a cool plate and a D too which is nice. I know what you mean about the prices, I had a similar thought when the engine went and figured I'f stick with what I had! They're much more fun to build when it's not your money ! I've got some ideas and repairs to do - she'll never be totally finished!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Jul 31, 2023 13:30:12 GMT
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Thanks Jonsey, considering it was done by eye I think it went well! The last few weeks have been a bit of a blur so I haven't had chance to update the thread but since new year I have had one goal to focus on and that was getting the Cortina to the Le Mans 24hr (the full fat one not the classic!) Since going for the first time in 2009 with broady we had a plan to go for the 100th anniversary race which was 2023 - it was easy to commit knowing I had 14 years to prep for it! In all the years I had been to Le Mans I have wanted to go in the Cortina but for one reason or another I had been unable. It was a simple plan of make sure I can sort as many teething problems as possible and take enough oil and tools to get there and back! In the days leading up to going I put a fresh MOT on her to find that the handbrake needed sorting as it wasn't scoring very highly on the test but easily sorted after the 4th attempt! The really important job was to sticker her up as is tradition! it started off so easily, give her a wash and then things got a little carried away... 6 hours! I thought it would be simple - cut some squares and it'll make sense as I go but trying my best to keep the gaps correct and in line. It took a lot of effort but I really like the look of it The drive down to Felixstowe was fairly smooth apart from the traffic on the M25 but the Cortina held up well making it to the hotel in time for an evening meal and a relax before heading into France the next day We nearly picked up a stowaway! Having spent a full day driving on the motorways the Cortina kept up well cruising between 60 and 70mph despite using a considerable amount of oil due to a leaking rocker cover that had started the day before. We made it to the campsite mid afternoon and had the tent setup and a beer in hand in record time! The next few days were spent watching cars drive fast and general debauchery with some retro content thrown in After the end of the race on Sunday we headed back towards Blighty, stopping at a hotel just south of Rouen. A night sleeping in something called a bed and having a shower I didn't have to queue for it! I was ready for the home journey which was 400 miles or so with a stop mid way whilst we're on the tunnel. it was a hot day and the Cortina did well again to keep up with motorway traffic and getting some thumbs up along the way, still dropping oil however! We stopped in a. town near the tunnel to get duty free stuff and a glancing blow from a speed bump had me concerned as I thought I could hear the exhaust blowing... We made it to the terminal and was lead down to get on the train only to find it couldn't be used as the fire alarm had triggered so we had to hang out till another train was available A new train acquired and it was off to the UK A fairly stress free run home up the A1 apart from getting separated at the Dartford tunnel and us somehow ending up 20 miles ahead of broady! My suspicions were confirmed closer to home when the exhaust blowing got a bit louder - we managed to get home safely and a list of things to do!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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You've got the panel gaps looking great Jonsey
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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I bought this supercharger a few years ago with the intention of using it on yhe cortina but I'm going to go another way with it. Tge supercharger is from a r53 mini, I don't know the mileage but its a non Teflon coated version that turns over nicely. I'm based in Mansfield and would like £200 ono for it
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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May 11, 2023 12:40:50 GMT
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Having spent a few days last year repairing the exhaust after the manifold broke on the motorway I had some issues with it, there was an awful rattle on idle and it leaked and awful lot! I made the exhaust system many years ago when I did a dry build of the Cortina before painting and since then I have learnt awful lot and realised I had made a few things look awful... When inspecting the exhaust I found that the rubbers and adjustable hangers their diameters weren't the same i.e. the ID on the rubbers was 10mm and the OD of the hangers was 8mm so the exhaust wasn't properly supported. The droop had caused the exhaust to sit on the handbrake rod which then needed to be straightened Instead of hacking the exhaust yet again I decided to bite the bullet and start afresh, purchasing multiple 45 degree bends, 2 180 degree bends, a silencer, 2m of straight pipe and 10mm bar stock for the hangers all in 304 stainless steel. To improve on what I had made before I have also purchased a band saw so now my cuts are clean and level rather than the gnashings I made using an angle grinder whilst squinting! A few hours of measuring, cutting and fine tuning had an exhaust that sat quite nicely tucked into the transmission tunnel without being too close to the floor or the prop shaft I opted against the polyurethane mounts