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My Puma Cossie - Few Bits And Bobs. (very Picture Heavy!) A running diary Rate Topic: -----

#1 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:10 PM

I originally wrote this else where hence the dates so you can see progress.

20/01/09


Well i decided to do a thread now ive started to mess around with the car. Theres a few things need doing, mostly from bits rushed at the end of the build and i want to tidy things up and tweak a bit.

Here she is resting in her nice dry garage!


And heres the reason i love her so much:


Unfortunately Tony didnt make any record of how he wired the two looms together which is annoying!!! Everything works at the moment except the heated windscreen which i think is the relay.

Have got a few issues with exposed relays and spare plugs.




These two are the relays used to run the cosworth engine loom. Personally i would have integrated the wiring with the fuse box, but thats just me, plus id run the circuits off the original ignition relay.



This is just an untidy mess to be sorted and horrible clips on the coil!!!



The first thing i have modified is the clutch cable arrangement:

The old clutch was VERY heavy due to kinks in the cable routing and also not quite enough travel making it hard to engage/disengage gears unless road and engine speed matched. That was because the modiefied clutch pedal has slightly less travel than a standard escos pedal and the cables were stretching due to heavy pedal and the auto adjusting ratchet was at limit of travel. Ive now got a stronger cable and also removed the rubber gromit at gearbox end of cable which reduces all the wieght on the pedal as the rubber used to be compressed tightly to get enough travel to use clutch. But alls fine now!!

Also fitted a cambelt cover as seen above as the cambelt used to be exposed with a turbo pipe running very close to it. Technically it was fine but it only takes a cable clip to come loose or when tweeking things to put finger in wrong place!!!!

Ive also fitted a boost gauge so i can see whats what and its also a good indication things arent right if its not holding boost or excessive boost etc. I had to make a carbon frame for it so i could mount it in the drivers side center vent. I made it out of some carbon ive bought and kept it nice and simple.

I had to find a way of plumbing it into the manifold and found my two spare vacuum take offs have been linked together rather than correctly blanked off. Easier I guess but not perfect!! Im just trying to find a blank so i can use only one of them.

Anyway i got a bit bored so i decided to see how much boost pressure and vacuum i could pull!! :-D



Anyway back onto the sensible stuff!!!

I decided to experiment with some small carbon parts before i go onto bigger parts, namely a pair of wing mirrors and an FRP fuel cap. Got myself some scrappy mirrors and a brand new from ford FRP cap.

had to prepare the parts as "plugs" for moulding the GRP moulds.

Then wax them loads and loads prior to setting up in my kitchen cum workshop!!


Now as some of the resins and gelcoats are quite nasty one needs protection


Then mix up some resin gel coat. nom nom nom nom yum yum


Then this is what it looked like after the first coat:

Then applied a second coat and run the heat gun over it so it was and even coat.


Next will be fibre glassing!!!
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#2 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:16 PM

02/03/09



compare the two indicator stalks!!! ones escort, ones puma!!

Guess which one im fitting to the puma??!!??

Yes on the fly variable intermittant wipe WILL be on my puma soon!!!

My next project is to fit my "small turbo" escort cosworth cam cover. I currently have the early version but the lettering has been ground off and i prefer to have the cosworth logo on my car so i dont get "what is it" questions!!! Also the shape of the ST cam cover is nicer and curvy which suits the puma better I think!! Also being curved and smoothish it will be easier to remake in carbon.


As with all things theres a minor problem!!! the front bolt holes dont line up!! they changed the bolt pattern on the heads.



As you can see from the gasket, the front two holes are wider out. This is easy to solve though. I need to find 2 alluminium M6 bolts, screw in, cut off heads then drill and tap 2 new holes as they overlap the old ones.

Also need to paint the cam cover and fit a aeroquip pipe for my oil breather tank.

My other project is ford racing badge replicas. This is a summary of the progress and soon i will be in full production!!!

First of all i sacrificed a genuine badge to make the mould:

i then used high grade moulding silicone so that i can mould direct from the silicone moulds.

