Insanity

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Bitterend
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Insanity

Post by Bitterend » Tue Sep 29, 2020 11:37 pm

So I got the Scimitar SE6A a few years back and put in the Cosworth BOB. cobbled together the wiring for the ECU and it ran.
I didn't want to leave the birds nest of wiring so......;
decided to make up a new engine loom.
Then things got put on hold.
Son No1 got a house, so I ended up refurbishing that from top to bottom. Mum died and I had to deal with that. Son No2 got a house so.... de-ja-vu I refurbished that one.
SWIMBO then wants ours re-done to the same standard. No1 wants an extension. Then he moved his business so fit out new premises. And I was still trying to work.
Scimitar on back burner.
Then lockdown and I have nothing to do except the odd paid jobs.
So the Scim is now getting done.
I had already made most of the new loom.
IMG_0340.JPG
The loom being made. The PATS unit is the black box on the left.
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I decided to use the ford scorpio fuse box with all the relays, it had the ecu wiring and plugs all there so just had to work in the scimitar wiring.
20200413_124241.jpg
Underside of Ford fusebox
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The engine was in and all the mountings made and welded.
20200427_113019-2.jpg
Engine in, but not a tidy yet. The big gromet on the bulkhead is for the fusebox.
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So then evrything stopped!
Fast Forwards a couple of years!
The engine was in, but far from properly installed, no exhaust manifolds, no fuel pipes ETC ETC.

So to work. for the PATS I had to fit the original Ford steering lock with the coil for the Ign key. Most of the conversions that had been done had the chip taped to the coil and pushed up the back of the dash.
Oh No! this has to work properly. In goes the Scorpio steering column complete.
20200427_113103-2.jpg
Scorpio column only needed a small mounting bracket. I now have an adjustable column.
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Now all I have to do is wire up the indicators, hazzards and lights. It took a bit of sorting as morden vehice wiring is more complex, the switches cannot take much current, and they are wired to switch relays to ground. Quite a bit of extra wiring. Also I now have 2 speed wipers with variable timed intermittent wipe. Oh and an air bag!
The slightly bizzare thing about all of this is the splines on the bottom of the scorpio column were exactly the same as the scimitar coupling shaft. Result!

Electrics sorted, time to turn my attention to other stuff. Engine out and paint engine bay. I decided at this point to check the timing chains and guides. there is a bit of history with the BOB engines shredding the chain guides and Ford issued a modification. Stripped down the engine and found the giudes were failing. One had broken completly and dissapeared up the oil strainer, the bores however were absolutly fine.
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The top of one of the cylinders. The bottoms were as good.
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A good pressure wash to clean it all up. I did a top end overhaul with new seals and uprated followeres, new chains and guides and put it back together.
20200801_131621-2.jpg
New chains fitted, heads back on
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New followers and all the rest of the valve gear cleaned and ready to go in
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Ready to go back in
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20200806_160021-2.jpg
and back in the car.
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adamwilkes
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Insanity

Post by adamwilkes » Wed Sep 30, 2020 6:11 am

Wow! That's a lot of work - and a great-looking intake casting :D Very impressive, keep going!


Adam Wilkes
Scimitar GTE 5a 1973, kinda Highland Purple; after months of work, still a ruin!
I can't help myself - I have to ask questions and find out why. Why ? Dunno :shock:

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DARK STAR
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Insanity

Post by DARK STAR » Wed Sep 30, 2020 6:55 am

Seriously impressive.
I bet the performance is too.


Chris Johnson
RSSOC 1979> Rhubarb SE6a V8 1979-1997 Dark Star Coupé 1989> Scimitar France 2010> Vert Soleil GTC 2014-2018
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On the road I don't drive fast, but I don't slow down for corners
In competition I drive very fast, but not always on the track ...

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philhoward
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Insanity

Post by philhoward » Wed Sep 30, 2020 6:59 am

:shock: :shock:

Well done.


Phil Howard
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SS1 1600 Rooster Turbo; Sabre Mk1.5, Sabre Mk2
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Crouchie_b
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Insanity

Post by Crouchie_b » Wed Sep 30, 2020 8:38 am

Nice!
Following this with interest.


Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

Diyhell
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Insanity

Post by Diyhell » Wed Sep 30, 2020 10:15 am

Looks V good!


SE6a needing lots of work...

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Old and Slow
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Insanity

Post by Old and Slow » Wed Sep 30, 2020 11:05 am

That looks sooooo complicated...
Well done so far, can't wait to see it finished.


Philip Needham
Ashley-bodied TR3; '54 Ford Consul; '55 AC 2-Litre Saloon;'65 850 Mini; '70 Ford Zodiac MkIV; XR3i
'81 911SC Targa, '64 Sabre Six

Bitterend
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Insanity

Post by Bitterend » Sun Oct 04, 2020 2:27 pm

The wiring was a challenge. I seriously underestimated the problems with trying to reverse engineer the Passive Anti-Theft system without access to a wiring diagram. Fords naturally do not publish details of security systems, however I got there.
The rest was just working out how to integrate it into the existing loom. To anyone contemplating this sort of job, Draw a diagram, check and check again. It will save time later when you come back to pick up the loose ends. Oh and label the loose ends!
20200429_125039.jpg
Wiring diagrams are key. You WILL forget what it all does.
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Exhaust manifolds now made and fitted but the rest of the exhaust yet to be done. I have got to weld in another Lambda boss and re-do the last bend, I got the angle wrong. One side only fortunately.
20200531_130036.jpg
The right hand one is also done. They have to come off to put the engine in.
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The Steering rack has now been stripped and overhauled. New track rod ends and new pipes made up to connect to the pump and reservoir.
20201004_095711.jpg
Steering rack back in
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I had to make a new front plate to relocate the alternator and PAS pump.The pump is now at the bottom left.

