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Postby Rhinopower on Fri Aug 18, 2006 6:15 pm

waterpump will be fine, its only the recon's that need extra sealing.

rocker cover gasket will need doing though, ford is the best i've found
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Postby Smo on Fri Aug 18, 2006 7:07 pm

Rhinopower wrote:rocker cover gasket will need doing though, ford is the best i've found

Ok, will do! :) And yeah, I always try and go for Ford stuff like that. They must love me the amount I'm going in there at the moment :lol:
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Postby chris-fiesta on Fri Aug 18, 2006 10:51 pm

looking good m8, i never used any sort of sealent when i fitted my new water pump and gasket :oooh: but touch wood i havent had any probs yet!!
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Postby Smo on Sat Aug 19, 2006 11:12 am

Couple of random pics...

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Should have taken a picture of the passenger side - the wing is still a bit bent from my accident 2 and a half years ago, but I have a new one to go on (also from 2 and a half years ago :lol:). Hopefully I'll put that on once the engine's in and running. Also have a new genuine Ford front panel as the current one isn't in the best of shape.

Once the FRST suspension is on, it will sit just a tiny bit lower which should look nice :)
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Postby XRMike on Sat Aug 19, 2006 11:20 am

Proper stealth, it should stay that way too!! :P :D
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Postby bakewell001 on Sat Aug 19, 2006 11:23 am

Oit Joe i am nobodys B*atch! But i do like maccy d's :P

Anyways its you that will be doing all the B*tch work on my RS1800 (please) :devil:

P.s Looking good Si :wink: Im still awaiting a date so i can help (and learn things)
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Postby Smo on Sat Aug 19, 2006 6:59 pm

bakewell001 wrote:Oit Joe i am nobodys B*atch! But i do like maccy d's :P

Anyways its you that will be doing all the B*tch work on my RS1800 (please) :devil:

Behave in my topic! Or you'll be doing it yourself :bonkers:

bakewell001 wrote:P.s Looking good Si :wink: Im still awaiting a date so i can help (and learn things)

Might be sooner than you think what with my purchase today :D

19/08/06 - Some parts and a handy tool :)

Still nothing of great interest, but I collected my water pump pulley bolts from Ford today, along with an alternator bolt and nut which I didn't have, and an o-ring for the dipstick tube, although I'm still not sure whether it's needed... Bit of an odd tube I have as it doesn't seem to tally up with Ford's system.

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Bought some latex gloves too :bonkers: Thought I'd see what they're like as I'm fed up with grubby hands (even after 30 washes :cry: :lol: )

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And finally, what could quite possibly be the most useful tool during this conversion:

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... my new engine crane :) Also means I can make a start on this next week as opposed to waiting until the bank holiday weekend and taking it to my dad's work to use the fork lift truck!

Just waiting on a couple more tiny bits, then I'm ready to go :D
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Postby joe boy on Sat Aug 19, 2006 7:27 pm

:D :D get it in there :D those pics look good, such a sleeper :D
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Postby Smo on Sat Aug 19, 2006 8:03 pm

~joeboifiesta~ wrote::D :D get it in there :D those pics look good, such a sleeper :D

Steve's was parked next to it just before I went home, it looked sooooooooo high compared to it :lol:
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Postby chris-fiesta on Sat Aug 19, 2006 9:39 pm

:D :D

chuffed for you m8, nice to see you not waiting around either!!

catch you on msn later :wink:
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Postby Max M4X WW on Sat Aug 19, 2006 10:17 pm

Great stuff, Really needs black bumpers and 2i spoiler from those pics. Mk3.5 rub strips as well :)
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Postby Smo on Sun Aug 20, 2006 12:21 am

Max M4X WW wrote:Great stuff, Really needs black bumpers and 2i spoiler from those pics. Mk3.5 rub strips as well :)

Well I have some bumpers, but not sure if I'm going to use them yet...

Afraid I'll have to say no to the spoiler :( but you probably knew I'd say that :bonkers:

Have though about the MK3.5 rub strips, but I want to get some proper black bumper insert and I'll use it all the way round if I do - should make the current side ones look a lot less cheap :)
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Postby eddy on Mon Aug 21, 2006 1:59 pm

Looks good Si.

Wouldn't mind coming and having a look while its all going on.

