The Daily

[millworm]

Seeing as i spend just as much time playing with this as I do with my nova I guess it's only right it gets it's own project thread. So on Christmas day last year i crashed my nova in a mad rush to pick up my nan in the morning, The original plan was to fix it back up and get it back on the road but after digging deeper and taking some measurement I decided it was too far gone especially as I wanted to plonk an xe in it the torque would have done horrible things to it. Fast forward a month of getting the train to work (I wouldn't wish rush hour London trains to anyone, Especially covered in grease and oil on the way home) My mate calls me and tells me he heard about my car and he has one I may be interested in as I like my 'old shit'. I went over and saw the sierra for the first time, I was amazed at how clean it was, I didn't hesitate and £350 later it was mine. She was a 1.6 pinto 80 something thousand miles, one family from new, a genuine survivor car. Only a small dent on the wing witch was the only thing on it! https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t34.0-12/10866933_10152512895755846_1622997395_n.jpg?oh=7b2 da5a7f6371f177de94923139949eb&oe=564FA47C
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-frc3/v/t34.0-12/10872432_10152512895700846_2032566399_n.jpg?oh=841 6381cc09a85f345725bcc11610518&oe=564F28EA
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpt1/v/t34.0-12/10887965_10152512895775846_487797129_n.jpg?oh=4ac7 5e7d92ef7b8f8dd4db342e4fd1af&oe=564F7C78

After bombing about in it for a while i decided it was way to standard for my liking so first thing was the ride height I worked a bit of magic and installed a set of mk1 focus coilovers to the front and chopped the rears down a bit and fitted renault master rear shocks. I also had a set of cosworth 4 pot callipers modified to fit my standard hubs.
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/11811444_10154295179442281_1761975603418226878_n.j pg?oh=f0e3089ae1b250cda2f9b2d2f7de7ff7&oe=56AF2EB3

Then i picked up a set of rs2000 wheels for a bargain and painted them grey but I soon got bored of them
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xtp1/v/t1.0-9/11128199_10153986386532281_338328675707414374_n.jp g?oh=f52d4eb4f98ee470fd31e18c165abd63&oe=56B771B5&__gda__=1458255507_7ea5b27da76d21d23e9cad4295087fc 1

Just before I changed the wheels again I was approached in traffic by some bloke who asked if I wanted a cossie interior, so obviously I said yes! I also took the opportunity to install Central locking and electric windows, what a ball ache give me nova electrics any day!

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/11009924_10153885642897281_743441253855359924_n.jp g?oh=370ee0252cc811a4911bbcfba852423a&oe=56EE8BFE
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/11011275_10154068772687281_2579510748052471683_n.j pg?oh=227b175758f0cd787c34791c06ded6a3&oe=56BA5EE5

I binned off my standard spoiler for a more sporty cosworth one
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfl1/v/t1.0-9/11257902_10154081400067281_3287271429712897687_n.j pg?oh=6ce8bc6b4053eb036325f922ec57d157&oe=56E42A7E
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10922515_10154081400097281_8367192696825298195_n.j pg?oh=2da92c7734c9e6f680fd3459afdaa53e&oe=56EB474E

It was around this time the stem seals went on the 1.6 so naturally I tore the engine out rather than fix it and put a 2.0 in lol
I have pics of the swap somewhere but oh well this is the new engine.
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11188440_10154266861917281_4959430307773365723_n.j pg?oh=1743616cac36063cac12e583226b24c4&oe=56E59FE0

And a new set of wheels to celebrate my extra 20 hp Also fitted a cossie front bumper at some point i forget lol
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xaf1/v/l/t1.0-9/11891151_904486752919774_3727235612091987591_n.jpg ?oh=f7edf458b4665cbd223555e1899fa46a&oe=56EF186B

These wheels still didn't do it for me so i bit the bullet and bought some proper ones

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xtf1/v/t1.0-9/11993277_909782832390166_3791315352714871111_n.jpg ?oh=3d8b21755d149509a060f3bdbba80f4b&oe=56F3FBE9

[millworm]

A few pics of me at pod i ran an 18.1 lol nova was better when it wasn't even running right!
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/11260463_912393152129134_5201272942797995001_n.jpg ?oh=133aa18a4adb64ee2c8a616b48212978&oe=56B1B5F9
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/12004129_912391595462623_169493070608379713_n.jpg? oh=1b97ef7ed9da2febf66692f981eb8f8e&oe=56F164A9
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11053260_912405892127860_8925346318989813492_n.jpg ?oh=139d51fb7838592a764c3f396a2e5fad&oe=56E6F372

I was happy for a while I changed a few bits i fitted cosworth rubbing strips as the pov spec ones are massive, i'd liked to have deleted them but they leave holes :(
Old ones and some rather snazzy sandles
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlp1/v/t1.0-9/12079149_10154471201617281_6629225951009606911_n.j pg?oh=67fd1c858f213dfe142c7834bb06727b&oe=56EF9B8D

new skinny ones :)
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/12118879_10154471201592281_6664397504322425963_n.j pg?oh=3d368fc74779b23296da767429bb2b1c&oe=56B741E3

After a while i decided that the car just wasn't quick enough any more. not to mention the mpg is shite so I made an executive decision for engine swap number 2, this one was a lot more involved as I'm going from carb to injection so lots of wiring and swapping tanks pumps ect. also the standard ford looms are really hard to splice compared to xe/let looms!

