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Zetec into a bay
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Superleggo
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Joined: 12 Nov 2009
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Location: United Kingdom

PostPosted: Sun Jul 18, 2010 9:59 pm    Post subject: Zetec into a bay Reply with quote

Hi

Has anybody put a 2.0ltr zetec into a bay with any success. I have just obtained a 6 rib 091 box and a vw to ford adaptor plate. So the zetec seems the ovbious way to go for a reliable 150 bhp. Has any one got any info. Which flywheel clutch and pressure plate should be used. What about the clutch slave cylinder? or have you got any better ideas on ford engines. Dont suggest the for V6 cosworth as I sold one only 3 months ago as I had not got a use for it!
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steamo
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PostPosted: Sun Jul 25, 2010 9:13 pm    Post subject: Reply with quote

I looked into it, even went so far as buying a donor Mundano and releving it of its engine and entire loom. Unfortunatley the ford adapter that I have has the starter motor on the wrong side for the Zetec so I sold the engine and bought a 2.0 Pinto (can't find a starter to fit that either ha).

Incidentally I don't think the V6 fords fit the same bellhousings as the 4 pots either. Get some pics up of your adapter and I'll see if it looks the same as mine. My build thread has a bit more info on my engine selection woes and some pics of my adapter see here - http://www.vwkd.co.uk/bb/viewtopic.php?t=125
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89rallye
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PostPosted: Wed Aug 25, 2010 11:42 am    Post subject: Reply with quote

I'm thinking about the same conversion only with a 2.2 ST Tdci engine, I have just sourced a renault UN5 box so im in the early stages yet.

I may just take the easy route and put a 1z engine in as its tried and tested.
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Superleggo
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PostPosted: Thu Aug 26, 2010 9:54 pm    Post subject: Reply with quote

Hi

I have just made a step closer and bought a 2ltr Zetec engine. I arrived today and have just hauled it int othe garage. I am waiting for a flywheel to arrive as I plan to use the 1.8 flywheel as it is about 1kg lighter.

I have also just bought a ford spigot bearing for the end of the crank and was pleased to find that it fits the imput shaft of my 091 gearbox. I have not got a bell housing for my 091 box. Does any one know if the bellhousing from a 3 rib box fits a 091 box? I have got this ford to vw adaptor plate but not sure it is ideal as it is for a pinto and the starter looks to be a problem. Will investigae further over the weekend. Anyone know where there is a drawing of the bolt layout of the 091 gearbox to bellhousing bolt pattern as I am thinking of making a complete bell housing? Are any of the vw bellhousings Aluminium or are the all cast iron?
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Alex (FTS)
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PostPosted: Mon Aug 30, 2010 8:55 pm    Post subject: Reply with quote

I've gotta 1.6 bell housing on my 091 so no probs there chap i also run a ford adaptor plate and a 1.8D escort engine (soon to be 1.8TD). I noticed your in Cornwall? I'm in Falmouth if you ever want to pop over and check my bits?
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Superleggo
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PostPosted: Wed Sep 01, 2010 3:44 pm    Post subject: Reply with quote

Alex

Thanks for the information. I am in Liskeard. I will PM you to get some details for a chat.
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Superleggo
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PostPosted: Tue Sep 14, 2010 11:33 pm    Post subject: Reply with quote

hi
I have been collecting a few parts and doing a bit of measuring to see how thing may fit together. I thought I would look at the posibility of using the bellhousing from the Mondeo gearbox and cut it about a bit so that it bates with the vw 091 box less the bellhousing.

I thought this may be a good starting point as it left the starter motor in the correct position which seems to have caused a problem for others who have thought about this conversion. I am using a 2.0ltr black top engine and 1.8ltr flywheel as they are about 1kg lighter and hence make the engine more responsive. I plan to use the zetec pressure plate and VW friction plate. Not sure if these will match yet as I have not aquired all the parts yet to see if the match for size. I am hoping to be able to retaine the Mondeo Hydraulic clutch release system from the bellhousing as it looks like it will be ok but I need to do some more measuring to confirm. I know this will mean converting the clutch peda lto a hydraulic system but I guess this is possible but can't check this at present as my bay is in the paint shop at present.

The diff portion seemed a bit surplus
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Superleggo
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PostPosted: Tue Sep 14, 2010 11:55 pm    Post subject: Reply with quote

The diff section of the bellhousing seemed a bit of a waste of time so I gave it a quick slice to remove the surplus aluminium



A bit of measuring showed that the mondeo bellhousing is 155mm in depth. Would you believe it but with the input shaft sticks out of the 091 box by 150mm and with the offset of the crank on the Zetec and spigot bearing to the engine flange it is spot on. I need t ocheck this again without a beer in hand as I am not normally that lucky!! Happy

Out with a bit of wood to see how things would overlay.


Not a great fit. I thought I was getting too lucky. Still a but of ali fabrication should solve the problem.

I thought I would mock it up in plastersine to get a feel for it


May be easier to mill 10-15mm off the top and weld on a plate to suit rather than make up the missing bits.

Time to measure twice and cut once!!
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Superleggo
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PostPosted: Thu Sep 16, 2010 11:25 pm    Post subject: Reply with quote

I have been doing bit of research on clutch plates but now confused. I measured the imput shaft of a 091 box to be 24 splines 3/4'' (19mm). but looking at some clutch plate websites they list the camper clutch plate as 13/16'' (20.5mm) Having just measured my old one it measures 20.45 mm so I guess this is the modern equivalent as some site list as 3/4'' and others list 13/16''

looking throught the cluch plate book it appears there is no available friction plate 220mm x 20.5mm x 24 splines. Best options seen Audi 90 2.2i at 228 diameter or Audi 90 quattro at 215mm. A quick calculation show that suprisingly the smaller plate will have a contact area with in 3%. I was suprised to see that the 228 plate would have approx 20% less than a 215 plate if you use a 220mm pressure plate. unless anyone knows of a suitable 220mm plate it looks like the are 4 options at 215mm

ref no C915AF, C1095AF, C1038AF and C1623AF I can't find what is the difference so Time for a chat at my friendly motor factor
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Superleggo
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PostPosted: Thu Sep 16, 2010 11:48 pm    Post subject: Reply with quote

a bit more measuring looks like the Mondeo bellhousing could be made to work but talking to a Ali casting firm it looks like I could have a one off bellhousing cast if I make up a timber pattern. At less than 200 this did not seem too bad. I made use the Mundeo one as a trial and the cast of one off if it seems to fit.




Mondeo pressure plate 220mm and camper friction plate 200mm

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jp
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Joined: 09 Nov 2005
Posts: 1976
Location: Chippenham, Wiltshire

PostPosted: Fri Sep 17, 2010 10:57 pm    Post subject: Reply with quote

Some good stuff going on here and 200 sounds a bargain for a bespoke bell.

In answer to your question about the hydraulic clutch there are a few on here that have done this.. now can I find one....


Mr Baker has done it to his EB CLICKY HERE

Keep up the good work and pics coming Grin
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ElusiveStranger
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Joined: 23 May 2006
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PostPosted: Sat Sep 18, 2010 2:55 am    Post subject: Reply with quote

Gotta say, TWO Hundred QUID?
Fill your tecking boots, do it. Followed by grinning yer face off at shows "all my own work mate"

Proper backyard engineering, that's what we love on here

If you're not deft with carving, ask. I'm sure the Plasticine(TM) would be ok though.

Dunno if I'm being condescending here, but Google "Draft" & "casting techniques" "Shrinkage in alloys during casting" or better still, talk to the foundry before progressing.
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Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin
Bugger, missed out on "Live fast, die young"
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