New Engine!

When we had the car out a few weeks ago we knew there was something not right with the engine and not just the ecu map. The problems we had were different every time we started it sometimes it would idle really fast other times it wouldn't idle at all. It sounded like it was running on 3 cylinders when it was revved up and also got really hot quickly. We wondered if one of the injectors was not working properly so we took the inlet off to check and they were fine so shoved the inlet back on tried it again and it ran better like all 4 cylinders were working. This made us check the inlet more closely and realised 1 of the seals for the injectors was missing and another one was damaged. This meant air was entering where it shouldn't which made it run badly. Dad got hold of some new seals for the injectors and re worked the inlet too to make sure it was all air tight. We took all the coolant pipes off to re seal them as well because they were a bit leaky and wanted to make sure that was all working well to keep the temp down. But having tinkered with the current engine loads and scratching our heads why it still isn't running properly we have decided its knackered. So out it comes and we got hold of a new one to put in. Didn't think we would be changing the engine already lol. After reading a bit more into the problem it turns out the Zetec engines are quite sensitive to what oil is used. Because they run quite hot they need the right oil 5w30, we had been using some stuff dad had lying around lol 10w40 at a guess. Bought the new engine from a local scrap yard for £90 2.0l zetec 99 focus. We set about stripping it and tidying it up.

Maiden Voyage!

Finally drove her out of the garage all be it in 3rd lol. Got it started and running but realised we could'nt change gear when the engine was running (somehow never tried before lol). Dad managed to get it in 3rd so that's why it sounded like granny driving pulling out. Once we figured out we couldn't get gears when engine was running dad started it in 1st and went down the road but got stuck at the end trying to turn around ha ha ha. We turned it round and i drove it back and shes a beast!!!

Had some nice sunny days was nice to work on it out of the garage :)

Fuel Filler

Was a bit nerve racking drilling a great big hole in the back panel but we managed to get it spot on luckily. We thought lining the holes top and bottom would make the cap sit straight but we should of double checked really as it is a bit wonky but its on and doesn't look too bad.

Exhaust On

Finally got the exhaust on! its blowing a bit but fits a treat and sounds ace! Dads going to weld it all up fully and make a gasket for the flange. Need to fit some heat protection around the hole in the bodywork and wrap the exhaust too. Also need to weld in a nut for the lambda sensor to screw into

Got a couple of the bonnet catches on they work really well and pull the bonnet down nice and tight. Going to put 2 on the front as well so 4 in total.

Radiator Reposition

We quickly realised the nose wasn't going to fit over the radiator where it was so dad chopped off the bracket we made then with some faffing figured out where it could sit with the nose on and made a new bracket. Looks snug but fits ok now. Also got the mesh on the nose cone now which is hard to photograph but looks ace on real life.

Charlie called shotgun for the first drive lol. 

Exhaust

Started on the Exhaust at last decided we're going to make a mild steel one for now and maybe look into a stainless one later after IVA. Figured out we need two 90 degree bends and a short length of straight we also need a CAT too. We have to make it split to get it through the bodywork and up to the manifold. We used the support that came with the exhaust and drilled through the chassis then bolted it on so its really strong.

Drivers Side Panel On & Other Bits

Finally tackled the drivers side panel we've been putting it off because we thought it was going to be a pain in the arse to do as the fit of the panel was bad and needed a bit of work to make it fit. Any way in the end we cut a piece of the bottom lip off to allow the panel to sit on the chassis better and then siliconed the hell out of it to stick it on. We used some bolts too for extra support but the silicon stuff is bloody brilliant really so it's nice and solid.

We weren't  too happy with the old wiring as it looked a bit messy and needed sorting so dads been busy re wiring and made a great job of the new fuse box, ECU etc. It will all hide away nicely under the scuttle.

Battery in hidden away nicely and as low down as pos for better centre of gravity (don't think we would notice any difference if it was higher really but makes us sound like we know what we're doing lol)