After an initial rough edged set of moulds i redisigned the mould so i got perfect edges and this is the result:

Ive gone on to make 4 moulds so i can batch produce them.

Once they are made, they are trimmed up and then glued onto the "racing" logo printed sheets.

I then ordered some special 3M high stick tape:

and then i stick the trimmed badges to the tape.

Then they are trimmed out to get the end product. Heres some mixed with genuine badges. theres a slight difference in the red but its as close as i can get!!!



Ive still got a big list of things to do which will happen quicker as weather improves and i get money now ive got a job!!

Urgent
New tyres all round.
Finish carbon wing mirror moulds and end product
Fit carbon top mounts
fit solid steering rack bushes
Rebuild drivers seat slide as slide catch is sticky.
Full service
fix boot release

Medium term
fit front diff strengthening plate
buy and fit new stronger gearbox
hydraulic clutch conversion
turn boost back up to 2.1 bar laugh.gif
Fit big wing gated oil sump
fiesta Ghia temperature sensor mod
digital dash
replace distributor with coil pack
live mapping with closed loop fuel control (all available on my ecu when remapped!!).
carbon bonnet

Long term
carbon boot
carbon F2
carbon roof
carbon doors
interior carbon trim pieces
adapt loom to fit 3 button remote without changing entire loom!!
launch control
fully strip interior.
Weld in roll cage
respray, either silver blue chequer as per old puma or red/blue JWRC.
replace suspension front and rear with Grp N /WRC componants.
replace coilovers with custom set up ones.

That little lots going to take me a fair while!!! probably 18 months or more!
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#3 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:21 PM

08/03/09

Still working on wiring diagrams!!! might look a mess but makes sense to me!!


this is the end product!


well done my wiring diagram to convert to running a escort intermittant wipe stalk.

The escort stalk is "plug and play" on a puma loom without the variable intermittant function working, so youd think it would be a simple thing to add one wire, except the relays are completly different and so are the wiper motor wirings hence slightly more complex to integrate the escort intermittant relay.

Just need to design a "plug and play" loom to connect between puma wiring loom and escort stalks with the escort relay integrated correctly then i will trial fit it!!

20/03/09

Been doing some more now. Taken apart an escort and puma stalks to look at internal electrical differences.

They are basically the same circuit board inside with only minor differences, being the lack of variable resistor wired into the puma stalk and one less pin on the puma stalk (the variable resistor timing pin on escort stalk!).


The differences are circled in red. Also means i can easily swap around stalks if bits are broken by soldering on the new stalk.

It also means when later on i remove the factory steering wheel i can fit a fiesta light stalk with horn button on the end.

Just finishing wiring up the "plug and play" loom to fit the correct relay.

Also finished fitting my temp sensing clock after making the mini loom. you dont need 5m of wire as in the guide, but 4m is plenty.


Ive also robbed a ford of heated washers:

Will wire them up sometime soon.

23/03/09

Just finished my wiring loom for variable intermittant wipe


Will test it this week and fit it permenantly once im happy!!
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#4 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:32 PM

14/04/09

Finally sorted a few bits out now!

sorted out the seat slide mechanism which was occasionally failing to latch. Cleaned and greased and it seems to be fine now!!

Ive also got my variable intermittant wipe fully working now!!!
I changed the loom idea as there was such a simpler way of doing it by keeping all the wiring in the fuse box except one wire to the back of the stalks!

the wire in the back of the stalks is just inserting the extra pin into the back of the stalk where there is an empty hole so dead easy to do.


I shall do a guide eventually as its not a difficult mod to do!!

I also sorted out my temp clock with a proper connecter from a fiesta.


All you do is dismantle it at the prongs on the side:

And then swap the pins over from your original clock connector and the 2 new pins from the temp sensor. then you have a factory look and fit plug which makes it neater and easier to use when your pulling dash apart.

Only a few more jobs to do really!! including putting dash back together!!

16/04/09

Interior all fitted up again and the intermittant wipe looks factory!!


20/04/09

Thought id killed the fuel pump today :'( when engine died!! Luckily it was just a dodgy wire that was breaking at a connector:


bent wire to get enough connection to get home and i shall put on a new connector and sort it so its not so bent that it snaps with heat etc in future!!

