BE 646

[dkp_cobra]

The new engine / gearbox combination is much longer than the 289 with the toploader transmission.



but it is so slim



What should I do with all the space in the engine bay I got now?






Of course, new problems arise. The type 9 gearbox hits with its mounting point exact the cross strut. This must be modified. And the position of the gear lever is much too far rear. This must also be modified and I have to make a complete new transmission tunnel  >:(

[AE 501]

.....and if you start producing a small batch of gearbox tunnels, please remeber to do one for me an my AC engined Ace  ;D 8)

And be happy about your tube in tube solution! 2.6 Aceca's should have a thicker tube wall I think. So well done  ;)

[B.P.Bird]

What should I do with all the space in the engine bay I got now?

Install 100D 762 and a BWCR 12 ?

[dkp_cobra]

I am still alive and sometimes I am working on this project. The new gearbox doesn't need so much space as the Ford Toploader so it's time to close the bulge in the footbox:


rl]
Finally, I got the right rubbers for the front side windows:

The top rear end of the doors hides some wood:

this is the look without the aluminium skin:




I removed the wood and made a new piece out of aluminium:




The result can be covered by the aluminium skin:






Since the new gear box is smaller the foot panels need different sizes. So, making new food panels:

This time I used the right aluminium: AW1050. Normally, I use AW5754 which you can buy at every corner. The problem is that only AW1050 can be formed with hand and hammer. The difference between the old solution:

and the new one is clear.


Fired by this success I decided to make the side panels of the boot again. The last time they were made of 1.0 mm AW5754, this time 1.2 mm AW1050.





The fitting in the curves is much better.

[dkp_cobra]

The old and the new rear inner wings:

and mounted


and the other side

[dkp_cobra]

The old inner fender for the front wheels:




and the new ones

The old mesh will be replaced by a panel

Mounted in the front wheel arch





The old spare wheel cover




was hold together only by the carpet

The new cover is made of aluminium and it's not heavier










Maybe you noticed the hinges are the old ones. So, not everything is new  :)

[dkp_cobra]

Ford Zephyr conrods (NOS) before

and after

shot-peening. I can't see the big difference but I hope it made the conrods a little bit stronger. Maybe it is like homoeeopathy:  you have to believe ...

[dkp_cobra]

I have two valve trains and I try to find the best looking parts to make one which is ok:



After I received the engine back from the work shop I painted it black:



Time to install the missing parts. The mechanical fuel pump will be replaced by an electric version, the adapter allows to use modern oil filters.


Overhauled waterpump with new connection pipe and time chain cover:


Normally, the oil pump is screwed by two bolts to the engine block.

Something to feed my paranoia: the lock wire should prevent the bolts from releasing.



The poor condition of the valve train is normal for the Zephyr engines due to a bad oil supply.


A new construction using fittings from Earl should improve the oil supply.

[dkp_cobra]

Together with the Zephyr MK iii engine I got a set of SU HD6 with electic choke.

I sent them to Burlen for a complete overhauling. Not cheap but the result is quite impressive:




Mounted on the old engine to check space in the car:



Oh, the first carburettor looks out. I have to check this with the bonnet  on the car.

Not much space but should be ok. And enough space for the accelerator pedal.

[dkp_cobra]

I decided to use a relative modern transmission: a Ford type 9 from a Sierra. It's a 5 speed transmission, strong enough for the Ford Zephyr engine and the best: Quaife has a lot of parts to make it bullet prove just in case that it might not strong enough.
This transmission has the big advantage that the bolt pattern is nearly identical to the orginal transmission used in the Zephyr. Instead of 5 bolts only 4 are used and the yoke of the transmission case where it meets the bell housing is a little bit bigger. No problem if you have access to a modern CNC milling machine.
One speciality of the Type 9 transmission is that the selector shaft looks out of the transmission case  at the front. Thus the Sierra bell housing has a closely notch to take the selector shaft. It's not a problem to make a little piece of metall to use it as this notch but it is a problem to weld this to the bell housing since it is cast iron. Since there are no big forces working on this part it can be glued.
Here is the result:

[James Eastwood]

Keep going! It's always a pleasure to see these updates.

[dkp_cobra]

Martin, the distributor doctor (http://www.distributordoctor.com/) overhauled my Lucas distributor


and converted it to electronic ignition from Pertronix:

Together with a lot of small parts the ignition system is nearly finished.

[dkp_cobra]

I got some engine parts back from powder coating. The valve cover

the brackets for the heater pipes and spark cables

and the oil pane

I weld a plug in for a oil temperatur sensor:

Due to the new engine I had to modify the engine mounts (again). But I am sure that this was the last time so I dared to glue it onto the frame.




Mounted (and glued) with the engine brackets:

Gear box bracket:


and a new propeller shaft:

All together in the car:




I had to learn that the flywheel of a Ford Zephyr MK iii engine has a bigger o.d. than the MK ii flywheel. Here you can see a MK ii flywheel mounted on a MK iii engine. The starter wheel doesn't gear into the tooth ring of the flywheel.

With the correct flywheel the fitting is much better.

It wasn't easy to get a MK iii flywheel but finally I got one. At this point I would like to thank June and John from Golden Day Parts (http://goldendaysparts.co.uk/). The helped me a lot with all of these Ford Zephyr parts.

[dkp_cobra]

The floor panels got a rail at the transmission side in order to enforce the strength.

New gear box means new transmission tunnel. This time a full alluminium version.

[dkp_cobra]

The old radiator doesn't look good:


The frame of the radiator is rotten:



I built a new frame


and the radiator was overhauled by a specialist. He added a thermostat switch and an outflow so I can change the cooling system to a closed version.

In order to increase the effectiveness of the electric fan at low speed the fan is surrounded by a box:

The air guild panels in front of the radiator must also be replaced:

The outlet for the fresh air is missing but this will not be a big issue.