My take on the Zetec SS1

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chats371
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My take on the Zetec SS1

Post by chats371 » Wed Mar 30, 2011 1:21 pm

Hi everyone,

Well thought it was about time I put together my project thread for my take on the Zetec SS1.

I bought the car as a full rebuild way back in 2004 and after coming out of the Armed Forces and getting back my rebuilt chassis, started putting it back together in September of last year.

My engine is the Zetec 1.8 130PS from the Escort XR3i and is going in pretty much the way it came out of the donor car. Did a partial rebuild on it including new sump gasket, new mondeo oil pump to move the position of the filter housing, new cam gasket and new timing belt. Also got a nice shiny top cam cover and cover for the spark plug ports.

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Painted it gold to suit my SS1 (Brecon Gold).

I have decided to work around the EFI up and over inlet manifold so I can retain the wiring loom and non-PATS ECU that was fitted to the XR3i.

I am now at the rolling chassis point with my car which has Uprated RR 250lbs front springs with 200lbs springs fitted at the rear. I have decided to go with full spax adjustables front and back also. Also had my front top wishbones strengthened in the SS1 traditional manner.

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For brakes, went for the GW uprated front vented discs, uprated calipers and green stuff pads.

Other new parts include QRG Stainless steel 1800Ti fuel tank and new 1800Ti Radiator (bought a few years back due to originally wanting to convert my 1600 to an 1800Ti). Every bush has also been replaced with new.

Due to the fuel lines and brake lines being pretty wrecked when they were removed, I have run completely new copper nickel brake pipes and decided to go with full stainless steel braided lines for the fuel. 8mm on the feed and 6mm on the return.

Chassis paint wise, my dad about a year ago did it with rust preventative boat paint (not sure of the exact brand but was red in colour) and then I top coated with POR 15 chassis black. Not a show winning finish and will receive further touch ups in places but will hopefully last well.

Have 15" 5 spoke alloys to go on in black when I am at that point of the build.

Here are a couple of pics of the chassis at this point. Note that I have decided to go with a relocation of the fuel filter placing it before the pump so it can also provide that with protection.

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Here is a pic of the 4 branch ceramic coated manifold I intend to use in my build. Its inclusion has caused a couple of problems involving moving my starter motor to the drivers side of the engine with a bellhousing to suit this application and will involve the manufacture of a custom downpipe.

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Also a couple of pics of my modifications in order to make it fit. Due to using my up and over manifold, I have had my engine mount modded to seat the alternator lower down to give it room to fit.

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As you can also see, I have had to incorporate a new bracket and drive belt idler wheel as an afterthought due to the belt trying to move through the engine mount bracket in the standard alternator, crankshaft and waterpump triangular setup (Was my original intention but had to mod it to get it to work).

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The only part of my sump that I needed to modify was the removal of the rear original lower engine to transmission mounting lugs to enable the sump to clear the rear crossmember. I know that pauluspaulo has modded his sump to remove the front section of the sump but mine as you can see in the photo seems to fit without cutting and shutting the front end.

Well I am hoping that I will get the engine attached to the gearbox by the end of the week and both fitted to the chassis before I start my new job on Monday. Will depend on the arrival of some bolts from ebay and weather permitting.

Regards

Adam


Own a 1986 SS1 1600 was going to be a 1800Ti after Full rebuild but now gonna stick a 1.8 Zetec 130bhp in!.
1999 Lotus Esprit GT3 which has now been sold :-(

Coco La Blanc

Re: My take on the Zetec SS1

Post by Coco La Blanc » Wed Mar 30, 2011 2:49 pm

Adam,
Hi m8, long time no see. What are you doing now for work if not in the Navy ? Looks like you've got all the required mods covered and it should be good fun when it's finally finished and I'm guessing it'll perform a lot better than you expect. good to see you getting there at last !!! ;~}
Regards,
Viv



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Re: My take on the Zetec SS1

Post by chats371 » Wed Mar 30, 2011 2:59 pm

Hi Viv,

Yeah it has been a long while since I could get the car to at least a point to show everyone something. Left the Navy last October after 10 years service. Just wanted a change and more time at home really. Gonna be working for GE Healthcare as a Field Service Engineer on CT and XRay Scanners.

