Not the most productive day. Managed to finish off the front suspension etc. but had the same problem at the rear in drilling out the wishbone mount. Another lash up later and we have the wishbones in place. In general thought both the front and rear mechanics have gone on OK. The next problem was with the rear drive shafts, one CV boot was split, and I have also found that both of the drive shafts have right handed threads and finally one of the hub carrier spline fits doesn't go on too well. So going in order, I have new CV boots to fit (trying a local garage tomorrow), need to call Mark for the third time to sort out the threads, and I think brute force and ignorance may overcome the last. I have also started to lay in the break pipes and have bought a length of copper pipe for the fuel lines. Again, I found I need a return pipe connector for the fuel line adding to the tank. This one I am thinking about. Finally for today I am promised the engine bits tomorrow and the additional items from Fisher will probably be here tomorrow as well. Fingers crossed.
Having fitted the brake cylinder and the pedal box I then moved onto the rear end. Fitting the Diff was quite straight forward except that I have been unable to unscrew the filler port. As the diff oil has leaked out this is quite critical. It will be soaked in WD40 and I will try again tomorrow. The big problem today was fitting the rear wishbones. This included drilling out the mounts on the chassis to 1/2". This seamed easy until you find that you either need a drill that is less that 8" long or a drill bit longer than 18". I had to make up a bit extension that just worked but still caused much hassle. The rest of the rear end went on OK. The only problem left is to fit the drivers side hub and retaining nut which seems not to fit the rest of the system. Finally, I started to fit the front suspension. Upper rockers, spax shocks and passenger wishbone went on ok (after drilling out the wishbone mount) but had the same problem with the drill/bit size for the rear drivers side wishbone mount. I'll hit that tomorrow
Carried on panelling the underside of the cockpit. I used the large head rivets from Fisher. These give a better fix on the floor but you have to have forearms like Popeye to fit them. Suggestion - use a piece of pipe on one handle of the rivet gun and lever it against a piece of wood. Also completed the panel fit for the brake master cylinder. I now wish I hadn't gone for a servo version, but it fits now and will be used. The panel was sprayed in Hammerite for good measure.
Panels put onto the tunnel sides and the outer cockpit sides using 5/32 small head rivets. These panels were also bonded with silicon adhesive and any gaps sealed at the same time. The accelerator pedal was put in place and the pedal box loosely attached. A large cutout was made in the front of the pedal box so that the servo'd brake cylinder could be attached. This is to be mounted on a separate plate that is bolted to the front of the box. the cylinder will also need spacers making to stand it off a little way. The chassis was inverted and the floor panels marked up ready for fitting.
Next installment of the Cleave saga, called earlier in the week and found that the original package had been lost but another Escort Zetec had come in and the parts have been promised within a week. I'll call on Monday to find out.
A new baby has arrived in the Huggins household, no grunting, pushing or pain numbing drugs this time though. Today was the day that the Huggins Fury was collected. All of the parts just about fitted into the LWB transit, the fibreglass panels were delivered to my parents house for storage, the mechanical parts were then dropped off at my place. The chassis is sitting on three wheels at the front and six wheels at the back. This is a simple way of providing a waist high bench to work from that has a ribber top to lay the chassis on thus reducing damage. So this evening I have been through all of the boxes etc. and have found that the following are missing - side screens and hood frame, and I forgot to pick up the brake cylinder cap with switch and poly bushes for the steering rack. Tomorrow I am planning to get the paneling done and possibly the rear suspension started. I have all of the next week off from work so I am hoping to get up to a rolling chassis stage by the end of the week, we'll see. Yeeehaa, Wagons Roooooll. In a bit of a state of limbo at the moment. Chatted again to Cleave salvage and found that the clutch etc. parcel had gone astray at the delivery depot (so they say), but they have just received another Escort Zetec in exchange and so have promised to send the parts this week. I have also had a hunt around Adversane scrappers and found the Mk2 Escort steering rack mounts (new rubbers needed), Sierra door lock strikers, really neat Volvo 740 Estate header tank and a Passat radiator with fan and temp. sender. Finally, the day is set, I will pick up the kit etc. on Friday, the van is booked, here I come.
Went over to Brighton to view a set of 4 spoke Ford alloys, these were seen in July 2001 issue of Classic Ford Mag. The guy has 2 wheels on an old Capri and the other 2 were in his lock up. All four wheels were is good shape and had probably been refurbished in the last four or five years. The external surfaces had little corrosion, but the inner on one had a bit of pitting. But for £100, each having a fairly good 185/70/13 tyre attached (one almost new) the deal was done. These were then washed and scrubbed and treated to Autoglym wheel cleaner and they now look like new. Just in case you were wondering, I am still waiting for the clutch and sump bits to be delivered, I'll keep you posted.
Good news and bad news. The bad news is that my chassis will not be ready until 13th (one week late) so I will have to re-arrange my leave to accommodate. The good news is that after browsing through Classic Ford mag, I called one of the adds and have arranged top go and see a bloke about a set of 4 spoke revolutions. The best bit is that they are in Brighton, only cost £100 and come with tyres, here fingers crossed. As a back up, my mate at work is dropping of the Sierra std. steels tomorrow
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October 2010
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