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Frp 591 Comes To Life panther black FRP Rate Topic: ***** 1 Votes

#221 User is offline   d170sam 

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Posted 09 August 2017 - 08:44 PM

The light at the end of the tunnel is barely visible lol, lots of work to do yet!
to the steel workers of america: keep reaching for that rainbow!

#222 User is offline   d170sam 

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Posted 17 August 2017 - 05:54 PM

Few more parts have arrived and a bit more work done today:

Picked up some new Ford bits: anti-freeze, coil pack, oil filter, Cam and Crank sensors

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New Ford coil pack looks pretty cool

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Fitted

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Some special break-in engine oil and Quaife approved gearbox oil

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Parts for new exhaust system have arrived: Sports CAT, centre and back box, as well as 4x 3" V-Band connectors (il now be running a full 3" stainless system from the turbo back

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started making up some of the fuel lines, here is a little how to guide:

wrap them in masking tape and cut through with a 0.8mm cutting disc

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assembly tools and parts ready

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disassemble the fitting

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push on one end

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put the olive on the tool and jam it in the end of the hose

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Push in the other end as far as it can go

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ta-daa!!

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Here are the hoses fitted roughly in their final positions in the boot (still need to drill holes for the bulkhead fittings to run the hoses under the car and to the fuel tank but you'll get the rough idea)

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to the steel workers of america: keep reaching for that rainbow!

#223 User is offline   happy-kat 

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Posted 18 August 2017 - 09:13 AM

They look robust clamps.
searching is fruitful | I'm a sponge not a mechanic | The Wiki is cool, please do check there if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own link coming soon

#224 User is offline   d170sam 

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Posted 22 August 2017 - 02:39 PM

Got my gearbox mount and gearbox shell back from vapour blasting, mmmmmmm shiny!

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I got on and did the most scary part so far today, I cut vents in the bonnet, there is something very sickening about sinking an angke grinder in to a carbon bonnet... anyway it turned out pretty good!

Made a little template for my Escort RS turbo vents

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Some highly technical marking out going on here

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After a lot of moving around and checking positions, i finaly settled on the final position, marked out on the bonnet, ready to cut

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Cut a little test hole to see how the cutting disc felt and how the edges looked

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Past the point of no return now...

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after lots of sanding of edges we have a reasonable fit

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I put a little guide coat of satin black on to see how they looked, i still need to make some proper mounts underneath but il leave that for the weekend now

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to the steel workers of america: keep reaching for that rainbow!

#225 User is offline   d170sam 

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Posted 27 August 2017 - 06:24 PM

Two hard days of graft on my own done, doesnt look much but i have removed the front end panels (hood, wings, bumper) pulled out the current engine and gearbox, and today i have removed the wishbones, subframe and steering rack, it takes a whole lot longer when you don't have any air tools or an engine hoist!

stage one, get the panels off

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stage two, pull the engine and box, radiator, hoses

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small selection of now superfluous parts

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stage three, remove fuel lines, EVAP system wishbones and subframes and steering rack, I also made a start on removing the now redundant engine sensors

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next stage: finish removing engine sensors then power wash the bay. After that i can make a start masking stuff up to paint it, meanwhile il drop off the subframes, wishbones and various other parts for powder coating and send the rack off for an overhaul
to the steel workers of america: keep reaching for that rainbow!

#226 User is offline   d170sam 

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Posted 06 September 2017 - 07:11 PM

New parts arriving

New Hella fan

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Manifold has had its mounting faces skimmed

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Vibra-technics engine mount pressed in

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New track rod ends, wishbone ball joints, inner CV boots and rear wishbone bushes

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New OMP lower strut brace

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Also done some grafting, sanded back my bonnet, splitter and bonnet vents (they have now gone off for re-laquering and painting

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Also started getting rid on the now superfluous loom

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Picked up a couple new small gaskets from Mr Ford

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to the steel workers of america: keep reaching for that rainbow!

