1994 - Ford Escort Cosworth - power steering fluid tank

Its interesting, when I was doing a search for Granada Cosworth catalytic converter it doesnt return anything. The only ones listed are the scorpio cosworth ones for the BOB.

I've been looking at exhaust tube / bends kits and will make something :-)

Those are the bits I have (1 and 2) but none of them have cats in them. They are empty boxes.....

Unless the cats have failed and been blown out, or someone has pulled the internals out.

😆😆😆

My M10x1.5 die turned up so used it to finalise the thread profile. It took a very small amount out and left a good fit on a nut

P1070736 by jono_misfit, on Flickr

P1070737 by jono_misfit, on Flickr

I took out the last couple of threads to prevent a stress raiser

P1070738 by jono_misfit, on Flickr

then test fitted the internal from the gear knob

P1070739 by jono_misfit, on Flickr

goes on like so

P1070740 by jono_misfit, on Flickr

But a raw steel shaft is going to go rrange very quickly.

Time for some alchemy

P1070741 by jono_misfit, on Flickr

some detailed instructions..

P1070742 by jono_misfit, on Flickr

Basically clean for 10 mins, in the blue solution (copper selenide) for 10, and oil for 10.

clean

P1070743 by jono_misfit, on Flickr

dried

P1070745 by jono_misfit, on Flickr

Just into the blue

P1070746 by jono_misfit, on Flickr

10 mins in the blue

P1070747 by jono_misfit, on Flickr

rinsed

P1070749 by jono_misfit, on Flickr

de-watering oil

P1070750 by jono_misfit, on Flickr

cleaned part

P1070751 by jono_misfit, on Flickr

its come out OK.

Goes well with the gear knob

P1070752 by jono_misfit, on Flickr

I'm going to give it a coat of matt laquer to protect it, as I think it'll corrode with time still otherwise.

I need to deal with this hole as will let in fumes.

P1070744 by jono_misfit, on Flickr

I have this bit, which has a plastic insert, but doesnt fit my car, but is close enough to use

P1070748 by jono_misfit, on Flickr

I need to make a bracket

P1070753 by jono_misfit, on Flickr

mark out some 3mm ali

P1070754 by jono_misfit, on Flickr


roughly trimmed

P1070755 by jono_misfit, on Flickr

bent some alignment tabs

P1070756 by jono_misfit, on Flickr

and in situ

P1070757 by jono_misfit, on Flickr

and gearstick in

P1070758 by jono_misfit, on Flickr

I think its come out quite well

P1070759 by jono_misfit, on Flickr

P1070760 by jono_misfit, on Flickr

Doing some brum brum noises the gearstick is a massive improvement over the original. No flex, very positive shifting, and just the right length for me.

I kocked some transfer punches up and marked out and drilled mounting bolt holes.

P1070771 by jono_misfit, on Flickr

Plate back up with temp bolts

P1070769 by jono_misfit, on Flickr

gives 25mm clearance to the bottom of the subframe and about 35mm to the bottom of the sump

P1070770 by jono_misfit, on Flickr

used some more transfer punches on the rear and marked the sump guard

P1070772 by jono_misfit, on Flickr

P1070773 by jono_misfit, on Flickr

drilled

P1070774 by jono_misfit, on Flickr

with a second skin the countersink bolt will sit flush

P1070775 by jono_misfit, on Flickr

folded up the rear corners

P1070776 by jono_misfit, on Flickr

P1070777 by jono_misfit, on Flickr

then onto the side stiffener plates

rear sections, marked

P1070778 by jono_misfit, on Flickr

trimmed

P1070779 by jono_misfit, on Flickr

transfer to the other side

P1070780 by jono_misfit, on Flickr

both trimmed

P1070781 by jono_misfit, on Flickr

stitch welded on

P1070782 by jono_misfit, on Flickr

I was struggling to get nice clean welds, and after much tweaking got it running OK but not amazingly.

P1070783 by jono_misfit, on Flickr

in situ

P1070784 by jono_misfit, on Flickr

P1070785 by jono_misfit, on Flickr

I may need to add slightly more clearance around the compression strut rode end

from underneath

P1070786 by jono_misfit, on Flickr

starting to shape the next section

P1070787 by jono_misfit, on Flickr

P1070788 by jono_misfit, on Flickr

getting the front curve set

P1070789 by jono_misfit, on Flickr

P1070790 by jono_misfit, on Flickr

more fettling

P1070791 by jono_misfit, on Flickr

P1070792 by jono_misfit, on Flickr

welded up and tweaking fit

P1070793 by jono_misfit, on Flickr

P1070794 by jono_misfit, on Flickr

front needs trimmed to shape

P1070795 by jono_misfit, on Flickr

We'll see how I get on next sesuion.

I bought them.

I got them from a rally page on Facebook, but I think ATM / Prestige motorsport do them.

great thread this some great fabrication , not sure 3mm sump guard would be any use on the rallies i have done!

Today was a fill in day as I'm waiting for more gas to turn up.

my box of exhaust bits arrived

P1070812 by jono_misfit, on Flickr

I fitted the bar I used to position the rear sump guard mounts, as this is sets the plane for the sump guard that the exhasut has to clear.

P1070813 by jono_misfit, on Flickr

it doesnt fit as is so needs a trim

P1070814 by jono_misfit, on Flickr

Oh, and this is why there is no cat present in it

P1070815 by jono_misfit, on Flickr

cut and cleaned

P1070816 by jono_misfit, on Flickr

cut a 45deg bend in two

P1070817 by jono_misfit, on Flickr

And added a wedge to change the angle of the pipe in two direction, and used tape to temporarily hold in place. This side has loads of space.

P1070819 by jono_misfit, on Flickr


This side does not....

P1070820 by jono_misfit, on Flickr

not quite as bad as it looks here, but still pretty tight round the prop and tunnel

P1070821 by jono_misfit, on Flickr

I bought a couple of weld in silencers, however they are too big for my original intention

P1070822 by jono_misfit, on Flickr

nicely sized to allow the pipe to slot into it for welding

P1070823 by jono_misfit, on Flickr

Because its so tight round the gearbox / tunnel this side I need to make it turn in two directions

P1070823 by jono_misfit, on Flickr

P1070825 by jono_misfit, on Flickr

I was trying to work out what I need to aim the pipe at, so put the silencer in positon where I wanted it to be

P1070826 by jono_misfit, on Flickr

its all very tight

P1070827 by jono_misfit, on Flickr

P1070828 by jono_misfit, on Flickr

P1070829 by jono_misfit, on Flickr

I'm not sure I want it hanging down as low as it is. I need to find some oval silencers, however they don't seem to be that easy to get hold of.

I'll do some searching to see what I can find.

I need to get past the edge of the gearbox so need to make a bubble.

Using tape to work out centre points

P1070830 by jono_misfit, on Flickr

cut on lines intersecting with this and taped together

P1070831 by jono_misfit, on Flickr

and tacked

P1070832 by jono_misfit, on Flickr

goes in like so

P1070833 by jono_misfit, on Flickr

tight, but clears with some room to move

P1070834 by jono_misfit, on Flickr

I got fed up with the tapering wedge under the car, so put in the rear stands

P1070835 by jono_misfit, on Flickr

P1070836 by jono_misfit, on Flickr

Will see how I get on next time I'm in the workshop.

Nice bit of design assembly work going on there - as usual I may add - Anther reason I like mid engine and rear engine cars - no room for that sort of faffing about creative fabrication needed