My offer of the garage is still there, especially now its empty!
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Postby Smo on Mon Aug 21, 2006 2:12 pm

eddy wrote:Looks good Si.

Wouldn't mind coming and having a look while its all going on.

My offer of the garage is still there, especially now its empty!

Too late now, car is now disabled! :lol: Started about 12pm :)

You at home at the moment? If so, I'm sure you can work out why I might be a little bit annoyed at this very moment! :cry:
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Postby eddy on Mon Aug 21, 2006 2:23 pm

Nope i'm not at home, so can't work out why you are a little annoyed?

Hows it going?
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Postby bakewell001 on Mon Aug 21, 2006 2:24 pm

Smo wrote:You at home at the moment? If so, I'm sure you can work out why I might be a little bit annoyed at this very moment! :cry:


Im at home... its only a small flash flood! Get on with it.

Anyway its not like its going to mess your hair up :bonkers:
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Postby Smo on Mon Aug 21, 2006 3:10 pm

bakewell001 wrote:Anyway its not like its going to mess your hair up :bonkers:

I know, it's bad enough already :lol:

Eddy, as I'm sure you've gathered now, it rained a "little" :cry: :lol:
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Postby bakewell001 on Tue Aug 22, 2006 9:00 am

Where's the small update from last night Simone? :D
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Postby Smo on Tue Aug 22, 2006 9:06 am

bakewell001 wrote:Where's the small update from last night Simone? :D

I'm still scrubbing my hands clean :cry:
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Postby Smo on Thu Aug 24, 2006 10:39 am

24/08/06 - Think an update is due.
Well, Monday morning, I woke up with this odd urge to pull my car apart - although I didn't do anything about it until about midday :lol:

So, started something like this...

Car with 1.1 beast:
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Drained the old coolant:

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Removed the rad and fan:

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... and coolant hoses, air box etc:
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Unbolted the exhaust:

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After disconnecting everything else (cables, engine loom, CV joints etc), I got my crane out to support the engine while I unbolted the engine mount and gearbox cradle:

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At this point, Steve (bakewell001) came round and helped me lower and guide the engine down to the ground. We then strapped the shell up at the front and lifted the shell into the air to move the old engine and gearbox out – because of the way the crane was, we had to lift the engine and gearbox out from under the car which wasn’t particularly light work :lol:
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And there it was, end of day 1, the engine that it had known and loved for 16 years, gone :cry:

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It’s done me well that engine, sad to see it like this:

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:lol:


So that was the end of day 1.


Day 2, and I’m afraid the pics are a little bit thinner on the ground :(


First job of the day was to take the old gearbox off, remove the mounts/cradle and fit to the new gearbox:

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Once that was done, I then wanted to get the rear Zetec engine mount in place. So I took the top stud of a buggered engine mount I had and bolted it up into place with the side bolt to see where it would sit. Using a sticky label stuck to the underside of the metal where the mount would be bolted to, I scratched a circle through the top stud hole in the mount to work out where I needed to drill (neighbour's idea) so that the top stud of the mount would go through and fit perfectly - make sense? :lol: Unfortunately I took very few pics so can't really explain any better than that :(


Made a test hole using the scratched label as a guide:

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It was a slight bit off centre, but as the hole had to be opened up anyway, it was still within the area of the hole needed. After a bit of drilling and filing, the hole was perfect and the mount bolted up lovely :) :

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That's about it for the pics on that day. I didn't seem to get a great deal done, but I did, with the help from my dad and my neighbour, get the new engine up from our back garden (took three of us to lift it up the steps!) and into the front garden. I then fitted the clutch and gearbox so that it was all ready to go in.


Day 3

I had no help most of the day, so it was physically quite destroying on my weakself :lol:, but I managed to drag the engine up to the car ready for when the shell is lifted to drag into position:

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Strapped the shell up and lifted it with the crane:

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... and dragged the engine under:

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I then lowered the shell over the engine down onto the axle stands:

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I then strapped the engine and craned it up into position so I could get one of the rear engine mount bolts in:

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And then bolted the gearbox cradle up (no pics of that part itself) and remaining rear mount bolt, and the engine was now in place:

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Not bad considering I had to do that alone :lol:

I haven't trasnferred the pics yet, but after this I then popped the CV joints back in, fitted the new gear linkage (for the 5 speed), and played with fuel hoses for the rest of the day. I'm not happy with the way I've done them though, so hopefully I'll be getting some fuel pipes next week which are from an RS1800 so that it's all done properly. I've also got to fit the front engine mount, but I couldn't do this until I knew where exactly I had to place it, however the engine is pretty solid in there so hopefully it will be ok for a little while.