I also need to have "words" with Tony the next time i go to pumaspeed as hes secured the fuel pump with cable ties!


23/04/09

Well now ive got 12v at the pump I'm content that the wiring repair is satisfactory!! It will do for a couple of weeks until i can make a complete new loom to go from the in car connector (which i shall rebuild to be safe) under rear seat all the way to the pump.

I might buy a new pump at the same time as the current pump is a standard escort cosworth one which is ok for my spec but its a few years old so cant hurt to replace it with a sightly uprated one, and as i understand it, aftermarket pumps have posts for ring terminals so id be better off replacing pump with loom so i can put rings on the new loom.

While i was dirty i decided i might as well fit the carbontec strut top mounts i bought ages ago, just hadnt got round to sorting.


Things didnt go quite to plan on the passenger side!! for a start i noticed the AVO hex bolt for adjusting dampers is missing...... and secondly the strut top bolt decided to jam at top of the thread!!! This is despite me cleaning thread and WD40 ing the lot. heat wouldnt loosen it and i didnt want to clamp the thread as it will be damaged so i gave it one more warning and gave the bolt strict words. I did warn it that if it didnt loosen i would cut it off!!!

hahahahaha that'll teach the bolt!!! doing the last bit by hand with hacksaw blade so i dont cut down to thread then i shall lever it apart once ive done the same on other side!! Good job i have new bolt to go on!!!

Warren 1 : Nut 0


Fitted this sides carbon cover now!!

This post has been edited by warrenpenalver: 26 July 2009 - 05:33 PM

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#5 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:44 PM

27/04/09

Built another intermittant wipe loom for Jacko and fitted it at the meet! Cant get it to work at moment on his car, despite it working fine on mine! Im thinking its either a loom difference between the two cars or the escort stalk i fitted to Jackos car has a wiring problem within it!!

No matter when i get hold of some spare puma stalks i will rebuild the escort stalk into the puma stalk unit so in theory its electically the same as what he has!

Ive now aquired a new loom so i can add some more features as well as fit some new fuel pump wiring.

First of all i want to aquire the newer 3 button remote alarm unit so i can upgrade from mine.

The joys of ford and modular construction means the alarm module is simply clipped onto the fuse box so can be unclipped for removal:

as with many modules, ford outsourced this one to siemens:

At least youd like to think it was well made.
removed the 4 screws to have a look inside to find what looks like a typical modern PCB which appears in good nick with no burns on, so should be up to the job for a while yet!!


Now i just have to rewire my old alarm stuff to fit in with new module!!!

01/05/09

took the car down turbosystems to get it checked out.

Took ages of fighting with the ECU to remove it from the car because pumaspeed/bodge used tons of mastic glue and literally glued the ECU to the glovebox :cry:

Eventually had a look inside and plug it in to work out whats what. Seems i am running a very early collins copy of a pectel board with a Terry Drury rally car map!!! the maps meant for a restricted 300bhp car!!! In theory theres nothing wrong with the chip if it was on a rally car with restrictor......... obviously my car needs to be sensible to drive on the road etc. Also being an early collins board theres no easy way of telling if the version i have had software which corrected some faults on the first few versions of copy pectel board they made!!

Also welded a lamda boss onto the downpipe so he could check out the AFR and see whats really going on.

Then moved to lowering the boost which was going off the boost guage scale (so well above 30psi!!!!:shocked:) to a more safe 20 ish psi!!! the hole in the vacuum pipe has been temporarily fixed till i can get a bit of new pipe.

Limiting the boost until i can get it fully mapped and some proper boost control obviously slows it down but its better than me killing turbo or engine or gearbox!!!

While trying to find somewhere new for my ECU to go, I have found 2 more relays that are not puma but from the escort:


So now ive got 4 relays to do with the engine.

Also bought a nice new shiney fuel pump so i can sort that out when i fit a new fuel pump wiring system.


02/05/09


One little mod today. I finished off my outside temp sensor mod fitting a sensor under the front to meet with the wiring id prepositioned.