The engine seems to be ok inside so hope that there are no problems with it. With the mods I have for engine I would imagine I will be pushing between 140 and 150 bhp hopefully (4 branch sports manifold, Superchip for the ECU, BMC CDA forced induction kit and will probably get a custom exhaust made for it once it is running).

Once its finished, I intend to bring it to Curborough at some point so everyone can have a look.

Regards

Adam


Own a 1986 SS1 1600 was going to be a 1800Ti after Full rebuild but now gonna stick a 1.8 Zetec 130bhp in!.
1999 Lotus Esprit GT3 which has now been sold :-(

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Re: My take on the Zetec SS1

Post by CNHSS1 » Wed Mar 30, 2011 9:30 pm

cracking project there Sir! Good work fella


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Re: My take on the Zetec SS1

Post by reliant-reviver » Wed Mar 30, 2011 9:40 pm

Fantastic project
chats371 wrote:Painted it gold to suit my SS1 (Brecon Gold)
Bonus points!


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Re: My take on the Zetec SS1

Post by Roger Pennington » Wed Mar 30, 2011 10:11 pm

Looks very good - I bet you can't wait to get it finished! :D


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Re: My take on the Zetec SS1

Post by Raz987 » Thu Mar 31, 2011 11:58 pm

Some really nice work going on here, like it!


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Re: My take on the Zetec SS1

Post by pauluspaolo » Mon Apr 11, 2011 2:41 pm

Looking good :) :)

Not sure why my sump wouldn't fit & yours did :? - it would have saved me a whole load of trouble/effort if it had done - I can't think that I did anything wrong when trial fitting the pree-hacked sump so I'm a bit confused really (not a difficult state for me to reach it has to be said)! It's also interesting to see your solution to the alternator siting problem, I think yours is probably the neater solution & I'm not sure that mine will work very well in practice.

The exhaust manifold is a problem I've yet to overcome. Due to budgetary constraints I'll probably have to adapt an existing part. I'm thinking of a Mondeo duratec manifold with a Zetec flange fitted - It's a 4 into 1 system so more restrictive than a 4 - 2 - 1 but the downpipe is angled forward slightly so should clear the starter motor & the chassis rail. The other option would be a much modified Focus ST170 manifold - it's a lovely bunch of tubes (for a production car) but it would, I think, need an awful lot of modifying to fit a rwd application (if anyone knows differently please let me know). I'd love to get one of the manifolds fitted to Paul Hunts' car but I just can't stretch to it at the moment.

I look forward to seeing more on the project & best of luck with the new job :)



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Re: My take on the Zetec SS1

Post by chats371 » Sun Oct 16, 2011 4:18 pm

Hi everyone,

Some more long awaited progress to my zetec 1.8 130bhp build. Due to the nature of the way I have done things and the ceramic coated second hand exhaust manifold I got for cheap on ebay, this is my take on the DIY exhaust. Took a lot longer then I would have liked as I had to get a custom made flange plate for the downpipe and built the whole downpipe as you look at it (though it is covered in exhaust wrap in the pics) in a slow process of cutting many different stainless pieces of ebay pipes to fit and then jigsaw puzzling them together. As I am not a welder, it took a few visits to a custom exhaust builder on various spread out occasions to get it slowly welded up (all cash in hand though and was very reasonable). It is not the prettiest thing in the world but gives me options for the future and will be a good enough exhaust to run for a bit while I complete the project and get the car up and running.

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Ceramic manifold with the new downpipe installed. Also had to make a custom gasket for the downpipe to manifold as these are not available either.

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Another showing the downpipe routing

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Shows how it connects to the remaining stainless exhaust. Using the one I have got at the moment which is not brand new until I have a working car and will then see what the options are after that.

Also managed to fit my raceline water rail but no photo's of this yet.

Now looking forward to getting my body tub in when weather and time permits.