Next up on the list, I need to get the coolant hoses on, rad/fan in and connected, loom fitted, fill up with engine oil, gearbox oil and coolant, oh, and some petrol!

Almost there and hopefully I can turn the key later :D

:)
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Postby Max M4X WW on Thu Aug 24, 2006 10:52 am

:D :D :D Wish i was there lol.

Was going to say something else but forgotten.

Oh, Gear linkage. Is it easy to remove? I wanted to fit a b+m or rally design one!
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Postby Smo on Thu Aug 24, 2006 10:58 am

Max M4X WW wrote:Oh, Gear linkage. Is it easy to remove? I wanted to fit a b+m or rally design one!

Yeah, I found it very easy, just four 10mm nuts to drop it from the shell, plus a 13mm on the selector rod and the big stabiliser bar bolt (19mm? Can't remember now).

:)
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Postby bakewell001 on Thu Aug 24, 2006 11:08 am

I can see my feet! Lol

Coolant hoses are all in place, you just need some more hose clips!

Hehe when i do mine next week i think ill just have a before and after pic :lol:

No i cant do that really after all the moaning ive been doing to make you do this post!

Really well done on putting the zetec in by yourself, just wish i could have been there to help :rolleyes:
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Postby Smo on Thu Aug 24, 2006 11:12 am

Yeah, it would have been so handy to have a few more people about, reckon I'd have had it done and running by tuesday night :lol:

Oh, and just for you and eddy (as I see him nosing too):

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:lol:
Last edited by Smo on Sat Aug 26, 2006 12:00 am, edited 1 time in total.
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Postby chris-fiesta on Thu Aug 24, 2006 11:16 am

nice one simon :D

job looks a gooden so far, keep it up :Q :Q

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Postby bakewell001 on Thu Aug 24, 2006 11:19 am

LOL Im even holding the pot of grease in my hand.... :lol:

Ill get you back next week dont worry :D
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Postby Smo on Thu Aug 24, 2006 11:21 am

:cry:

Cheers Chris :bonkers:
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Postby chris-fiesta on Thu Aug 24, 2006 11:23 am

shame you dint clean the bay up a bit tho...... *tut tut tut tut* :P
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Postby Smo on Thu Aug 24, 2006 11:31 am

chris-fiesta wrote:shame you dint clean the bay up a bit tho...... *tut tut tut tut* :P

I did a bit, it's a huge improvement over what it was, but I didn't want to waste time that I needed to do other stuff :lol:

It will be getting a good clean up when it's running fine though, I've done a lot of the loosening up already :)
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Postby chris-fiesta on Thu Aug 24, 2006 11:36 am

:D good good
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Postby Excursion on Thu Aug 24, 2006 11:38 am

That's the early HCS with the rounded rocker cover, my first car had that :)
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Postby Smo on Thu Aug 24, 2006 11:42 am

Excursion wrote:That's the early HCS with the rounded rocker cover, my first car had that :)

Yeah, it's the 1117cc one. It was cheaper to insure than what Directline, Tesco, etc., have down as the Popular Plus (1118c) :lol:
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Postby Percy! on Thu Aug 24, 2006 12:04 pm

Great stuff.

I really do hope when its done you turn the key and it goes first time with no problems :)
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Postby eddy on Thu Aug 24, 2006 12:40 pm

Nice update.

Was a shame i wasnt dressed to help more.

Would be nice if the weather would stop being so wintery!
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Postby Smo on Thu Aug 24, 2006 12:46 pm

eddy wrote:Nice update.

Was a shame i wasnt dressed to help more.

Would be nice if the weather would stop being so wintery!

Nah, don't worry about it! I lost a bit of enthusiasm last night with the hose clip snapping and the fuel lines not being ideal, so I knew I wouldn't get much done. Just glad you picked up the RS1800 last night! Steve said you might be having a nose/play with it tonight - if you do, let me know, as I wouldn't mind popping up and taking a look at a few things :) If you don't mind of course!
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