#227 User is offline   d170sam 

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Posted 07 September 2017 - 06:07 PM

Got the gearbox rebuilt finally, i had the shell vapour blasted then i had it painted silver and the end cap powder coated black, I fitted the Quaife ATB differential after my mechanic friend pressed on the bearings for me, and fitted all new seals and gaskets, the box was brand new anyway so i didn't change the bearings, it was a bit tricky to get everything back where it should be but i'm pretty confident that its all as it should be

The parts:

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Diff in its new home

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lots of cogs

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All done and looking sweet

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Lots of things going on simultaneously at the moment, i also made a start on the engine bay masking up

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once that was done i got a first coat of etch primer on

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Also bolted on a couple of engine parts

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more updates very soon!!
to the steel workers of america: keep reaching for that rainbow!

#228 User is offline   happy-kat 

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Posted 09 September 2017 - 08:40 PM

Did you have any rust on the spot welds on the engine chassis legs on the wheel arch side?
searching is fruitful | I'm a sponge not a mechanic | The Wiki is cool, please do check there if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own link coming soon

#229 User is offline   d170sam 

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Posted 10 September 2017 - 10:00 AM

a very superficial ammount, just cleaned it up and painted over it :)


got my steering rack back from its overhaul, Pupper is doing me a help

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Also managed a quick 1st coat of matt black this morning

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to the steel workers of america: keep reaching for that rainbow!

#230 User is offline   d170sam 

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Posted 13 September 2017 - 07:27 PM

Bit more work done today, started fitting part back on, got the new wiring loom through to engine bay, also got the new heat shield fitted

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Also got to polishing some parts before refitting, also painted the inner CV housing and centre shaft

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Breather tank

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Lightning motorsport large bore throttle body added (powder coated and new bearings fitted by me)

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to the steel workers of america: keep reaching for that rainbow!

#231 User is offline   d170sam 

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Posted 18 September 2017 - 07:40 PM

Lots more progress!!

Picked up the last lot of new parts from Ford: new ARB brackets, bonnet switch, gearbox speedo drive holder, all the bolts that hold the subframe, wishbones, rack ARB in situ

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Got all the parts back from the powder coaters, heres the subframe

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Wishbones (with new bushes pressed in, radiator/far support bar, upper strut brace ends as well as the FRP inlet support bracket and gearbox mount

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FRP carbon splitter sanded down and re-laquered

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Aux belt (non-aircon) fitted as well as the alternator

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Subframe now fitted

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ARB greaced up and fitted (with powerflex bushes)

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PAS rack in - note it has the adapter and Aeroquip fitting for the high pressure line from the pump

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All ready to go back in - its make or break time!!

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trust me i think i know what im doing.....

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just as i note i fitted the flywheel, clutch and gearbox too before i craned it in (sorry, no pic)

Aaaaaahhhhhhh yyyyeeeeaaaahhhhhhhh!!!!!!!!!!!!!!!!!!!!!!!1

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Engine and box in, rad and fan fitted

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Nice and shiney!! also you can see the other aeroquip fitting for the PAS pump (now located at the front of the engine now the A/C in deleted)

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Delighted with my efforts (i did all the above in one day on my own, with out power tools too!)

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she's now been loaded up ad taken away for exhaust fabrication as well as hard pipes for the intercooler and airfilter, should be back in 7-10 days for me to finish off the last bits before the first start up!!!

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sorry for the long post (been too busy to update lol)
to the steel workers of america: keep reaching for that rainbow!

#232 User is offline   happy-kat 

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Posted 19 September 2017 - 08:43 PM

Wow now that is progress, well done great achievement.
searching is fruitful | I'm a sponge not a mechanic | The Wiki is cool, please do check there if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own link coming soon

#233 User is offline   d170sam 

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Posted 22 September 2017 - 06:01 PM

More progress achieved, the car is half way through getting its exhaust, hard boost pipes and inlet pipe fabricated up, i've also been inspired with my new horn button to call the car megatron lol

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anyway here are some exhaust pics, its a full 3" system from the turbo back including v-band connectors throughout, a sports cat and 2x silencers almost identical in dimensions to the ones that were on te car before (Piper stainless system)

down pipe

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flexi pipe and sports cat

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mid section

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first silencer

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over the rear beam

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back box

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should have the car back tuesday (26th) then its finish up the last bits of wiring and tidying
to the steel workers of america: keep reaching for that rainbow!