Regards

Adam


Own a 1986 SS1 1600 was going to be a 1800Ti after Full rebuild but now gonna stick a 1.8 Zetec 130bhp in!.
1999 Lotus Esprit GT3 which has now been sold :-(

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Re: My take on the Zetec SS1

Post by scimjim » Sun Oct 16, 2011 5:32 pm

looking good Adam - perhaps a Ti exhaust would mate up to that Y piece - and it goes under the trailing arm so you don't get that massive restriction? not sure if a single box would be a tad noisy though?


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Re: My take on the Zetec SS1

Post by philhoward » Sun Oct 16, 2011 5:40 pm

Ti exhausts go over the trailing arm as standard, Jim - and still have those not-so-good bends, but does still flow more than a stock CVH one as its a larger bore (from memory).


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Re: My take on the Zetec SS1

Post by scimjim » Sun Oct 16, 2011 6:37 pm

hmm - not sure where i got the idea that the Sabre SS exhaust went under the trailing arm then? still it was a good few years ago that I fitted it! should be fairly easy to chop it in front of the wheel and add a straight section to the silencer? G97s new exhaust definitely will :-)


Jim King

SECURE DRY STORAGE FOR YOUR SCIMITAR

Current: SE5 (8Ball), TI SS1 (snotty), 1600 SS1 (G97), 1600 SS1 (C686CCR), 2.5TD SE5a (diesel 5a), 6 x random other SS1s.
Previous: SE5, 3 x SE5a, 2 x SE6a, 3 x SE6b, GTC, 2.9i GTC, 3 x 1600 SS1, 1300 SS1, Mk1 Ti Sabre, Mk1.5 CVH Sabre
Chief mechanic for: 1400 K series SS1 (Megan3), 1400 CVH EFi SS1 (Grawpy), 1300 SS1 (Number One) & Sarah's coupe.
CURE THE FAULT - NOT THE SYMPTOMS

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Re: My take on the Zetec SS1

Post by chats371 » Mon Nov 07, 2011 3:11 pm

Another update,

With a little help and a bout of good weather, I managed to get the body tub back into the chassis after nearly 6 years spent under a sheet in various gardens. As is the case with a lot of rebuilds, it is not a perfect fit but pretty good considering that it was welded by two different people (First person had it for around 3 years and only managed to do half the job so retrieved it and a family friend did the other half).

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Only slight problem is that the A posts seem to be welded on about a centimetre too low . It is not much but can be seen in these photos below and stops you attaching the front armature bonnet supports in the current state. This can be seen in the two photo's below

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Am undecided on how I am going to rectify this at the moment but it may involve some GRP modding.

More to follow as more is completed.

Adam


Own a 1986 SS1 1600 was going to be a 1800Ti after Full rebuild but now gonna stick a 1.8 Zetec 130bhp in!.
1999 Lotus Esprit GT3 which has now been sold :-(

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Re: My take on the Zetec SS1

Post by scimjim » Mon Nov 07, 2011 3:15 pm

that doesn't look good - it's also going to affect the steering rack/windscreen wiper mount crossmember height. are the footwell bolts in and tightened down?


Jim King

SECURE DRY STORAGE FOR YOUR SCIMITAR

Current: SE5 (8Ball), TI SS1 (snotty), 1600 SS1 (G97), 1600 SS1 (C686CCR), 2.5TD SE5a (diesel 5a), 6 x random other SS1s.
Previous: SE5, 3 x SE5a, 2 x SE6a, 3 x SE6b, GTC, 2.9i GTC, 3 x 1600 SS1, 1300 SS1, Mk1 Ti Sabre, Mk1.5 CVH Sabre
Chief mechanic for: 1400 K series SS1 (Megan3), 1400 CVH EFi SS1 (Grawpy), 1300 SS1 (Number One) & Sarah's coupe.
CURE THE FAULT - NOT THE SYMPTOMS

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Re: My take on the Zetec SS1

Post by chats371 » Mon Nov 07, 2011 3:18 pm

No they are not yet but they are positioned such that they can be. Both the metal supports for these were replaced on either side when the sills were replaced and need drilling and tapping as a result of that. Intend to do that soon as the tub is just resting in the chassis at the moment.


Own a 1986 SS1 1600 was going to be a 1800Ti after Full rebuild but now gonna stick a 1.8 Zetec 130bhp in!.
1999 Lotus Esprit GT3 which has now been sold :-(

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