Body work in production

Some great step by step pictures of the Bodywork being created.

Project Cyana

Rob emailed me a number of photos of the process of producing the bodywork.

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Two sets of body work and and the sports kit.

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Engine mount issue

I while back I ordered up the engine mounts from Fury Sports Cars and other than taking them out the packet hadnt really done anything with them.

This weekend I decided to bite the bullet and get the engine properly mounted and drill some holes in the chassis mounting plates, and thats where I had a problem.

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The horizontal line going across the rectangle is the centre point for the engine mounts. Now unfortunately that line was also dead centre one of the chassis members! So it turns out that the chassis mounts supplied were actually about an inch to short on the passenger side.

After some deliberation the easiest and simplest method of sorting this is to create a spacer moving the mount away from the engine. Otherwise its a cut and shut job with Mr welder and Mr grinder and to be perfectly honest I just cant be bothered!

Ive mocked one out of 19mm Mdf and it works perfectly so the next stage is to get some 20mm aluminium bar and make the real deal.

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Can you fit an engine by yourself?

The answer apparently is with great difficulty!! I had a spare hour yesterday so thought I would get the engine and gearbox in and mark out the mount holes ready to drill.

Being the time concious and efficient fellow I am, I thought the best course of action would be to join the engine and gearbox together a la…

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And let the whole lot slip easily into the engine bay. Turns out there isnt as much room to manoeuvre as I thought and I managed to get the whole lot wedged dramatically at an angle between the suspension and the transmission tunnel!

The even better part of this venture was that the engine which I thought was completely drained…clearly wasn’t! And whilst jammed at an angle decided to release a never ending flood of oil all over the garage floor.

In the end I gave in and split the whole assembly. And for anybody interested the method for fitting a zetec into a fury is as follows…

1. Gearbox into tunnel
2. Engine into bay
3. Attach engine to gearbox whilst still attached to crane
4. Attach engine Mounts
5. Finally lower into position

I now need to work out how far back I can mount the engine, before the clutch fork fouls the chassis. Overall not a particularly constructive hour… It does at least however all fit.

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ST power

Just a quick shot to show how the engine will fit. Im surprised how high the zetec engine is, however I test fitted the bonnet whilst my brother in law was over, and it all fits nicely.

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How to remove a flywheel?

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How do you remove a flywheel without the correct locking tools?

As per the picture above you will need something that can hold the flywheel in place and stop it rotating whilst you undo the bolts.

Ive used Uni Strut as its like grownup Meccano and has elongated holes which means it lines up with the clutch bolts easily.

You could use anything, as long as it is long and strong enough to do the job.
You just nees to measure the holes where the clutch cover plate would attach and bolt it on. Then simply wedge your homebrew locking tool either against the floor or under your foot, and hey presto the flywheel is fixed in place allowing you to loosen the flywheel bolts. Simples