Build days 15 & 16

Water rail

I was all ready to permanently fit the water rail to the engine only to work out that it would make fitting the headers difficult once the engine was in the car and it also requires removing the one of the eye bolts I use to sling the engine. I'm not complaining too much though because I now know how it goes on and that it's straight forward. I also worked out that the temperature sensor for the Speedhut water temp gauge fits in place of one of the smaller bungs. Below is what it looks like installed.

Flywheel etc

So while I had the engine on the bench, as a trial I also fitted the flywheel, friction plate, clutch cover plate and bell housing. Again just as well as I don't have all the bolts for the bellhousing.

Gearbox

The bellhousing bolts made me think it would be wise to trial fit the clutch slave cylinder and bellhousing the the gearbox but I appear to have everything there. 

Dash

I've finally got all the holes for the dash finished but I've realised because the Speedhut use a standard wiring for all their gauges and supply harnesses to match, I'm going to have to rationalise the Birkin-supplied harness just to remove a fair whack of un-needed wires. Once I've finalised the harnesses I'll fit the gauges.

Pedal box

I've also bolted in the pedal box. Interesting in that the housing for the accelerator cable is bolted to the side of the pedal box but has to unbolted and moved down for installation.

Build day 14

Sump

I was able to get a sump gasket (apparently for an Escort MKVII) from Bursons; the Ford dealers were useless, I mean I don't expect War and Peace but an email response of "NLA" does not encourage me to approach them ever again!! And not just one but two major Brisbane franchises. I assembled the sump according to the Raceline instructions. Torqueing the windage tray hex head bolts required a quick dash to Autobarn for a 3/8 to 1/4 adapter but otherwise as described.

Con Rod Bolts

As part of the sump changeover I swapped the con rod bolts to the ARPs. The ARP bolts are a 10mm 12 point star head so I picked up a socket with the adapter.

Removing and replacing bolts one at a time

Done

 Sump 2

With the new con rod bolts in, I fitted the new sump. The "crank" plates front and back of the block create a small step so I applied some silcone gasket goo to all four joints. I also bolted on the bell housing to cross-check the alignment. I then torqued it from 10 ft lb through 15 to 18 in a "star" pattern of the 10 bolts. Just like tensioning the head on my banjo.

Sump on!

Build day 13

Exhaust

Started on the motor, taking off the exhaust assembly. As you can see in the second photo it looks like I will be able to re-use the original gasket with the headers.

Original exhaust

Removed

 Sump

To start with, I tried to take the sump off as a single unit; leaving the pressed metal bottom half still bolted to the cast top half. However the oil pickup pipe won't allow you to do this. So I put a couple of bolts back to hold the cast section, unbolted the pressed metal section and with the help of the rubber mallet broke the gasket's grip of the pressed to the cast.

Original pressed metal oil sump

Then I took out the oil pickup pipe.

Oil pickup pipe

And finally the cast section.

Original cast sump 

I was all ready to assemble and fit the Raceline sump but I'm concerned that the orginal gasket (which is two metal part held together by moulded rubber) does not look adequate. The flat metal sides don't match the channel which goes all the way around the Raceline, the channel also has locating pockets, and the rubber does not fit the channel of the Raceline (it's too thick).

Raceline sumps and original

Raceline sump and gasket from original

Build day 12

Front Stabiliser Bar

I have fitted the aluminium strengthening bracket to the brackets for the steering and the stabiliser bar. Not difficult once I undid both bolts from the stabiliser bar brackets.

Front Shock Absorbers

I've received my Protech shock absorbers so I fitted the front ones.

I'm holding off to fit the rear ones; waiting for my gauges to finalised my dash - with the dash done, I can refit my scuttle - with the scuttle in, I can fit the fluid reservoirs for the brakes (and clutch) and fill and bleed the brake lines for leaks - with the brake lines finalised, I can fit the diff and finish the rear suspension including the shockies...all for the want of a nail.

Rear Stabiliser Bar

I've also fitted the rear stabiliser bar.

Dash

And I've laid the wiring through the dash and connected some of the switches etc to get an idea of the scope. I noticed that the holes drilled for the warning lamps will need to be expanded.

Radiator

Since my foray into bracket making last build day, Jeff visited and pointed out that the fibre washers and associated hardware in the radiator fan kit were to mount the fan directly to the radiator core. Hence...