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Hurmeez last won the day on June 28

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About Hurmeez

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  1. Hurmeez' 1977 Mk2 Escort Estate

    Once I had the hole approximately the right size to fit the box, I started to roll the edge over to meet up with the new tunnel. I could do it the easy way and trim the two panels to fit and just weld the outside corner, kind of like this, (I know this is a diff tunnel but use your imagination) but I don't like the hard edge it gives. I'd rather make it nicely curved, more like a factory shape would have been. So that's what I've been trying to do. I did the same on the tunnel side as well. Just a slight flare for now until I confirm the two shapes will match up. Which turned into a bit more flaring and shaping which turned into this... As you can see I kinda cocked up the trimming at the back edge but it's nothing a welder and some scrap steel won't fix. You can also sort of see how far off the new tunnel is from the brace loop. This was really bothering me because there was no way I'd be able to mate the two up neatly so something was going to have to change. I've come up with a plan. I'm going to get rid of this stock(ish) hoop and replace it with one that fits the tunnel better. I will build the new hoop out of 6mm plate and put it in a position that will still help to brace the floor, as well as being the top half of the driveshaft loop. The bottom half will also be made of 6mm plate and will bolt up with four captive nuts on either side of the tunnel to the top half. The bonus will be that the captive nuts will be hidden underneath the seat boxes so there will be nothing sticking up through the floor to get caught on anything. Before I can do any of that though, I need to get rid of the current loop. Praise jebus for spot weld drills. To think when I put it in I thought "fuck I hope that never has to come out. It'll be a hell of a mission." Never mind that then. With that out, I could get the tunnel as close as possible. It's getting close. It's not perfect yet and it still needs some dicking around, but it's getting close. While I had it clamped in place, I figured I should check the heater clearance since I want to keep running the stock unit if I can. It's tight. Bloody tight. As in it touches the tunnel just before I can get a bolt through into the mount. And you can imagine once there is some carpet over that, it's not going to fit at all. Hmmmm. I'm going to cross that bridge in a bit. For now, I'm going to keep trucking with getting the tunnel fitting the firewall and floor perfectly first.
  2. Hurmeez' 1977 Mk2 Escort Estate

    Ten days since the last update! Time flies when you're busy as fuck... School has just finished and I've been trying to focus on my exams but in between I've still been working away. Actually, I have to come clean on something. The adapter plate hasn't been coming together quite as smoothly as I made it look. The positions of the holes that receive the locating pins were very slightly out, along with a couple of the other holes. They were close enough to fit with encouragement on the cardboard but it was in no way acceptable to put it into steel. So that means the dimensions I found online weren't quite right for the engine side, however, the bolt pattern for the gearbox side was dead nuts on. It was absolutely doing my head in trying to find the right dimensions for the engine so I decided to take a step back for a second. The one option that I wasn't considering was staring me in the face. I could just measure the damn thing myself. Obviously, while vernier calipers are ok for guesstimations, they aren't nearly accurate enough to get the precise hole positions that I need. Now, while I'd love to say I just slapped the engine on the CNC mill table and swept in the XY coordinates, in reality, I haven't actually got around to designing and building the machine yet, so I took the engine down the road and asked one of the local machine shops nicely to do it for me. They were more than happy to and I'm going down tomorrow morning to pick it up. Between me being annoyed at inaccurate online drawings and making the decision to outsource it, I wanted to do something to get the engine and box together in the meantime to help me start mocking up the new tunnel. So I found some 16mm MDF and drew in a few bolt holes as accurately as the vernier would allow. Then I drilled them out well oversize and chucked a couple of bolts through where they'd fit. Once it was reinforced with a couple of clamps it was solid as (ish). It did feel bloody good to at least get it looking close to how it should. With the engine and box all together I slung them both roughly into place. Sits a nice long way back But not far enough obviously. The bell housing was fouling the tunnel and not allowing it to sit as far back as I want it to. So I bit the bullet and made a small hole into a really bloody big hole. This made everything fit much nicer. This is the box roughly in position with the shifter in 4th. Even with the stick in the position most likely to foul the hand-brake, there is plenty of space for activities. Also note the stock Escort boot in place. I reckon it'll be cool to have everything looking close to stock until you pop the hood. While I was in there with the grinder out I started to look at where the new tunnel would meet up with the existing one. Due to the way we replaced the side panels of the tunnel last time, there was going to end up being quite the patchwork quilt of different panel plug welded to each other over and around the tunnel brace hoop. I wasn't happy with the thought of this so I pressed on and cut even more of my tunnel away. Hey remember when I said this? Yeah me neither...
  3. Hurmeez' 1977 Mk2 Escort Estate

    That could be very serendipitous. I have a mate who's driving up from Invercargill so he may be able to pick it up for me. Let me know if anything comes of it and I'll see if I can organise for him to swing round on his way up.
  4. Hurmeez' 1977 Mk2 Escort Estate