So now i push the button on clock and can see the temp as well as it having 2 stage warning for black ice conditions


19/05/09

The TCS switch is actually for antilag. looks better than a fog light logo anyway!!

Well decided to have a mess with the wiring. Started making my fuel pump loom ready for the 044 pump. Just need to get the fitting kit and measure the loom up in place on the car as the tank is further back than on a standard car. Also currently my fuel pump loom although well clipped up is not far from exhaust and totally exposed to elements etc so it is being relocated so that the wiring comes out of boot floor via a gromit directly on top of the fuel tank, that way its all protected and has a short run. This is it so far:



Need to do some measuring then fit a relay connector. Im using the original fuel pump power feed as the trigger for the relay in the boot and the power and earth is being taken direct from the boot (boot mounted battery!) so i get a good stable supply.

Set about pulling apart the engine bay wiring today as i need a new header tank cap as my old one leaks and my fans keep blowing the fuse so i cant really drive it unless i rely on the "backup" radiator fans commonly known as the heater fans :cry:

Firstly i removed this stupid air bypass valve thingy that wasnt even connected:

It was fed by its own relay and fuse taken off the battery junction box and triggered by an ignition live and switch next to my antilag switch. Removed it all!!

I then took a look at the wiring near the coil to try and find the lecktron valve connector.

Found i have a group A coil apparently because of the connector on it.
I have found all taped up what i believe to be the amal valve connection:

So a bit of repair and that shall be set up ready for fitting a new chip and a lecktron valve.
I also found another bodge!! The alarm sensor on the bonnet is defective, yet the alarm doesnt sound the fault signal!! this is the sensor plug and he had bodged it with a bit of wire so the alarm doesnt detect the fault. Left it under the tape as it works for now until i get the new bonnet sensor.


Oh on a side note, be careful when using your nails to pick connectors open:

Yes that hurt!!

Ive also started to trace the fan wiring so i can rip it out for new. So far its all wrapped with the rest of the car loom so going to take a while to unravel and find the relay etc. Was looking at the fan switch on the radiator and im a bit confused:


The circular connector only has two wires which seems wrong to me. Surely there should be 4 wires, 2 for each fan stage, ie supply in and feed to fan for each fan. the earth i have found so thats solved. Anyone know why only 2 wires??

Ive been told my loom is a saphire 4x4 engine loom which in theory makes it easier as at least i know what im looking at. Ive had a look at the two main engine loom relays and arent sure which one is which.


If i can find a saphire wiring diagram i can identify each one by the colours of the wires.

Also these arrived in the post today:

Just need to get them fitted!!! Local garage wanted £130 PER tyre fitted!! Camskill came up £128 the pair delivered!!!
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#6 User is offline   warrenpenalver 

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Posted 26 July 2009 - 05:55 PM

21/05/09

Started to pull apart a spare fusebox i had. The original puma has a two stage fan system with a low speed and high speed relays feeding one fan via a resister, all fed by a 60A fused supply.

Now thats ideal to be modified for my needs. I wont be using a resister as i have two fans and the switch is on the radiator not ECU controlled, BUT it means i have 2 spare relay positions in my fusebox with all the right supplys for a new fan wiring installation!

Luckily for me, most modern fords use a easy to dismantle modular fuse box. All the relay holders unclip for easy maintenance and repair (yet ford claims it will only supply a full loom - so why design it modular and repairable then? go figure!).

All the connectors disconnected from the fuse box:


Looks a mess but its all colour coded, even the relays match colour of relay holder so you cant mix things up!!!

And this is where it all fits:


I only need to remove two relay holders and thier wiring from the loom so the spare connectors will be cut off and kept for recycling and any future repairs.

I also finished my wiring plans for the later "3 button" remote alarm. In essence all ive had to do is match the new pin to the equivilent old pin, no complex rewiring as such. So ive aquired the right connectors for the new alarm box:


Just need to raid the scrappy for an old style remote central locking box as i need to cut off the connectors on the box so i can link them to the new alarm and have the unit able to directly plug into the loom in my car. I intend to make it so its "plug and play" with no major butchery of the loom.

20/07/09

Just a couple of pics really!