#234 User is offline   d170sam 

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Posted 23 September 2017 - 12:40 PM

Picked up the bonnet from the body shop, looks nice and shiny now, the vent were gloss black but unfortunately the paint reacted when drying, so they got redone in matt black, i'm pretty happy with it, also had half hour free this AM so i cut and stuck on some heat shield material

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to the steel workers of america: keep reaching for that rainbow!

#235 User is offline   d170sam 

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Posted 11 March 2018 - 04:21 PM

OK so its been a few months now and I've finally got a day to update this! old 'Turbo Tubby' has had a few ups and downs over the last few months, its had a couple of teething issues and I've broke a few bits but its going well.

So i finally got it running after many a headache with the ECU, i had issues with a bad power supply and it kept draining the battery, in the end i redid the main power to the ECU which solved the problem but not before it killed the battery, replaced the old battery with a new shiny Bosch one and that cured a lot of the problems!

Its now been mapped up to 4K rpm and is currently running 8psi boost (whilst the engine is being run in) its now had a power run so i don't now what power its making though, pretty sure its well beyond standard as it pulls real hard on boost (even though its only running half the boost it will finally be running as well as only half the RPM range!) it still needs cold start mapping as its struggling to idle until its fully warmed up though, I'm up to around 750 miles on her now, the rest of the mapping will happen after she reaches 1000-1500 miles

Its run through two lots of competition 'running in' engine oil (Millers CRO 10/40) and original ford filters and now is currently running on its third lot of oil (now switched over to its long term oil - Millers 10/40 competition CFS oil)

Things I've/she's broke:
- Oil pressure gauge line burst at the oil sandwich plate (now replaced with a new one and working well)
- Second hand Vibratechnics gearbox mount shit itself and split in two, replaced temporarily with a cheap standard one, new
Vibratechnics one has arrived and I'm waiting to get it pressed in and fitted
- Vibratechnics torque link was a good 7+ years old and had quite a bit of play in it so i replaced it with a new one, much less
play now and feels more solid
- Turbo to down pipe bolts worked their way loose, now re-tightened
- Centre drive shaft bolts worked their way loose, now tightened and secure
- Secondary fuel pump died, likely due to poor feed from the swirl tank and the cold weather, fuel filter now moved to after
the pump and supply to pump increased from -6 hose to -8 hose, pump also replaced and running again fine
- Heat shielding applied to the HCV hoses as they are quite close to manifold
- Turbo oil drain melted during initial mapping, hose replaced and heat-shield applied (seems to be working well)
- Replaced a t-piece in vaccume lines that was blocked
- Steering rack blew a seal (after being overhauled!!!!) sent it back to be done again, then the hose failed, had smoke pouring
out from under the car as the PAS fluid was dripping on to exhaust! after a quick call to Lightning Motorsport i got a standard
second hand replacement from a fiesta Zetec-S (for non-AC cars) that now doesn't leak :)

Things I've had to finish off:
- Digital dash has had more parameters set up now, she has the odometer updated and now has both boost and water temp
values showing
- Engine bay wires tidied up and moved out of site/ziptied together for neatness
- Added a wideband Lambda from Emerald including a little flashing LED for exhaust gas temps

Anyway that sounds about where I'm up too, here's some pics as i know that's all you lot tune in for lol

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Getting the tracking done and camber adjusted

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Gearbox mount that turned out to be as tough as a richtea biscuit after one dip in a cuppa

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Cheeky interior shot, think she makes a good Decepticon (note steering wheel centre cap) which is appropriate i think lol

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Number plate relocated to increase airflow

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Melted oil drain with its heatshielded replacement

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to the steel workers of america: keep reaching for that rainbow!

#236 User is offline   d170sam 

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Posted 11 March 2018 - 04:21 PM

A few more pics :)

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Fuel system, pump and filter now under the car, new -8 bottom hose to replace the restricting -6 one that was originally used, i might redo some of the other hoses to neaten them up a little

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Being recovered when the fuel pump crapped out and left me stranded in the snow last week :(

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Cheeky snow shots

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Think this might be the point i became a petrol head! lol

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to the steel workers of america: keep reaching for that rainbow!

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