The Donor not bad for £100 still had tax and test!
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/12002971_10154395991967281_553602301609249300_n.jp g?oh=1adf1afef35456cfe12130167f146177&oe=56E9E17D

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpl1/v/t1.0-9/11990602_10154506913692281_7918216269237687956_n.j pg?oh=3f04ba9d809ca4b68433b5b4c1963a27&oe=56F52C79

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/12027563_10154506913637281_8215020620205825199_n.j pg?oh=156fa17f4db14e64914f1bef7a1b61a6&oe=56F067B5

This is where we are now, in the process of wiring/plumbing in the zetec wish me luck as there is very little support for this swap into sierras
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/11222704_10154548494097281_1269407430491401668_n.j pg?oh=872e4a47f397ba970a153ceb426ca055&oe=56F93992

[Mxcrazy]

Carb the Zetec maybe? Set of webers on there will do the trick.

[millworm]

Carb the Zetec maybe? Set of webers on there will do the trick.

The injection has to stay, need the economy

[chris862]

Good stuff! Sierras are a bit of a bargain :) hehe you just can't compare the fuel economy to the nova, my capri does about 36mpg the nova nearly 50! with performance to match lol, I would be tempted to service the twin choke weber from the pinto and fit it to the zetec, manifolds are available http://i.ebayimg.com/00/s/MTIwMFgxNjAw/z/3QQAAOxyF0pTjYxs/$_35.JPG
but I guess injection might have the edge on economy, have fun! ;)

[millworm]

I'd be lucky to see 25 from the sierra, the plan is to turbo it when the nova is up and running

[Iain]

Sierra is badass, nice daily.

[L14MNP]

Loving the direction of your Saph, mate.
Shame a mk1 Mondeo estate had to die, though! #bumpergaffertapejokez

[millworm]

Cheers guys, it's getting more time than the nova at the moment lol once the conversion Is finished by the end of the week hopfully I'll be full steam ahead on my let rebuild.

Here's a little of what I did today, no off the shelf hoses for these as no one puts zetec in sierras really hahahttp://i271.photobucket.com/albums/jj141/millworm95/20151124_154547_zpshq72qnh7.jpg (http://s271.photobucket.com/user/millworm95/media/20151124_154547_zpshq72qnh7.jpg.html)

And just a pic of how it sits, wiring is almost done. Need to get the fans and wire them in and fit fuel pump,tank and we're nearly there!http://i271.photobucket.com/albums/jj141/millworm95/20151124_135232_zpsjea6w8jm.jpg (http://s271.photobucket.com/user/millworm95/media/20151124_135232_zpsjea6w8jm.jpg.html)

[Steve]

Bloody hell mate, so much for a sensible daily! I've had thoughts about the cali but i just want something reliable, hence leaving the 8v in

[Stuart]

much likes :) especially doing a mod no one else does lol

Zetecs are ace, throttle bodies ahoy...

[millworm]

much likes :) especially doing a mod no one else does lol

Zetecs are ace, throttle bodies ahoy...

Yeah im supprised it's not done more, it'd be a really a very easy conversion into an injection sierra especially a cvh. I'm thinking more a low of a low boost setup and going for 200 brake ish.

Bloody hell mate, so much for a sensible daily! I've had thoughts about the cali but i just want something reliable, hence leaving the 8v in

Haha I wanted an injection engine for economy orginally so that was the thinking behind it. The pinto only done like 20mpg on a good run. And was so as lol

[millworm]

Right, so I finished the conversion off, and it wasn't without its problems... The car needed a diffrent inlet manifold as the mondeo one fouled the engine mount and the servo, so I opted to replace it with a fiesta si inlet that hangs over the top of the engine. The exhaust manifold wouldn't stop blowing for love nor money and after the 5th gasket I just caked it in paste to get a seal (it's temporary) I had a missfire witch was a real pain, I was to quick to jump to conclusions and replaced the coil pack seeing as they're common but had no joy, then replaced the plugs and number 2 did me the joys of shattering to bits and falling in the bore... After pulling the plugs again I found out it was no3 injector, the loom was so degraded it wasn't getting it's earth. I also had major cooling problems, it turned out my water pump impeller spun the wrong way do I changed it for an escort item witch was step one, second was routing the expansion tank into the bottom hose rather than the rad and he presto it worked spot on. I then found out how much of a restriction the fiesta inlet is so then bought an rs 100 inlet witch is the same bore as a 2.0 one and I got myself a fresh injector loom to go with it. I made up a temporary induction system while I find a 1.8 airbox as they sit in the correct place. Just as I managed to get the thing where I wanted it I for some unknown reason decided it needed an lsd lol I got a cracking deal on an xr4x4 lsd disc axle with a full set of konis to suit it even came with a spare diff! Fast forward a couple days and I was testing the diff as you do haha and I managed to snap a bolt clean out the ns engine mount, mainly because it only has 2 of the 3 holes as the mount is for a cvh sierra. So I made up a strengthening plate to stop that happening. So nearly up to speed with where it is now, I always noticed the clutch felt weird could never put my finger on it just weird. Turned out I need to replace my pivot for the fork with an extended item so now I have to pull the box, however I'm seriously considering using the retro ford redrilled 1.8 flywheel. Not only is it lighter but it'll take a pinto clutch with means more standard parts witch is always a good thing.

