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D.P.N.S the other mk3


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decided it may pay to run a oil cooler  and i had one sitting on the shelf (may be bigger than i needed but it was there) i struggled to find somewhere for it ..i am trying my hardest not to just cut the shell up and remake stuff...so i removed the inter cooler trimmed 2 tabs off the oil cooler an mounted it on its side.

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remounted the intercooler for the 3rd time ...even had room to just snake the oil cooler hoses out by the intercooler outlet.51328551_oilinter1.jpg.635af30009c5d109e7ecaca9deb7f668.jpg

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i remove one of the grill mounting plates an decided to mount the airfliter there ..by the headlight an under the slam panel.. should get plenty of col air an i can make a shield to block it off from the engine bay heat..

the filter is a k&n with a 6"inlet lol....i knoe its over kill but i ha 6 filter adapters (6" - 2.25" )from the 6 cylinder cortina  (was going to make trumpets out of them.......lo dint  work)

also may need to move the battary tray to the rivers side so ecided to use some heat ducting for the turbo to filter .....should work well.

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  • 3 weeks later...

i made a list today of what needs doing and its huge....man its huge.

so i decide to try and finalize each part as i go...

so 1st up was the fuel supply .

i finished welding the pump mount face up.

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the tank needs to sit lower in the car so the pump has room under the floor and doesn't get squashed ...i worked out it need to sit about 40mm lower.and lucky for me i have some 40x40 so i cut some the length's of the rubber tank pads and welded them on and then glued the pads onto them.

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the filler neck needed to be extended as well

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the end of the filler is stuffed

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so i cut from a spare tank.......yes 40mm longer

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that was welded on and even tho i trust my welds i also learn from my mistakes so i took the time to seal all welded areas and check for pump clearance ..i also put the factory sender unit back in with the feed pipe cut and bent over

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the tank straps needed to be made longer .

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so did the tank strap bolts.

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fuel pump back in for the last time..breather run to the filler neck.. fuel feed and external filter added and a short fuel return....these will go to the hard pipes once they turn up and are made.

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and the tank all mounted

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next up was the thermostat housing replacement

because i don't have a thermostat and i wasn't sure what rad i would end up using i thought i would just grab a Davies Craig 90 bend and just make the base out of 10mm alloy. ..i drilled all the holes about and tapped them all so i can have adjustment if needed.......didnt drill all the way through....lol

but thats that done and the top hose should nice and easy ....apart from needed the turbo water out runnig into it as well.

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  • 4 months later...
  • 2 weeks later...

I was about 99% done with the wiring from rear end to bulk head ...till I hit the hazard switch.... it didn't work ....I turned the key off...shut the garage door.... that was last weekend.

just having a play with the engine bay loom with what's going to go where and start laying it out 

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and I thought I would have a quick look at the hazard switch  ( thought I might have left a earth offf) turns out ut was a power wire....

temporary power to one red wire

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fucking bang ......hazards are go

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also couldn't get the heater motor to do anything other than be on or off.

and seeing as I only want demist I decided to rip it all out .

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screwed and riveted the heater box to demist so it won't move

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..removed all the controls and shit

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and going to replace with a simple switch........1 step forward 2 steps back ...but may as well do it now

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waiting on some parts to finish the wiring on the inside and under dash..

so thought I would get a few things done elsewhere. 

had some old carrozzeria speakers with ......stuffed speakers

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so I fitted some cerwin vega 4" speakers. with some sound deadening..gave them a clean and even got the carrozzeria lights to work.

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that led me to that parcel shelf trim....its stuffed and in a few bits .

20220115_083715.jpg.857cdd698fc53413371aeaef234d2757.jpgbut bloody hard to find another one so with some thick card and duct tape I remade it.

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I had a spare rear seat back in the same colour as the actual seats I have for the car 

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so I covered the parcel shelf

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cleaned it

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test fitted the new carpet

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but I still have driveshaft hoops to do so that will have to wait for now.

but next I think ut will be the roof lining....have no idea what I'm doing here but what's new...   it does feel very brittle 

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maaaaaaaan what a mission sorting the roof lining out .the edges are all ripped and brittle. 

but I got there in the end ...shit loads of spray adhesive.. and then a coat of black to make it all one colour.

it's not mint but is is so much better.

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then thought I would put the carpet back in and rear seat as well as parcel shelf....looks good with all the cream on cream action and some chocolate brown.....even got the neat lines and parishes lined up.

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I've got some mk5 Giha seatbelts for the old girl.

and doing the rears ..there are holes in the Parcel shelf . but I made top plates and doubler plates.  I went 80mmx800m and 5mm thick .

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I put them in with 2 rivets in opposite corners. 

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cut out a section of the Parcel shelf tray  and mounted them..the top plates helped space them up a wee bit as well so they work smoothly. 

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even git the factory mk5 covers so they got cleaned and went in.... only held in but 1 screw ...but look cleaner.

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all the lower mounts for the seatbelts and buckles are all there and just have bungs to remove.

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al the rear seat base is held in with 2 PK screw 

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so I drilled it out and waked some rivnuts in there.

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got the rear speakers mounted...some more clips for the Parcel shelf.. the seat back and base properly mounted and the seatbelts in place......I'm very happy with how it's coming along.

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before I can get the carpet down for ever...

the last thing to get in place are driveshaft hoops.....

so I bought 2 kits .

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then cut them up as no matter how much you play with them they would drag on the ground...and I would like to get them mounted and done.....and just remove a section be able to get the driveshaft out.

front 

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rear ...even tho it's like 500mm from the other one...

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front mounted right by the boxing inside .....got 2 holes lined up with factory holes and had to make 2.

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the rear was fine and on the floor....just had to remove sound deadening for bolts

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and both inplace....

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after @Raizer pointed out that the cert man will want plates ontop of the floor as sandwich for the driveshaft loops I changed both front and rear ...

and then got the rear part of the carpet down for good.

then I moved my attention to the fuse box....

I had already got shot of the factory one when I reworked all the wiring ..

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I also had moved the wiring around a few time  and blown some and while I was changing them I couldn't help buy notice that the wire in the back were becoming lose and sometimes getting pushed out all together and I can't be fucked with that.

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so I bought one for a boat/race car.

way more sturdy and even has LED to let you know what one is blown...

also easy to add wires when needed.

so I mad a panel for it.....and finally hot the front section of carpet in for good.

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and the fuse panel you can see in the center under the dash.......and my miss 11 calls the Flux capacitor 

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