My front suspension strut died a while back!!





whoops!! the whole bearing and top cup is knackered so replacing it with new!!! The damper is being rebuilt with a new central rod to sort out the snapped one and im rebuilding the other side with new bearing etc just to be safe!!

Nice table of new bits and bobs to sort things out!!


Reassembled my rad and some escos fans i picked up ready to go back in:


This is the coilover i need to de-rust before taping the threads up.


I shall also sort out the springs!!

need to find a rubber grommit to go on this brake pipe clip:

A cable tie is just asking for chaffing damage!!! There isnt any damage so far but theres the potential so it needs sorting for piece of mind.

Cleaned my wheels properly today!! Nothing like a good soak to get them clean!!


Will do a proper update later this week as ive been busy doing a few bits and bobs trying to get it ready for ford fair after my suspension broke!!
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#7 User is offline   Neil 

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Posted 26 July 2009 - 06:41 PM

Nice thread Warren smile.gif

I haven't a scooby's what half of it means, but the pictures are interesting!
2006 - 2008 Ford Puma 1.7 Lux | 2008 - 2010 Ford Racing Puma #0013 | 2010 - 2012 Mini Cooper S | 2012 - ? RenaultSport Clio 182 Cup

#8 User is offline   mitch9987 

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Posted 26 July 2009 - 07:39 PM

Love the ducks with the wheels in the bath biggrin.gif




2008/2009 - Silver 1.4...2009 - Thunder

#9 User is offline   warrenpenalver 

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Posted 26 July 2009 - 07:58 PM

I thought id add a bit about the engine management. The engine management is pre EECV which a normal puma has and is an off the shelf "Magneti Marelli webber P8" management system that was made by Pectel (now PI) and being an off the shelf unit has a LOT of extra functions available to it that were not used on fords at all in some cases, and only activated for motorsport cars in other uses.

The basic printed circuit board is similar in concept to the earlier cosworth ECU's and even uses the same outer casing as the "level 8" ecu which was its predecessor. It has more memory than its predecessor as well as the ability to run closed loop control, coil packs all from the factory.

It also has an add on board that carrys extra memory and for motorsport can be swapped for "pectel board" or similar which can encode the Chip data as well as add extra functions such as antilag etc. It also enables datastreaming externally to monitoring systems subject to them being able to read the pectel "protocol" (in theory similar to the way a more modern ECU can be monitored).

As it stands i have a early collins copy of a pectel board but not sure which version it is.

I know my chip has to go as its a terry drury chip which is a rallycross map for a restricted rally engine using air injectors - and my car has no restrictor and is a road car! whoops

To aid identification i pulled ECU out car for a nosey (cars broken).

Removing the cover:

WTF bits of foam!!

Under the foam there is yellow tape:


And under the tape you can see the chip. note theres no manufacturer sticker etc like other tuners do to identify the product! As i understand it, the red paint is what terry drury did on his products.


Nothing under the board to help me either:


It does have "P8" written on it in two places but thats it.

Also on the main ECU circuit board there are these big blobs of white stuff:

Nothing is wrong there it just looks very odd!!

I wonder if the circuit board used in other cars/had later revisions???

I notice theres a lot of unused componant pads and tracks on the circuit board:

And this is where there is sometimes a CO adjustment screw!!

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#10 User is offline   warrenpenalver 

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Posted 26 July 2009 - 08:35 PM

Thought id do an update for today!!! laugh.gif

Had to buy a few bits for preventative maintenance and tidying things up!!



First of all a massive bottle of kurust!! Will be spraying it liberally on the chassis and underbody while cars in the air to hold rust at bay until the winter when i can do a proper clean up of the underside.

Got myself some nice nimbus heat shield at coombe which is going to go round the turbo and downpipe area for shielding!!


Hopefully it will look something like this:

And it will then protect the brake system!

Ive got some new inlet manifold gaskets:

I need these as one of the securing bolts was missing on my car and the gasket is slightly displaced albiet not leaking with bolt replaced, should be changed to be on the safe side.

Ive also got some spare ignition amplifiers:

I need 2 to go coilpack but also wanted the backing plate so i can mount the second amplifier.

