'72 Bay - Ford powered - Pinto coming out, Zetec going in.

Wilfred · Darth Admin Joined: 13 Nov 2013 Posts: 366

That looks good. Did you also use the subframe from the donor car?
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

steamo · Posted: Sat Feb 09, 2019 10:00 pm Post subject:

It's s ford capri crossmember which I used for the pinto. Needed a bit of tweaking to fit the zetec though. I had to make some new mounts, although i managed to chop up the capri pinto mounts and utilise them too.

Exhaust is all made now, clutch release bearing worked out. Mainly plumbing left to do. Fuel and coolant. I hate plumbing... oh and wiring. I hate wiring too...

Pics to follow.

I have to say I think if I'd been starting from scratch I'd have been very temptedto have been following the diesel and upside down gearbox route too. It looks best of all worlds to me.

steamo · Posted: Wed May 22, 2019 9:40 pm Post subject:

Keep forgetting to post up. We're all up and running again, pretty pleased with the setup overall. Its fine in pretty tidy. If I thought it was quick before, its flying now. New rad setup is working soooooo much better too. Not calculated it yet but fuel seems like its lasting forever compared to the pinto.
Few little finishing touches to do but went through another MOT couple of weeks ago so just getting some miles on it now before Le Mans next month.

jp · Posted: Fri Jul 26, 2019 4:27 pm Post subject:

Any updates on the Zetec? still going well ? Did you make it to LeMans?

Have a question.. how are the noise levels in the van? I'm finding my diesel just too noisy.. done a few motorway trip now and the drone from the engine is horrible. Not sure if a new exhaust set up will resolve it or I need to go petrol which I think will be a bit smother and more suited to the gearbox.

Cheers
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

Wilfred · Darth Admin Joined: 13 Nov 2013 Posts: 366

jp · Posted: Mon Jul 29, 2019 9:30 am Post subject:

Hmmm that's interesting I can defo hear it on tic over not massively but still noticeable. Anything over 2500 rpm and you're shouting to the person sat next to you. I've plastered the inside of the van with sound deadening and have a very short zorst going straight into a single pretty big back box from a Sierra diesel. If I flick van into neutral when doing 60/70 then noise levels are great so defo engine noise Sad

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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

Wilfred · Darth Admin Joined: 13 Nov 2013 Posts: 366

I have had that too, at first.

the reason was that some parts of the engine (coolant outlet on the head) was hitting the chassis of the van. So the noise/vibration was transferred directly to the van, which made a massive amount of noise.

I cut out the section where the engine hit the van (where originally the gearbox is mounted at the highest point) and I used the original hydraulic engine mounts.

Quite as can be. REally the only noise I notice is the wind or the rubber on the road.

Maybe check if your engine is hanging completely free exept from the mounting parts? Is everything rubber mounted?
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

jp · Posted: Tue Jul 30, 2019 10:21 pm Post subject:

Pretty sure everything is rubber mounted but I will go through it again when I get back from hols... Wife gets annoyed when I start tinkering when we're away in it Happy

great to know you're running quietly so there is hope

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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

Wilfred · Darth Admin Joined: 13 Nov 2013 Posts: 366

yesterday, I did a nice trip of about 160 km.

On the way I was thinking about what you said, so I paid extra notice to engine noise. Turned off the radio and started listening. At 80-90 kph, on the highway there is absolutely NO engine noise at all.

The only thing I hear is the rolling of the front wheels, and a bit of wind of course. I am thinking of covering the cabin floor and wheel arches with dynamat or something, cuase wheels rolling is the only thing I hear.

Whish I could give you a ride to let you hear what it sounds like. :-)
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

steamo · Posted: Sat May 23, 2020 5:07 pm Post subject:

Long overdue update.

Zetec is going great, Le mans and back was awesome, did nearly 30mpg and that was keeping up with my mates T5 and a Vivaro on the motorways all the way. Only problem was a tired starter motor that wouldnt play when warm so we had a few push starts which was a little embarrassing especiallyin the queue for the tunnel... replaced that with a small high torque jobby and its spot on.

Cooling was always fairly marginal with the pinto but now even in high load situations on hot days it'll sit below 90 with no fan.

JP it's quite when driving, I often have the wife and boy in the back and it's fine to talk. It's still got a nice noise to it though. I have zero sound deadening in the van too. I can thoroughly recommend the conversion if you do ever decide to go petrol.