Cosworth 2.9litre in my Crewwy

[dickspanner]

Well the rear gearbox mount is now fully fabricated and it has sorted the problem out.

I now have two almost equal distances between driveshaft flange and reference point of 422mm and 424mm, so I am happy with that.

Just got to modify the front cradle mount and I am finished in relation to the engine and the build can continue.

Hopefully I will complete the cradle tonight and get the cradle and rear gearbox mount painted up.

I just hope that these modifications have not impacted too much on all the parts I have already made during the first assembly of the setup.

Pictures to follow.

Dickspanner

[dickspanner]

In this case it was measure 3 times pal.

All tacked together to ensure it works. wip it off and fully arc weld it up, not my favorite kinda arc welding, in confined access and upside down. If I don't get splatter in my ear hissing away, it either goes in my hair or down my sleaves, then you end up doing the ow f**k ow f**k dance untill the splatter cools down on your skin.

Few more jobs to do on the cradle yet, weld the exhaust mounts on back of gearbox mount, then rebuild the support cradle and hopefully engine and box will be dropped for the last time. Cosworth power sponcered by hokey kokey engine installers

Dickspanner

[jamesc76]

you end up doing the ow f**k ow f**k dance untill the splatter cools down on your skin.

Cosworth power sponcered by hokey kokey engine installers

Dickspanner

Oh that made me giggle

glad its coming together now for you !

[dickspanner]

Engine in full glory, back out again.



Gearbox mount is not right, have to modify it again, this time dropping the holes that mount to the rubber mount on the chassis, as the engine was at an angle, pushing the exhausts downwards which I was not happy with.

Feel free to join in at the chorus.

You put the engine in,
the engine out,
in,
out,
in,
out, you don't half fanny about,
You do the hokey cokey and turn around,
thats what a cossy v6 is all about

Oooooooooh hokey cokey cokey
Oooooooooh hokey cokey cokey
In,
Out,
In,
Out,
You fanny all about.

I have to larf, or I will cry, up in 4hours for work.

Sheeeeesh.

Dickspanner

[toomanytoys]

Seemed like a brill idea all them months ago... eh? will be ace when its sorted though....

[dickspanner]

Oh don't get me wrong pal, I am enjoying the conversion and if I do get made redundant, I will have to look into alternative sources of work and income and may open my workshop to the public and do work for people. Either on stock vans or conversions.

Conversions which are easier will be a sinch. This is a hardcore conversion and I got told over and over again before I started, but I am still enjoying it, just miffes me off when I do a school boy error. I should imagine a straight forward V6 without all the cosworth electronics would be easy.

I will be at my lock up each night next week and hope to get the assembly in its final stage, so the progression photos will hopefully show a radical change.

Dickspanner

[mrted]

This was interesting any progress?


John

[dickspanner]

Project has been on hold over last couple of months due to work commitments. Not been to my lock up for weeks so I have made no progress. Work have now cut my hours down to 40 per week so may end up doing a 3.5 day week and doing some excessive work on the crewcab over the next month.

Will post any progress photos and descriptions when I start work on it again.

Keep checking back and the thread will become live again soon.

Dickspanner

[dickspanner]

Well to force myself to start working on the crewwy, I installed the engine back into the cradle etc and took it off the ramp to free the ramp for one of the other projects which is ongoing.

The crewcab is now on the floor and I am not too keen on how low it is, the exhaust has about 5 inches of ground clearance and the exit pipes have about 4.

I will be there tomorrow night and will give it a wash and clean out and make a list of the next set of jobs that need doing.

I need a certificate of conformaty for my T4, does anybody know where I can aquire one at a resonable price.

Dickspanner

[dickspanner]

Well I went to my lock up and started the bling install now as all the mechanical stuff which is all finished needs to be bolted on and I am just going to work through it slowly to make sure it is all on and correct.

Here is a piccie of the engine installed.



More photos to follow as I finish more of it.

Dickspanner

[ringo]

Well I went to my lock up and started the bling install now as all the mechanical stuff which is all finished needs to be bolted on and I am just going to work through it slowly to make sure it is all on and correct.

Here is a piccie of the engine installed.



More photos to follow as I finish more of it.

Dickspanner

Is that it then? Nearly finished?

It looks awesome.

Good job - cant wait to hear it....

Ringo

[dickspanner]

I wish it was pal.

The Engine and gearbox are finally installed correctly. I am now starting to plumb it all in and allthough I had made all the parts to allow me to plumb it it I still have a verybig list of jobs to do. I am going down tonight and hopefully by close of play all the water system will be plumbed in, the driveshafts will be on and the fuel plumbed in at the engine side of things.

I still have the beast of a wiring harness to fit, I am not happy with the exhaust, the gearlinkage needs shortening, accelerator cable needs to be resolved and then the mechanical rebuild can begin, new brakes, bearings, bushes, etc etc, the list goes on but if I can break the back of the install I will be happier.

Alarm, stereo, electric windows, electric mirrors, spotlights, topbox needs painting and full custom interior needs installing, then hopefully and finally an MOT.

Will keep this thread live and updated untill the thing has passed its MOT and on the road.

Dickspanner

[jamesc76]

Might be a big list of to do's but its getting there buddy be worth it in the end!

[dickspanner]

Worked on crewcab tonight and did some of the pain jobs like mounting the boot lid ram as I lost the original position due to removing the battery tray and spent ages drilling out old sheared bolts from towbar to enable them to be retapped and finally lining up the rear bumper so it lined through with swage lines in bodywork, so not much progress on engine install, but annoying niggly jobs out of way.

Managed to mount air filter in the process of doing boot lid so there was no clash with boot lid gas strut mechanism.

Dickspanner

[dickspanner]

Well my evil, erm mental, just plain unbalanced side has kicked in again, just as things were moving along nicely and it was all coming together I have gone and purchased a full LPG conversion kit for the cosworth motor. So this has set me back again. After reading another forum I post on for the BOA cosworth engine, many, many, people have said they would like to do the conversion but because of the plenim chamber of the inlet it is a bit risky and people have heard reports of the side of the chamber blowing off. NICE.

It has come with a tank that sits in the spare wheel well of the scorpio so I need to buy a scud missile type tank to install in the cubby hole under the load deck unless I modify all the front end and put a support frame in place.

It is being dropped off tonight so I will take a piccie of the full kit and post it up later.

I must admit, I am completly bonkers , will I ever learn, the current conversion is hard enough, and I have just thrown a big spanner is an already rough running plan. I think I will get the crewwy MOTed first running on normal motion lotion, before I stick some gas on it.

I will do a lot of research in the matter first before I install and thread it all up so people can see what I have done, mmmmmmmmm, rather compulsive purchase when I look at the whole conversion but I am sure it will be worth it in the long run, especially on a 2000mile trip to south of France and back.

Dickspanner