    And as promised, the photos of the head. So as you can see, it is definitely in a bit of a state. What was left of the oil was solid as tar and the lobes were absolutely much worse for wear. I'd hate to think what the bottom end looked like. So for now, I'm still on the hunt but not overly urgently.
  5. Hurmeez' 1977 Mk2 Escort Estate

    Shit happens mate. No hard feelings whatsoever. Like I said, there'll be plenty more chances.
  6. Hurmeez' 1977 Mk2 Escort Estate

    What a bummer. Got to zebra and found the car fairly quickly. Was presented with a head that looked awful for our trouble. I'll put a picture up tonight once I get home but if the head was that caked in crap then the engine was obviously abused over its lifetime and wasn't worth getting. Bit stink but such is life. There'll be more fish in the sea.
  7. Hurmeez' 1977 Mk2 Escort Estate

    Well that was short lived. The car must have been scrapped between when @1963 AP5 looked and today cause it ain't there no more. We're heading over to zebra manuka now because there's supposed to be another one over there. Anyone still keen can meet us there.
  8. Hurmeez' 1977 Mk2 Escort Estate

    So the adventure begins. I'm heading in to the pick a part now. Wish me luck
  9. Hurmeez' 1977 Mk2 Escort Estate

    I started making good progress on the adapter plate over the last few days. I used a couple of drawing I found online to merge together and make a rough template of the plate. I used the laser cutter at school to zip it out of heavy card. This is what I got. I wasn't sure as to what size the holes for the gearbox bolts should be so I marked their centers and offered them up instead. It all looked good so I worked on to version two. Which gave me this: It's all looking really good. The plan to sort out the locating dowel at about 10 o'clock has two different options. First, it is a steel dowel pressed into an alloy block. Therefore, if I hit the alloy with some gentle heat from a heat gun I should be able to fairly easily pull the dowel out and ignore it. There should still be plenty of support from the plate without it and it would mean I could bolt the lot up easily without complications. The second option is to bore a blind hole on the back side of the plate about 5mm deep to sit over the dowel. Then drill a through hole from the front to accept the bolt from the gearbox. Assuming I use 12mm plate that would still give me 7mm of thread engagement which on an M11x0.7 thread would give me 10 threads engagement. Or if I used 16mm plate it would be ample thread engagement. The advantage of the first option is the simplicity. I don't have to do any tricky boring and so forth. The disadvantage is I lose the small amount of support the dowel provides, and it means any engine I bolt up to will need to first be modified slightly. I would prefer to keep the engine and box as factory as possible so if I ever have to replace either then it will just be a bolt up job. So obviously I'm leaning toward option two but any input is welcome. In the meantime, I'm going to keep tweaking the outside shape and finetuning the hole positioning in my spare time. On the other front, I made good progress on the new trans tunnel. I finished drawing it up, Then got it cut out and mocked up. It looked good so I transferred the shape to 1mm steel and cut it out. I left heaps of extra around the edge to give me space to trim and fettle because cutting shit off is much easier than adding it back on. Once it was all fully marked up I took it to a friendly neighbourhood workshop with a big brake and tweaked it into shape. Once I got it home I chucked it in the car to quickly see how it would look. It looks pretty smart if I do say so myself. Obviously it's sitting way high at the moment and needs heaps of trimming but the overall shape looks really good. I'd be lying if I said I haven't considered leaving it up there and slamming the car to the ground a la @pe-arce's Mk 1, but I think the bitching stance it would give me wouldn't be worth the grief. In a spare hour or two I also quickly knocked together the gusset that goes between the chassis leg and firewall on the driver's side. I went from the dimensions from the Ford Escort Rally Prep book and folded it up out of 2mm steel. I made sure to seam weld the chassis rail to the inner wing before I welded in the new gusset, then masked the parts where a weld would soon be and gave it a quick spritz with primer. And here it is all welded in. And painted up. I'll get on to the other side later on. It's all marked out ready for cutting so it shouldn't take long now that I know what I'm doing. The next update should hopefully involve a car with a big hole where the trans tunnel should be. We'll see.
  10. Hurmeez' 1977 Mk2 Escort Estate

    Looks like it'll be easier to plan to head down next weekend. Turns out I'm not as prepared as I thought. It should give people more time to figure out if they can help out or not. I'll keep everyone posted over the next week as to any updates.
  11. Hurmeez' 1977 Mk2 Escort Estate

    Ok thanks mate, I'll bear that in mind. I'd be aiming to get there as they open to give us the maximum time but even if people rock up during the day to help out it would help heaps.
  12. Hurmeez' 1977 Mk2 Escort Estate

