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Well after the engine was in place I fitted
the new Radiator and now it was time to start on the CBU.
I visited a local scrap yard and
removed the complete heater from a Mk. II Fiesta.
I made up a blanking plate and fitted two rubber
bends bought from Tony Stafford. The heater was fitted to
the Central Body tub before the tub was placed on the
chassis.
At this stage I also fitted the handbrake
lever.
And the Sierra rubber sealing gasket for the brake handle aperture,
using a specially made up frame.
The exhaust system was made up using various parts, including the front
part of a new Sierra system, which has the benefit of picking up the
existing support bracket underneath the gearbox.
The Rear Section. I fitted the tank temporarily,
mounting it on rubber, to gauge the positioning of the exhaust.
I bought a new K&N Sierra fuel injected engine air filter kit and
modified the brackets to install it in the position shown in the
photograph. I hope the air flow meter works in this position!
Having spoken to some of the owners at Stoneleigh this year, I had heard
that the new Sports fuel tank was prone to give problems when the fuel
level was low as it drained away from the intake pipe.
So I had the tank
modified to have a 2cm deep about10cm square sump welded in place with the
outlet pipe coming directly out of the bottom of it and with a side extension
available on which I mounted the fuel pump.
I also fitted the sender
at this stage. I then fitted the tank to the chassis again.
I fitted the CBU according to the
instructions in the manual, having glued on the chassis felt
previously.. and fitted the scuttle support frame in
place. I haven't smoothed out the seems in the CBU.
As I am doing a
complete strip down, to paint the Falcon.
This photo shows the engine management control
box sitting on top of the CBU.
It's final position will be here
underneath the battery box. I have already fitted it's cradle.
It was found that the brake cable could not be attached
to the brake without removing the transmission shaft so I've left that
meantime.
My next job was to fit the brake
servo unit and couple up the brake pipes to the brake balance
valve situated on the chassis.
The braking system could then be completed with all of the piping fitted
and the master cylinder and servo in place.
I fitted the pedal assembly after
altering them to the specifications in the manual.
The steering shaft was altered and fitted
next. I renewed the nylon bush and alloy ring where it fits through the
CBU.
I found that the steering shaft was
fouling the alternator on this engine set up.
After a quick phone
call to Bernard Telford who had installed the same
engine and he informed me that I would have to make
up a plate to raise the alternator
about 3cm higher.
The bracket I made is shown in the photograph and uses a
spare tapped hole on the engine adjacent to the original three tapped
holes as one of the originals cannot be used.
The EFI engine certainly fills up the
engine bay. One thing I did add from the Sierra was the
radiator expansion bottle.
I had to reduce the seam on the rear
of the CBU to fit the boot.
I fitted the new flush fitting fuel cap and the hose to the tank and as I
felt that I might need access to the fuel level sender,
I cut a hole above
it and fitted a screwed plate over it.
The stainless steel plates and brackets for fitting the grill had not been
sent with the kit but JBA kindly sent them on and I then assembled and
fitted the grill.
It really did give me a buzz to see
the Grill in place.
I still have a few things to do yet
in the engine bay. Sorting out this engine management loom for a
start. I laid out the entire wiring set-up from the Sierra and tried to
understand it. So far I have isolated the engine wiring and the rest
can wait until later.
Robbie visited me and brought his car, which was a great inspiration to me
and we kept referring to it while I planned the next stage of the build.
We kept popping out to see how this and that was fitted. Just where
does this engine bay dog leg bolt to.
Please
Note
Just in case anyone thought that a
TSR tank would fit a Sports, they are different.
This is the TSR tank in
the photo below, which is larger than the Sports and does not slope on the
rear.
Robbie
Well that's it for this month. Look back in
January to see what Doug has been up to. Wings, doors, and maybe the
windscreen frame. Remember the wooden windscreen tip. Meant to take Doug
up my wooden screen, it is 50mm lower than the new sports, but he has got on a lot further than
I expected.
I am looking forward to seeing him again. Robbie.
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Safe Driving All the Best Regards Robbie 
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