1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

tacked in the other side of the box

P1030203 by jono_misfit, on Flickr

then cut some steel for the sealing strip

P1030204 by jono_misfit, on Flickr

to go here

P1030205 by jono_misfit, on Flickr

marked up some lines

P1030206 by jono_misfit, on Flickr

because it will only have a fold down one side, unlike the rest of the box, I ran a step behind the lid nuts, then folded up everything

P1030207 by jono_misfit, on Flickr

started adjusting to shape / trimming

P1030208 by jono_misfit, on Flickr

it ends up with some weird and wonderful shapes due to the ..... used nature of the floor area.

P1030209 by jono_misfit, on Flickr

clamped in to position to ensure square and flat.

P1030210 by jono_misfit, on Flickr

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and tacked in

P1030212 by jono_misfit, on Flickr

I may add a central reinforcing strip, just to stiffen it up a bit.

P1030213 by jono_misfit, on Flickr

then got some steel and some hammers out

P1030214 by jono_misfit, on Flickr

cut in half

P1030215 by jono_misfit, on Flickr

and welded in to the corners

P1030216 by jono_misfit, on Flickr

to finish them off

P1030217 by jono_misfit, on Flickr

tank in position

P1030218 by jono_misfit, on Flickr

P1030219 by jono_misfit, on Flickr

i think i'll end up making a hose guide for the feed hose. to make sure it is suitably supported.

P1030220 by jono_misfit, on Flickr

Looks ok to me, next job will be on to the top.

[jonomisfit]

it was annoying me i was only one bracket away from this being complete and onto the next part.

So nipped out for 30 mins.

steel

P1030226 by jono_misfit, on Flickr

marked out and trimmed

P1030227 by jono_misfit, on Flickr

folded and swaged

P1030228 by jono_misfit, on Flickr

fitted

P1030229 by jono_misfit, on Flickr

P1030230 by jono_misfit, on Flickr

flange is rock solid now. Just needs cleaned back when its a more sociable hour.

[Deleted]

I don't think that the tank mount is going anywhere soon Superb fabrication work as always - I'm guessing you are on a 'working from home basis' - Chris

[jonomisfit]

Thanks.

It looks sturdy but total weight of its low. I'm conscious of not getting too much extra weight into the car.


I am working from home, however I'm still doing 40hrs of work work mixed with child care, so only really getting a day on the cars per week.

I'd prefer it was more.

[ian911]

Wow!That rear tank support piece was vert complexed,hats off to you mate, how did you form the dimples that match the original floor swages?

[jonomisfit]

Thanks.

A vice, a hammer, and some 25mm box section.

I opened the vice jaws about 30mm, positioned the part over them, then tapped the 25mm box down onto the panel into the gap at an angle. It gave a tapering swage runout.

With a bit of dressing once in position it fitted ok.

Theres also a dip mid floor thats wider, so I did similar then gave it a tickle with the stretcher to add a bit more depth, before dressing with the hammer.

[jonomisfit]

Box welded in

P1030326 by jono_misfit, on Flickr

P1030327 by jono_misfit, on Flickr

and given a bit of orange prevention

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Sunday should be on to starting the top.

I also tidied up the workshop a bit, and started looking at what tools I need for the CNC lathe. Boxford are so kind as to use a custom insert size (9mm) rather than the normal 7 or 11, so I need to buy new tooling. Boxford tips are £12 + vat each and they wont sell them to me as i'm not registered as a machine owner...

Luckily the tips might be an odd size but the shanks are 10x10, so normal tooling can be used.

On the plus side I've learned a bit about the ISO coding on tools and inserts, and cromwell / cutwell have what I need. the downside is a decent holder is about £50+vat, but tips are <£5 each.

[jonomisfit]

Bolted the fuel tank in

P1030330 by jono_misfit, on Flickr

P1030331 by jono_misfit, on Flickr

then took some measurements and did a dodgy sketch

P1030332 by jono_misfit, on Flickr

cut some aluminium sheet and started marking out

P1030333 by jono_misfit, on Flickr

more marking out

P1030334 by jono_misfit, on Flickr

start trimming

P1030335 by jono_misfit, on Flickr

more trimming, and make some holes

P1030336 by jono_misfit, on Flickr

swage the hole edges over, these are for access to the filler neck, vent / return ports, and fuel sender.

P1030337 by jono_misfit, on Flickr

start the folds

P1030338 by jono_misfit, on Flickr

getting closer

P1030339 by jono_misfit, on Flickr

and in position

P1030340 by jono_misfit, on Flickr

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its all worked out pretty well, other than the sloped rear edge, which I've folded 20mm too long, so will need to anneal the ali, straighten a bit, then re-fold. Which will be tricky but should be doable. I also might re-cut the filler hole slightly larger for a bit more clearance.

once i'm happy with it it'll get tigged up.

[jonomisfit]

with much effort and swearing I managed to re-bend the flange. Sits ok, Just a bit of dressing to do when Its sociable to hammer again.

[varelse]

Can't you just hammer at a distance?
Seems a bit obnoxious to go to a public space and hammer things...

[jonomisfit]

😁

My neighbor to the rear is only about 3m from the garage back wall.

So I'm always cagey about doing noisy things after 7pm.

[jonomisfit]

I went out the back this evening for some aluminium tig practice.

I managed to get some setting that worked, so had a go on the first couple of seams

P1030342 by jono_misfit, on Flickr

P1030343 by jono_misfit, on Flickr

whilst it wont win any prizes, its definitely a big step forward in my ali welding.

[varelse]

I know it's meant to seal off from the cabin... But can you find some swage stickers or something, so it matches the rest of the car?