    So I'm starting to look seriously at how we're going to pull this engine from the car at pick a part. Dad and I pulled my current motor in a couple of ~8 hour days so I'm thinking four or five of us should be able to pull it in a day fairly easily. I have a mate who is keen to come and help but the more the merrier. Tool wise I have a full Bahco socket set and other assorted tools. We found the handiest tool was the impact gun but it's air powered so I won't be able to bring that. If someone has a battery powered one then it would make our lives much easier. I'm looking at heading down on a Sunday at the moment. I'm free any Sunday but I'm currently looking at next weekend being the 5/10/17. I know @1963 AP5 is keen and he said @bigfoot and @Threeonthetree might be able to help as well. Is there anyone else that can lend a hand? If so when is a good day for everyone? Hell I'd even go down this Sunday if people are available. Any suggestions are welcome.
  13. Hurmeez' 1977 Mk2 Escort Estate

    Once I had that all buttoned up, I turned with giddy excitement to attempting to fit the gearbox into its tunnel. I began by starting to remove the gearbox mounts from the tunnel, which, if you'll cast your mind back a few posts, were fouling on the box. Initially, I started by using a spot weld drill but the big sloppy MIG welds that old me had used were proving to be too much of a pain in the ass so I chose instead to cut around the whole area with a slitting disk and resolved to weld in patches later on. I neglected to take pictures of all this. I then started to hoist the box up into position once more to see how it would fit. It wouldn't. It fouled on the sides of the tunnel, the clutch arm, and part of the bell housing. Even if I was to beat it with a sizable persuader, it was still going to be too tight for my liking. Which means I really only have one option. I've no other choice really. Or I suppose I could make a new tunnel that will fit it (and future proof it too). Yeah, that's probably the best bet considering how much it costs to hire a skip bin these days... So I whipped this up: It might look like one of those fancy Chinese fans right now, but if you can find yourself someone with a really really big hand, then you have a super lightweight, eco-friendly, and super cheap new transmission tunnel. I would have preferred to have a nice straight line from firewall to shifter but I was forced to put a small kink in it. Ten points to whoever can guess why... Unfortunately, my friendly giant that was holding it for me grew attached to it and ran away with my nice new tunnel, so I have been forced to start making another one. That or the first one was only 1:5 scale and it was actually my hand in the picture. Sorry if I ruined the illusion. I took a quick break from the tunnel though because my head has been chipping away at the adapter plate in the background the whole time and there was one thing that was driving me bonkers. I finally decided there was nothing for it but to mock my engine and box up and see for myself. So I got my fancy little locator that I had prepared earlier and slid to two pieces together. Sqeeee!! The excitement!! Now the thing that had been bugging me was this: Both Alex and Steve ( @yoeddynz, and @Transom) said that one of the bolt holes lines up perfectly between the rotary bell housing and the engine. Now I'm not saying they are wrong in any way (they actually have their motors and boxes together which is a step or two ahead of me), but according to my measurements and the drawings I have found online, this simply isn't true. None of the holes line up perfectly from what I could gather. So I finally had a look for myself. I got the engine and box leveled up in all planes and slid them together with my locator in place. This is what I found. The hole that I believe lined up nicely in each of their setups looks like this in mine. To avoid embarrassment I also made sure to check all the others and none of them lined up either. Now as far as I can know, all rotary bell housings use the same bolt pattern so the fact that they used RX7 boxes and mine is RX-8 shouldn't be the issue, however, I have been known to be wrong in the past. It may have been possible that the bolt spacings were adjusted slightly with the new Renesis rotary in the 8 versus the 13b in the 7. I don't know. I do have a plan to move forward from here though. The biggest bummer is the fact that the holes are very close but not close enough. It makes it very difficult when you get fasteners trying to occupy the same place in the adapter plate at the same time. But like I said, I have a plan. It is just not particularly easy to convey through text and without pictures. I'm going to try to find a way to illustrate it for you but for now, sleep easy in the knowledge that I'm pretty sure I can
  14. Hurmeez' 1977 Mk2 Escort Estate

    Time for another wee-hour tale from old Uncle Hurmeez then... I began Monday morning with finish welding the front inner wing repair. This quickly turned into Monday afternoon but the main point was that I got the bastard finished. Proof of finishing said bastard: But it simply wouldn't do to leave it as it was. And so I set to with the grinder and brought the shiny back out of it: Unfortunately, I wasn't able to get into every spot with the flap wheel and so the back side of the big vertical weld remains unground, along with some of the welds near the bumper mount panel on the inside. However, I feel I have been a very good boy this year and I'm hoping to find a power file in my Santa sack this year. If so, that will make short work of any more cleaning up I need to do. For now though, I was happy enough to give it a quick prime to keep the rust away and call it done. While I was in the vicinity, I noticed another hole that I made while I was butchering the battery box out. It had been there long enough so I set to filling it. It was a nice simple patch which made a nice change of pace from the rest of the work. Sweet. If you didn't know, you'd never know.
  15. Mk2Marty's 1976 Escort Moredoor Discussion

    Looks like you've got some work on your hands then mate. Good luck!