Started to clean the back end of the chassis and found where the tin worm have been. The load spreader plates for the rear seatbelts have all but disappeared. As the seatbelts are through bolted to a pair of straps which go down to the chassis I have to wonder what strength these 3mm plates add. However in the eyes of an MOT tester it is part of the seat belt mounting and corroded so it would fail.
20200929_151546.jpg
Seatbelt load spreader plate. Very Rusty
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20200929_153104.jpg
On the bench and waiting for steel to arrive.
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Whilst getting the belt anchorages out I removed the complete back axle, pressure washed it, gave it a coat of hammerite and then stripped it down. It is much nicer to work on when clean.

I made a puller for the hubs. The first one came off no problem. But the seccond one....... :P
20201004_125817.jpg
Puller couldnt move it
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I had to take the hub, shaft, and backplate complete to my mate with a press.30 Tons and heat to move it. Needless to say it buggered the seals.
Once I had it stripped I could have a good look. The diff had some nasty old oil in it, and a load of crud in the bottom. It was all cleaned out and evrything else seems fine. I did not strip the diff; it is going in as is until I can assess if the diff ratio is ok with my wheel/tyre combiation and also to se how it handles. I may install a power-lok at a later date.
The hub bearings were all cleand and inspected. suprisingly after being warmed up they are in good condition.
It was all reassembled with new seals and the endfloat checked and adjusted. For anyone doing this both halfshafts have to be installed and secured as the spacer in the diff forms part of the adjustment.



Bitterend
Posts: 44
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Location: N.W. London

Insanity

Post by Bitterend » Sun Oct 04, 2020 2:43 pm

In the meantime I have turned my attention to the brakes.
The master cylinder has been replaced with the Teves Mk2 system from a Sierra Cosworth. This dispenses with the vacuum servo and uses a 180bar pressure pump.
20201004_095732.jpg
Master cylinder and pump
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The pump is just in front of the master cylinder with the nice new shiny (I like Shiny!) PAS resevoir. In the middle is the vacuum resevoir for the VIS.
This setup did mean some more wiring. The new loom for the brakes can just be seen coming off the pump, dissapearing round the back of the master cylinder and then running above the brake pipes and through the bulkhead.
It does need a power feed and relay control.
20201004_095703.jpg
New fusebox installed
20201004_095703.jpg (329.65 KiB) Viewed 424 times
It has been wired back to the new relay & fuse box. This houses the ECU, PATS, fuel pump, Lighting and brake relays.



Bitterend
Posts: 44
Joined: Sat May 22, 2010 12:16 am
Location: N.W. London

Insanity

Post by Bitterend » Sun Oct 04, 2020 2:50 pm

Just to add for information.
The half shaft seals are as follows
Inner seal SKF CR13157 Double Lip Nitrile rotary shaft seal 1.31 X 2.282 X 0.25 INCH
Outer seal 1.87 X 2.75 X 0.37 INCH Nitrile rubber rotary seal with garter spring.
I obtained these from Simply Bearings, only because I have dealt with them for years.They should be available from other suppliers.
These are for the Salsbury axle. Other axles will be different so check.



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Nigel Clark
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Insanity

Post by Nigel Clark » Sun Oct 04, 2020 3:00 pm

Wow, that is impressive!

What a skillset, from figuring out Ford's security system wiring to fabricating exhaust manifolds. I can't wait to see how this project progresses.

Nigel



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adamwilkes
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Insanity

Post by adamwilkes » Sun Oct 04, 2020 4:06 pm

Well, you're not exactly hanging about are you :shock: Nice work - but why the high pressure brakes pump instead of vacuum servo?


Adam Wilkes
Scimitar GTE 5a 1973, kinda Highland Purple; after months of work, still a ruin!
I can't help myself - I have to ask questions and find out why. Why ? Dunno :shock:

Bitterend
Posts: 44
Joined: Sat May 22, 2010 12:16 am
Location: N.W. London

Insanity

Post by Bitterend » Sun Oct 04, 2020 4:13 pm

Nigel, Thank you.
I have a little advantage as an mechanical engineer. Although my welding is not so good.
As for the High Preswsure pump. The original servo was leaking. I had a spare one from a granada scorpio but it was huge. I also had aquired an amount of kit from a siera cosworth and also an escort.
The Teves system is set up for ABS should I want to go down that route.
Also there is an element of I can do it - so I will.
It's an engineers thing; we wont be beaten by a mechanical device. :)



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adamwilkes
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Insanity

Post by adamwilkes » Sun Oct 04, 2020 4:20 pm

You are definitely an adventurer 8)


Adam Wilkes
Scimitar GTE 5a 1973, kinda Highland Purple; after months of work, still a ruin!
I can't help myself - I have to ask questions and find out why. Why ? Dunno :shock:

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Nigel Clark
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Location: Market Harborough, Leicestershire

Insanity

Post by Nigel Clark » Sun Oct 04, 2020 8:38 pm

adamwilkes wrote:
Sun Oct 04, 2020 4:20 pm
You are definitely an adventurer 8)
+1. Not too many adventurers around since Scott went to the Antarctic.

Nigel



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