MK6 SWB Cosworth YB Conversion!

[Luke]

just got back - now have sump

still raining a bit might get a bit more done

[rover]

All be done by mid week then Luke

Cant wait to see this on the road

Rover.

[Ucof]

me and stu after a hard evenings graft

I assume:

<-- You Stu -->

[Luke]

All be done by mid week then Luke

i have my target and i'm sticking to it

I assume:

<-- You Stu -->

yup, he's the one with the long hair

while i'm on ......... todays progress .......... I degreased the new sump and stu ordered a new complete clutch assy and a sump gasket set

he also went to fords and tried to get a fan cowl but they couldnt get a price as the reg no. didnt match see other post

[Luke]

bit of progress today

got the engine and box back out
mounted the wireing
started swapping the sump and clutch

other things..... ford wont sell the cowl on its own £220 for it with the fans which we dont need and a similar price for a rad £70+vat is cheepest local so far and as the cowl isnt gonna hold us up it can wait for a bit

plan for this weekend is have the engine running

[custom]

good luck with it mate cant wait to hear this beast running whats happening with the body work and wheels/suspension?

[rover]

Wonder why they wont sell the cowl on its own surely its better to make a small sale than no sale at all

Rover.

[Luke]

good luck with it mate cant wait to hear this beast running whats happening with the body work and wheels/suspension?

thats up to stu - its certanly getting a full respray but he's still undecided wheels will be alloys but again not made his mind up and the suspention needs to be dropped 6" to get in the garage so that will be done - the suspention brakes will all get sorted as we go along we're aiming for the ultimate mk6 aim high

Wonder why they wont sell the cowl on its own surely its better to make a small sale than no sale at all

yeah you would think that - i bet the cowl gets damaged in accidents when the fans are fine - if there's anyone who knows another ford branch (we tried parkgate rotherham) that will sell it seperate let me know - other than that its breakers but the cowl wont stop it getting to north weald

[transitandy]

looking very nice m8

[Luke]

Todays progress

new sump and clutch fitted - engine and box back in van

thats the good bit - bad bit - the cossy starter wont fit close but no cigar its a bit annoying as were gonna have to try so start a fresh engine install by bump starting it

and we're hoping to have it started tomorrow if we get that done we should be on target and might have time to experiment with starters

[Luke]

SHE RUNS

Not without hassles tho

fellow forum member mk1 astra dave popped round this morning

haveing a look at the starter we decided it could be a rib in the gearbox casing stopping the starter going in so we pulled out the engine and box - split it and tried the starter without the engine attached
it wasnt the rib in the box but we did work out that the starter would fit on 1 bolt without the stone guard plate on
so back together without the plate and back in the van all wired up and just before we tried to crank it i manually turned the engine over and it wouldnt budge
the flywheel had gone back into the bellhousing
so we split it again and put washers inbetween to space it back - turned ok but ......... there was a banging that sounded like the crank hitting the sump
got a bit worried but realised it was the crank pulley triggers hitting the crank sensor mounting sorted that by grinding the edge off the nut

next wired it all up as much as we could mating between the 2 looms - got the starter solenoid to energise - so with the starter disconnected we energised the pinion lined it up with the flywheel and tightend the 1 bolt holding it on (will sort that later ) then as for some reason the fuel pump allready came on with the ignition we left it
then connected the perm live and the switched live to the cossy loom - thats really all there is to it anyone whos done a BOA loom could do a yb in their sleep

cranked it over with a screwdriver holding the starter still fired but wouldnt run

we then re-wired the fuel pump so it ran off the cossy loom as we suspected that it was cutting out when the pressure was lost, it was the problem and it fired up

only ran for a few secs as we had no water in but all in all a good day

[100 T280]

Cracking job!

[Guy88]

nice one mate

[mantav8]

Good on yer!-great feeling aint' it!

[Luke]

Good on yer!-great feeling aint' it!

oh yes no matter how many times it always makes it worth wile worth being outside all day in the drizzle

jobs left before it can go to north weald

buy radiator
sort out fuel pipes - at the moment they go round the front of the engine bay
pipe up radiator
refit propshaft
fit intercooler - gonna use the standard cossy one temp untill a custom one is made
accelerator cable - needs adapting so its transit pedal to cosworth
finish off wireng (needs a lot of tidying up)
have a new pas pump hose made up to fit cossy pas pump
adapt starter so its held by more than 1 bolt
get exhaust made - planning on a full stainless system
refit front panels

also needs fan cowl - but that wont stop us getting it on the road