The Zetec 'Ropacane

[Serge]

If you want a fairly simple solution for the front, there are kits available. They are marketed for caterhams, but work on our cars (they use the same upright).

I have their solid Powerlite kit (BK23M), but they also have a vented kit, that should fit under a 13" wheel.

https://www.rallydesign.co.uk/product_info.php?cPath=562_563_565&products_id=3914

This is their vented kit. Needs a small mod on the hub.

I have this kit:
https://www.rallydesign.co.uk/product_info.php?cPath=562_563_565&products_id=10509

But I haven't installed it yet, will try to do that in the upcoming week.

Serge

[Chuck Nukem]

Happy new year! Will 2021 be the year I finally get this running?? If the preceding years have taught me anything the answer is...NO! We will carry on regardless!

I am progressing with my dual master set up. I had originally ordered the 74 (longer master) after reading a MC replacement guide years ago. Now that I am fixed on a dual set up, their newer style units are more accommodating. The 75 and 76 pictured are the same stroke as 74, but are much more compact. Seems like everything will fit ok. It will have remote bias adjustment from the dash.

I have also made a dent in the foundry project. I built a little cart to hold everything and made a swiveling lid for the top. I began the cure last week and got it to 600C before it got too late to continue. Once everything is finished up I will take her to 1000C...Casting supplies are being ordered as I write this The cnc machine will be put to use as an oversize router for pattern milling...

I mated the zetec engine to the 352 and have it positioned where I believe it should sit in order to fab up some steel mounts. This way I can take sound measurements of the mount to the chassis for rev 2...

[BDA]

Great stuff, Chuck! 

Did you build a swimming pool to quench your castings? 

[Chuck Nukem]

No budget for a swimming pool...I'm afraid I will have to resort to spitting on them

[TurboFource]

Any issues mating Zetec to 352 transaxle?

[Chuck Nukem]

Any issues mating Zetec to 352 transaxle?

Not currently, but I just have it mocked up with my TC bellhousing. I need to source the correct dowel pins. I haven't mounted the flywheel assembly to the motor which still has its flexplate. Matching the clutch splines will be a problem, but I don't think it is too much trouble to have a compatible center riveted to the ford clutch. Maybe it would be worth searching for an off the shelf clutch disc that will fit. The OEM flywheel weighs a ton...Beyond the other standard zetec problems of the thermostat housing hitting the alternator bracket it looks to be pretty straight forward. Once I get the cad files drawn for the motor mounts I will share that on my zetec thread.

[SwiftDB4]

Unless you have to get vehicle inspections do you need a parking brake? I did Wilwood 4 pot Dynalites all round. Haven't had a parking brake in 20 years. Just leave it in gear and avoid really steep hills to park. Think about 1.75" pistons front, 1.375" rear. With balance bar it really gives effective braking.

[Chuck Nukem]

Swift,

Personally I could get away with running no P brake. I agree it would not be much of an issue. The parking brake on my M3 is about as strong as the grip of an elderly woman with damp hands. (It probably needs to be adjusted) I throw it in gear and go on. With dual masters the likelihood of a complete brake failure is pretty slim.

Here in Texas I had my old 66 pickup pass safety inspection with doors that were inoperable. They seized shut immediately after I bought it for some reason... The inspector had to crawl in through the window and he died laughing about it... What do you think MOT would say about doors that couldn't open?

I am chasing the P brake fixed rear caliper problem because it seems like such a complete design if it can be done... It's the Icarus mentality coming out... When I saw that Wilwood integrated caliper I had to get one to try...Now I am making my own shorter p-brake arms for it...and this is why I won't have a running car til 2025

[Bainford]

Great progress, Chuck. Some proper alchemy there. Exciting stuff.

[RoddyMac]

For the clutch disc, there's a Peugeot V6 disc that is the correct diameter and spline count, but trying to find one in NA is next to impossible.  I ended up using an Escort ZX2 flywheel, pressure plate and bearing, which is closer in size to the Fuego disc, but there's still about a 1/8" of the disc that overhangs the flywheel center depression. 

I had chatted with a local clutch guru about swapping the Renault center into the Ford disc but for some reason it was a no go.  He suggested a mating Toyota discs as the small spline Toyota clutches supposedly have a spline count that matches the Renault input shaft, and the larger discs can be made to work with the small spline hub.  But, don't quote me on this, I never did pick up the Toyota bits to compare.

Another option would be to get an older Escort flywheel and redrill for the Renault clutch, but the Escort flywheel lacks the 36-1 notches on the backside.

[jbcollier]

A Peugeot V6 clutch disc might be the same as used in the Alpine 310/6.  Meca-Parts has them.

[RoddyMac]

John,
That most likely is the one.  I remembered later that skoolsen posted on my build log about the disc:

Hi
I used a clutch disc from a peugeot 605 v6 24v 240mm, this fits the ng3 box and Focus Zetec flywheel/pressure plate.
I did a search in Sachs online catalog and found this among others to have the same spline as The ng3 box.

Magnar

[Chuck Nukem]

Thanks guys! I will look in to the Peugeot clutch.

Roddy now that you mention the Toyota clutch splines matching I recall reading about that. I have a friend who is building an AW11 MK1 MR2 so I may ask to borrow his clutch and fidanza lightweight flywheel to see what I can learn from them...

[Chuck Nukem]

I started working with the thermostat relocation. I think I will try machining this housing and welding an aluminum tube to a flange for the thermostat. I am going to switch to aluminum tubes through the chassis in place of the steel. Hopefully the bending goes well.

[Chuck Nukem]

I've decided to route the cooling along the intake side instead of the conventional under exhaust path like burton does. I think that is more for Zetec elan conversions anyway to rout the thermostat to a place near the front like the TC has.

I am also getting closer to making a starter adapter plate that should use the zetec MT starter with no modifications to starter or bellhousing. I am currently modifying the flywheel to accept the Renault pressure plate and I'm also milling some of the mass from the heavy ford flywheel. I just got a 6mm reamer so I can bore the holes out for the locating pins. I decided to keep the stock flywheel for now to use the crank position sensor. I may be delusional about running the stock ECU but I think it will save time this way. I might have to revert to the stock intake over my throttle bodies for now...

I have the aluminum coolant tubes bent up. I still need to bead roll the tips.

On the brake side I test fitted my bracket and it seems to be a go! I will get the mirror side made and then its on to the rear!