Got a bag of P clips off a mate in the right size for my fuel hoses so i can secure them a bit better as i feel the clip spacing is a bit too much at present in places!


Ive also been aquiring wiring loom bits so i can make my engine wiring loom:

and also a brand new ECU plug and terminals:


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#11 User is offline   warrenpenalver 

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Posted 09 August 2009 - 12:16 AM

While im sorting out various bits and bobs ive decided to start my digital dash wiring plans. Ive had to put my "3 button remote" conversion on hold as im struggling to find a second hand mk4 fiesta/early puma alarm module as my local scrappys only seem to have base spec fiestas with no alarm system!!!!:bat:

anyhow.... i have aquired a digital dash from a late puma:

And the connector with it:


I also want to try and fit this:

An ST170 focus dash!! Same level of technology and uses same kind of data inputs as the puma digital dash so i should be able to make it function. Primarily want it for the 160mph clocks and the fact its different!! Also going to rewire the dash illumination to utilise the dash dimmer switch from the focus.

Looking at the focus plug:

its simple computer pins and socket technology in the connectors so easy to connect up once ive done the wiring diagrams i need.

Ive got some pin strips for the loom:

and some connectors for the plugs:

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#12 User is offline   Ian G 

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Posted 09 August 2009 - 12:45 AM

QUOTE (warrenpenalver @ Aug 9 2009, 01:16 AM) <{POST_SNAPBACK}>
im struggling to find a second hand mk4 fiesta/early puma alarm module


Are either of these any good to you?





The first is from an October 1998 car, the second November 1997.

Got all the loom as well if you know what you need.

#13 User is offline   d170sam 

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Posted 09 August 2009 - 01:10 AM

lots of quality pumaspeed work there lol! glad you are re-doing it properly warren
to the steel workers of america: keep reaching for that rainbow!

#14 User is offline   JCDenton 

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Posted 09 August 2009 - 10:40 AM

So pumaspeed did this and screwed it up? They did that to my mates Ka/puma1.7 conversion left it in a half working state, he had to limp it to pumabuild to get finished off. They also droped a bolt into the engine fan so it over heated on our first tripout and left a load of engine mounts loose.

#15 User is offline   preacher 

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Posted 09 August 2009 - 11:56 AM

loving this thread! a lot of work and hopefully may get a chance to see your beast if we both go to a meet back home..

#16 User is offline   simon20 

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Posted 09 August 2009 - 04:29 PM

WOW well done

#17 User is offline   d170sam 

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Posted 09 August 2009 - 06:22 PM

pumaspeed are a bit pants really arn't they
to the steel workers of america: keep reaching for that rainbow!

#18 User is offline   warrenpenalver 

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Posted 11 August 2009 - 12:01 AM

Well i been working out some of the wiring for my dash.

This is the 2 connectors on my current loom:


I have worked out all the pin functions and stuff i need to transfer accross and labelled each function.

Ive then done the same on the puma digital dash plug:

Labelling all the functions then transferring across functions i already have on analog loom so i know which pin to connect to which and where new wires need to be made into my loom.

Ive done the same on the focus plug:


Next step is to turn them into loom plans and get some spare connectors to hack up!!!
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#19 User is offline   happy-kat 

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Posted 11 August 2009 - 08:18 PM

Looks like Ian G has a solution to your early Puma alram module Warren for your other project smile.gif
It looks mind blowing, but I expect it is a methodical process to work through/out smile.gif
searching is fruitful | I'm a sponge not a mechanic | please do try that 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 sometimes still seen for sale

#20 User is offline   warrenpenalver 

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Posted 11 August 2009 - 09:41 PM

most of its quite simple really. Work out the functions on the dash you have, do the same on the donor dash and match the pin numbers. Then its a case of finding appropriate ignition and permenant lives, the earths, illumination etc. Then its wiring in a speed sensor (cossies dont use one) and work from there.

Interestingly the focus does NOT have a washer low level alarm so i shall have to swap the washer lamp from my old dash and put it in a spare warning lamp place on the focus dash.
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