On the subject of sealing, is aluminium an accepted sealing material? I would have thought it would have to be steel of a certain thickness to hold fire at bay for a while or something. (No actual idea what the requirements are. Could be ok to make it out of cardboard for all I know!)

[jonomisfit]

I was going to swage it, but due to the throat on the bead roller I couldn't get it to fit.

If you look at tracks cars etc, they don't even shield the tank and pumps. Rally cars there has to be a metallic bulkhead.

It's meant to keep fuel and fumes in, it says fire as well, but theres no withstand criteria so cant be for any appreciable duration.

Most ones I've seen are aluminium, including the ones provided by pro motorsport fuel cell providers.

[jonomisfit]

Drilled off the tank cover for the hold down bolts the side flanges are a bit tighter than I would have liked.


P1030344 by jono_misfit, on Flickr

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I folded down the edges then made some infill pieces for the corners

P1030347 by jono_misfit, on Flickr

welded them in

P1030348 by jono_misfit, on Flickr

P1030349 by jono_misfit, on Flickr

they still need cleaned back

then marked up the fuel filler hole and enlarged

P1030350 by jono_misfit, on Flickr

on to the fuel sender access port

P1030351 by jono_misfit, on Flickr

piece of ali

P1030352 by jono_misfit, on Flickr

rounded the corners and marked out

P1030353 by jono_misfit, on Flickr

marked some more lines

P1030354 by jono_misfit, on Flickr

Which I then ran a bead round.

P1030355 by jono_misfit, on Flickr

The beading pulled it out of shape a bit so I gave it a go with the shrinker/stretcher to get it flat again.

marked out again and folded some flanges

P1030356 by jono_misfit, on Flickr

fitted some riv nuts

P1030357 by jono_misfit, on Flickr

cover in place.

P1030358 by jono_misfit, on Flickr

the panels removable so I can get into the fuel sender connections without having the remove the whole tank cover. just in case.


cut a stip of ali and formed round a handy former (a cutting die)

P1030363 by jono_misfit, on Flickr

ran a bead round it

P1030364 by jono_misfit, on Flickr

start tigging on

P1030365 by jono_misfit, on Flickr

(and take a break for a re-grind on the tungsten after I dipped it :-( )

welded in

P1030366 by jono_misfit, on Flickr

P1030367 by jono_misfit, on Flickr

needs cleaned up. but gives a nice 95mm diam stub to clamp some aluminium ducting hose to (to protect the fuel filler hose)

fitted the cover again, all sits nicely

P1030368 by jono_misfit, on Flickr

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P1030370 by jono_misfit, on Flickr

looks huge, but is lower and more central than the normal fuel tank location.I also think I went a bit big on the tank size, so I may end up trimming the tank down at a later date.

next session will be looking at a cap for the vent / return points.

[jonomisfit]

Vent / return cap

these two

P1030373 by jono_misfit, on Flickr

mark out some bits

P1030374 by jono_misfit, on Flickr

cut a piece of ali

P1030375 by jono_misfit, on Flickr

mark out

P1030376 by jono_misfit, on Flickr

cut some holes

P1030377 by jono_misfit, on Flickr

trim and fold

P1030378 by jono_misfit, on Flickr

clamp into position

P1030379 by jono_misfit, on Flickr

weld

P1030380 by jono_misfit, on Flickr

P1030381 by jono_misfit, on Flickr

trim another piece of metal

P1030382 by jono_misfit, on Flickr

goes here

P1030383 by jono_misfit, on Flickr

welded on

P1030384 by jono_misfit, on Flickr

drill cover and fit riv-nuts

P1030385 by jono_misfit, on Flickr

cover bolts on like so

P1030386 by jono_misfit, on Flickr

tank cover back in situ

P1030387 by jono_misfit, on Flickr

P1030388 by jono_misfit, on Flickr

I also bolted in a bearing to support the steering column through the bulkhead.The rubber bush thats standard is the source of many wayward steering on sierras and escorts.

P1030389 by jono_misfit, on Flickr

checked clearances with the seat in

P1030390 by jono_misfit, on Flickr

loads of room for a batter or extinguisher

P1030391 by jono_misfit, on Flickr

checked the pedal position again

P1030392 by jono_misfit, on Flickr

and swapped the seat to the passenger side

P1030393 by jono_misfit, on Flickr

you sit far too far back to be able to rest your feet on the bulkhead, so a foot rest is required.

[jonomisfit]

<cont>

put a string line across the car so I can assess what the maximum height of a brace bar could be.

P1030394 by jono_misfit, on Flickr

take a load of dimensions, and sketch out a design.

Mark out some ali

P1030395 by jono_misfit, on Flickr

some heel ribs

P1030396 by jono_misfit, on Flickr

fold

P1030397 by jono_misfit, on Flickr

cut out and fold two sides and tack in

P1030398 by jono_misfit, on Flickr

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trial fit in car

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the top needs trimmed down still as its touching the dashboard, but feels like it should work nicely. The strange slightly folded bits at the side are so I can roll the edge over some 6mm ali rod I have.

For me in the passenger seat it feels like the right position and angle to be a comfortable sit in the car. Once the trans tunnel to cage bar is in to fix it to it will be pretty rigid.

Will maybe get another go on it later in the week.

[varelse]

Solid update!

Would the heel box not do with being a bit wider?
I haven't been in a rally car, but I know I like to have my feet sort of wide if I'm in my mates car when he's giving it some beans around corners..

If there's room, that is.

[jonomisfit]

I'll take a pic when I'm out later.

For me it's a comfortable position with a bit of room to position feet. The bucket seat pretty much forces you legs to be straight out from the hips not splayed, so you're heels end up pretty close together.

I could probably make a bit wider at the top, but the bottom is tight for space where I need fuel lines to go past.

[ian911]

Your a clever curse word