Zetec Install Day...
Well I thought most of the bits had been sourced, and after being let down by mr TIG welder for the original alloy sump cut n shut I managed to source a CVH steel sump meaning I should be able to MIG weld and silver solder it myself
However the sump blatantly didn't fit and was completely wrong....so I sourced another (this time from a 1.8 sierra CVH) and an oil pickup, chopped the sump down as its a good fit, chopped the oil pickup down and managed to get arc eye by misstiming the flip down helmet/squeeze trigger sequence, only got a blast for less than a second which despite being told by others would't be enough to cause arc eye, I CAN assure you it it definately is enough, took a good few hours to get the blinding headache and sand in the eyes sensation, which just got worse and worse, till at 6 am I gave in and woke Fizz up to get me to hospital to prevent me from ripping my eyes out to relieve the pain
Got a really usefull leaflet advising me to use my head sheild (no shit!) and they looked in my eyes for damage, none found so just advised not to weld or expose myself to UV for a while and take pain killers
It took a couple of days for the red eye and watering to ease, bought an auto darkening helmet from eBay £20 well spent, though a tad too dark even on its lightest setting, NEVER going to let that happen again..
Managed to make a complete mess of re-welding the oil pickup (the shower head bit is VERY thin) and managed to blow enough holes to warrant throwing it in the bin
Another Locoster to my rescue (Thanks Whitestu I owe you brekkie at the next WLM meet!!), this time I silver soldered it after carefully making some nice joining collars on the lathe, all is good, nice and oiltight and just the right height :-)
OK time to re-weld the sump...which went OK, but again a schoolboy error of welding at ankle height in the shed wearing shorts...guess who had spectacular sunburn (2nd degree burns!) for 3 weeks!!!
Legs are now healed enough to actually get into bed, and I think shares in Aloe Vera must have shot through the roof!!
BE CAREFUL OUT THERE!!!!
Sump is now cut n shut, and is almost oil tight just a few minor areas where oil can seep over time, going to try flowing some solder or braze over those areas to seal, oil pickup is in place, ARP big end bolts fitted, new clutch (number 2, as first was completely wrong!!) arrived, ARP flywheel bolts have arrived, water pump replaced with the silvertop 1.8 escort item (so it spins the right way) clutch release bearing has landed,the JAW DIY Wideband Lambda kit and sensor are here..soldered, tested and calibrated, got the water cooling bits from Stoneleigh , so believing we were hot to trot I pulled the old Pinto out and started geting the Zetec in..
As you can see from the photies below, all went quite smoothly, and even managed to get some engine mounts knocked up..
Only issue is the oil pump and filter are stopping me from having any steering, so I now need to get a 1.8 Escort/Fiesta silvertop oil pump (much shorter and better angle) and strip the engine down ....again... to fit
Hopefully I will have Sweetpea2 back on the road in the next month or so...
Meanwhile enjoy the piccies of the BIG day :-)