Cause of my missfire
http://i271.photobucket.com/albums/jj141/millworm95/20151220_145702_zpslm1y2a2a.jpg (http://s271.photobucket.com/user/millworm95/media/20151220_145702_zpslm1y2a2a.jpg.html)
Plug hadnt even seen fuelhttp://i271.photobucket.com/albums/jj141/millworm95/20151220_140714_zpsiauusa34.jpg (http://s271.photobucket.com/user/millworm95/media/20151220_140714_zpsiauusa34.jpg.html)
number2 giving me griefhttp://i271.photobucket.com/albums/jj141/millworm95/20151213_133051_zpssgrozsb6.jpg (http://s271.photobucket.com/user/millworm95/media/20151213_133051_zpssgrozsb6.jpg.html)

Car more or less as it is nowhttp://i271.photobucket.com/albums/jj141/millworm95/20151218_181758_zpswtp3cdir.jpg (http://s271.photobucket.com/user/millworm95/media/20151218_181758_zpswtp3cdir.jpg.html)

Old diff coming out http://i271.photobucket.com/albums/jj141/millworm95/20151226_153752_zpsgainlqst.jpg (http://s271.photobucket.com/user/millworm95/media/20151226_153752_zpsgainlqst.jpg.html)

New inlet, looks the same as the current but runners are much larger so not restriction.http://i271.photobucket.com/albums/jj141/millworm95/Screenshot_2016-01-01-15-05-35_zpscx0j5cll_edit_1453641328566.png_zpsyfxj5g0k. jpeg (http://s271.photobucket.com/user/millworm95/media/Screenshot_2016-01-01-15-05-35_zpscx0j5cll_edit_1453641328566.png_zpsyfxj5g0k. jpeg.html)

Sterengthening/spreader plate for ns engine mount http://i271.photobucket.com/albums/jj141/millworm95/20160123_134852_zpsgglxyc8s.jpg (http://s271.photobucket.com/user/millworm95/media/20160123_134852_zpsgglxyc8s.jpg.html)http://i271.photobucket.com/albums/jj141/millworm95/20160123_140201_zpshud1i1ot.jpg (http://s271.photobucket.com/user/millworm95/media/20160123_140201_zpshud1i1ot.jpg.html)http://i271.photobucket.com/albums/jj141/millworm95/Snapchat-4713306588305483791_zpsaum9zxh8.jpg (http://s271.photobucket.com/user/millworm95/media/Snapchat-4713306588305483791_zpsaum9zxh8.jpg.html)

[cossienova]

Great project fair play. I feel your pain their much harder to mess around with than a nova but then not much is as easy and cheap to mess with as a nova. 95% my saff Cossie used it for 6 months just few bits to finish. Now time to crack on with the nova! Sure I saw your car at one of the ford shows at Santa pod last year.
heres mine after a lot of time and money!
http://i758.photobucket.com/albums/xx221/cossiecapri/FBDB2B80-3CC8-4CB2-98AF-7925BE4842BC.jpg (http://s758.photobucket.com/user/cossiecapri/media/FBDB2B80-3CC8-4CB2-98AF-7925BE4842BC.jpg.html)

[millworm]

Great project fair play. I feel your pain their much harder to mess around with than a nova but then not much is as easy and cheap to mess with as a nova. 95% my saff Cossie used it for 6 months just few bits to finish. Now time to crack on with the nova! Sure I saw your car at one of the ford shows at Santa pod last year.
heres mine after a lot of time and money!
http://i758.photobucket.com/albums/xx221/cossiecapri/FBDB2B80-3CC8-4CB2-98AF-7925BE4842BC.jpg (http://s758.photobucket.com/user/cossiecapri/media/FBDB2B80-3CC8-4CB2-98AF-7925BE4842BC.jpg.html)

Cheers mate, yeah nothing beats a nova lol simple as, I was at a few shows at pod last year so very likley. Love your cossie aswell, looks very smart. When my novas done i'll turbo the zetec and have a cossie rep with cossie powe and noise :)

[cossienova]

That will be cool zetec turbo. My mate had a zetec turbo escort and it went very well. My Sierra was at its best when it was 300hp, reliable and still decent on fuel and u could use the power, you should get that power easy out of a zetec turbo.

[millworm]

Yeah defiantly do able, probably go a bit less more around 230 as I'm only planning on using an St bottom end. My pals escort mk3 turbo is loads of fun, what made me want to do one