its been a while since ive updated but ive been doin a bit!!
ive basically been mocking up and making all the bits with the engine and box in place. once all this is done the engine and box ill be removed and cleaned up etc ready for final fitting hopefully.
few pics.
i got the clutch setup finished when i got the piece of flat steel back with a nice slot put in it for adjustment.
it seems to be working fine with a nice soft pedal. may have to fit a stop to the pedal to prevent overtravel on the pressure plate. gonna leave this till shes running.
also got the throttle setup sorted. i wanted to keep the original pedal inside rather than modding the bulkhead for the later type hanging pedal.
i got away with keeping the v4 cable after a bit of modding for stroke etc.
next i moved over to the exhaust side starting with the turbo manifold setup. i had to cut and shut a steel coolant pipe to gain bulkhead clearance for a start.
with the manifold left back on it can be seen that the boost outlet originally faces down on these engines. so i used a trick that worked well on the escort before and spun the compressor housing around 180 degrees to save on complicated pipework and give a more natural run for the boost pipe to the inlet manifold.
now facing in a better direction!
next it was time to make up an exhaust system. i kept the bore the same size if not bigger than the cavalier system and coupled up to the back half of the v4 system which was in good nick and almost the same bore so it should be ok.
started from the manifold back and fitted a new flexi joint before starting making the front section. i had to keep the front pipe well up in line with the bottom of the bellhousing out of the firing line of the axle as it hits the bump stops.
normally with this light engine there wouldnt be a chance of the van hitting the bump stops,.....but as she ill be running on pretty deep banded steels i think it may be rude not to give the springs a nice healthy press!!!!!
ready to rock!!
i used a cavalier flange type joint on the front pipe for easy dismantling.
fitted a mk2 tranny centre box i had in stock and all was done.
next job was to sort an alternator. i wanted to avoid using the izuzu one as its a jap 4 wire job with separate charging relay etc so the plan was to stick with good old henry for simplicity!! i still needed a vacumn pump to operate the remote servo the van is fitted with so ended up going for a mk4 transit one i had sittin on a scrapper in the yard.
for a start i had to spin the housing to convert it from right to left hand mounting and as it had a ribbed pulley i got an old izuzu pulley to fit with a bit of spacing and messing.
i knew to get it fo fit id have to mount it well away from the engine for clearance from the bottom coolant hose and the extended oil feed and return for the vacumn pump. it might look a bit mad but theres loads of room in that area so why not if it works ok. it will be easy to access with the front panel on the van anyway!!
i made up an extension bracket coming off the original alternator mounting bracket. looks a bit agri but should do the job grand!!
still have to make up an adjuster bar when i get a slightly shorter belt.
the vacum pipe is working out grand. will have to get a oil feed hose made up with an izuzu fitting on one end and a tranny one on the other and all should be good.
thats all the progress for now. next job is to start hacking up the inlet manifold!!