and purchased rubber instead to allow for movement of the exhaust rather than the flex joint I had which would have added 2 more joints (I currently have 3; 1 from the manifold to the axle, 1 over axle and 1 for the silencer) I had been on a TIG welding course as I do a bit of fabrication for work from time to time so had access to a TIG welder but unfortunately couldn't access it when the time was right so I have welded the exhaust using MIG with stainless wire. I'm pleasantly surprised by how well it went. new vs old The hangers were made by heating the bar and bending it in the vice - crude but effective! I takes a washer on to act as an end stop and welded a bead on the other end then field it back to make fitting the rubber easy but enough of a stop to prevent it falling off. For the over axle I made this using sections taken from the 2 180 degree bends rather than the off the shelf over axle piece I had originally, to prevent the handbrake from getting stoved in I extended the run over the axle and didn't drop it down as far as before, it looks a little odd but given it's a lesser seen part and it works without restriction I'm happy with it. The silencer has a similar twin 45 degree affair to the front because the tail pipe cut out in the rear valence is close to the chassis leg and someone put a leaf spring in the way! If I had the skills and impetus I would rework the rear valance so that the tail pipe exits the silencer without any bends but that is a project for a much much later date The exhaust has since done 450miles approximately with no issues and is slightly quieter with a nice rasp to it so I'm happy with it and so is Mrs Jim which helps!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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May 11, 2023 12:38:14 GMT
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I have been meaning to update the adventures of the Cortina for some time but there hasn't been a huge amount of anything going on other than small pottering jobs. When I took the Cortina off the road in December everything was just about functional so I didn't have many winter jobs to do compared to last year which was nice in a way but also meant I had to do manual labour jobs in the house which wasn't as fun! The diff has been rebuilt with new bearings and seals and the driveshafts have had new wheel bearings as they appeared to be worse than expected, I did have a bit of drama putting the lot back together as the 2 of the studs in the axle casing sheared under very little torque which took some finding for replacements but managed to get a full set. The old colostomy bag that I kept windscreen wash fluid in was not only looking pretty ropey but I couldn't get the pump to work with it so found a period correct Lucas bottle that I'd like to think won't go up in smoke like most 60's Lucas parts, I'll give it a proper bleaching and cleaning one day! With the weather improving Mrs. Jim and I headed over to ignition cafe outside Chesterfield for a post slumber run which was quite fun despite dropping some oil (more than usual). We had a good breakfast and talked to a few people, I got home and was sent this photo someone had snapped and made the Cortina look pretty good! I'm currently on Le Mans prep as I'm aiming to take the Cortina and finally do something I set out to do in 2009 but failed, as part of that I have raised the rear end by an inch (was currently on 2" blocks). The drive into work this morning was much nicer so I think will stay as it is for the moment. With the mercedes sold along with my fiesta ST I was scouring eBay etc for something that wasn't a hot hatch and a potential backup if the Cortina isn't ready for Le Mans, whilst working on giving myself gout over Christmas I found a Jaguar XJ8 3.2 a mile away and thought it would be a good idea - it sort of is as it is comfortable but 20mpg is less fun!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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The Escort is coming along nicely Jonsey
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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I sold my fiesta ST I bought this: We cleaned it, took the number plate off it and then sold it Then I bought this on Boxing Day as it was local and comfy - I have been enjoying it but need to take some more photos
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Nov 24, 2022 13:27:45 GMT
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Very cool car!
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Nov 10, 2022 15:09:48 GMT
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I printed that a few weeks ago out of PETG, it's made me smile a few times and has lasted about 300 miles so far
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Sept 22, 2022 10:38:53 GMT
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The work on the escort is very satisfying to see, have you got any events planned yet?
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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Sept 20, 2022 14:31:50 GMT
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:)I know exactly what you mean having to get creative with parts and materials because of budgets but I will definitely say hello next time as I would like some advice working with composites.
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1966 Ford Cortina GT 2018 Ford Fiesta ST
Full time engineer, part time waffler on Youtube - see Jim_Builds
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