Puma 4x4 Cosworth

Do you have a Puma that is a project? Do you want to track the progress with your own thread? Feel free to do it here.

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McCloud 85
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Post by McCloud 85 » Sun Jun 19, 2016 8:47 pm

More work done on the tank...

Fuel pump fitting and brackets made

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With that done I turned my attentions to the fuel filler pipe and cap - decided that the filler neck needed to be extended to allow a better/easier connection of the filler hose

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The wiring in the boot was left last time around, now with the tank being done I could finally get this last bit tidied up properly. Also decided to relocate the loom outlet for the tank into the boot floor using a ford grommit I had.

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Also made up the feed line from the pump to the fuel filter which is located underneath the rear passenger seat (where the standard tank would be)

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That's all for now, more to follow.

Thanks for looking.
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Wild E. Coyote
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Post by Wild E. Coyote » Mon Jun 20, 2016 7:28 pm

Pure art! :grin:
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McCloud 85
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Post by McCloud 85 » Wed Jul 06, 2016 5:11 pm

Update time, will try and get this to where I am now over the next few days.

With the tank out and before I put it back in I turned my attentions to the rear diff. This needed its oil changing as I had no clue when it was last changed and had a feeling it was topped up with anything lying around as it seemed to have a leak on the pinion shaft... Which appeared to be a red fluid. I'm guessing transmission fluid.

Because of the way the car has been built I can't get the rear cover off the diff without removing the whole thing from the car.. So spanners out again and got the diff out.

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Diff out I could now remove the rear cover, also realised that the fill plug was rounded and so out with the welder to weld a nut onto it so I could turn it out

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Knowing this won't be the last time I'll need to change the oil I set about fitting a drain plug

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Wasn't happy with just letting the rubber 'o' ring squash against the casing as it wasn't totally flat at the point. So of to my machining friend who managed to mill a flat area and even a small recess for the rubber 'o' ring to make sure it wasn't going to leak.

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Gave it all a clean and bolted back up again - some of you may notice the odd nuts on the diff mount and the old standard diff mount, the rear beam and everything is due to come out again at some point to be overhauled so new nuts, mount, bushes and everything else will be done then.

At this point I was keeping my fingers crossed that the pinion seal was leaking due to the transmission fluid and that with the correct oil I would get lucky and it would be OK. Only time would tell.

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With that done time to get the tank all bolted up and fitted. Gave it a very very quick polish just to make it look like one block colour.

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Tidied the original sender unit as best I could before fitting

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Fitted the breather and sender unit and then one last shot of new vs old!

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Tank fully fitted

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With that done it was filled up with some fuel and of on a test drive.

More to follow soon.
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Post by Wild E. Coyote » Wed Jul 06, 2016 8:57 pm

Can silicone hoses be used with petrol? I know they can't stand the power steering fluid...?
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McCloud 85
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Post by McCloud 85 » Wed Jul 06, 2016 9:26 pm

Wild E. Coyote wrote: Can silicone hoses be used with petrol? I know they can't stand the power steering fluid...?
Those silicone hoses used are fluoro lined which makes them resistant to fuel and oil. Below is a pic showing the inner lining of them

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Hope that helps!
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Post by Wild E. Coyote » Thu Jul 07, 2016 7:09 am

Aaa, I see! Nice job, as always! Out of interes, how much would those two go for and where can they be obtained? I guess I would need to replace mines as well, but the cost of Ford ones is OMG.....
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Post by McCloud 85 » Thu Jul 07, 2016 10:41 am

Seem to remember I got them of eBay. I bought a metre of each which cost for both around £50 I think, not the cheapest stuff but well worth it for reliability and resistance to the elements as they sit in a wheel arch.
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Post by red » Fri Jul 08, 2016 9:15 am

8-) nice updates!
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Post by PumaJay » Mon Jul 11, 2016 8:30 pm

Great project to follow!
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McCloud 85
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Post by McCloud 85 » Wed Jul 13, 2016 10:40 pm

Thanks very much for the comments guys, I'll try and get another update up soon.
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Post by yippeekiay » Fri Jul 15, 2016 4:19 am

:thumbs:
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McCloud 85
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Post by McCloud 85 » Sat Jul 16, 2016 12:39 pm

Quick update to get this to where I am now with it..

Drove to the petrol station.. Filled up. It leaked everywhere!! Now this is my own stupid fault and if you read the details on packets of sealing compounds it gives you all the information you need. I didn't and looking back on it now I'm really not sure why I thought it would work in the first place!

One leaking sender unit.. Basically the blue sealant I had used, is only for small gaps and threads not a gap of a few mm. So as the tank filled the fuel was able to 'creep' and push the sealant out and then just empty on the petrol forecourt. Why I didn't test this at home in the garage who knows. Lesson learnt!


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So sourced a length of viton cord and the glue to seal it together into an 'o' ring and did this

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This fits snugly in the groove on the sender unit and squashed down nicely when bolted to the top of the tank.. Decided this time to test at home.. Turned upside down and filled the tank half full and left for a few hours!

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Result all good this time! Drained the tank, bolted back to the car and filled fully.

I can also report that the input seal on the rear diff is leak free now, so must have just been the wrong oil causing it to seep.

Moving on... For those that might remember when I made my new steering column linkage I had to 'shave' some material of one of the UJ's to stop it binding, whilst this worked fine I wanted to get a more precise/machined UJ made. Back in contact with the company that made the original and they made this

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I also decided to shorten very slightly the end of the link shaft to give maximum clearance inside the UJ

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This has now stopped all binding at this point and just leaves a little rub on the down pipe to sort at a later date. I have a sneaky suspicion that at some point I will need to lift the bulkhead bearing in the bulkhead panel to give a better angle, but for now the rubbing on the down pipe is manageable.

After this I drove it about for a fair few miles, covered around 300 odd miles and during the good weather earlier in the year was even using it daily! Took a couple of pics, forget how wide it is..

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So it was happy driving miles for a while.. Until I got a burning rubber smell on full boost. Quick check on a suspicion revealed the doughnut was knackered. I think this is possibly down to me fitting the tripod through the wrong set of three holes, giving it a slight oscillation as it turned. This was the damage to the old one which hadn't actually been on that long.

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I had a spare in the garage which seems to be a much stronger rubber and hard to flex, fitted the tripod through the other set of three holes and seems to rotate more true than before, so I'm hoping this was the problem.

That's me up to date! The car is still in the air from replacing the doughnut and whilst it is I'm going to fit the front diff plate I've had lying around for a while and maybe a couple of other bits.

Will post any progress.

Thanks for looking.
1 x

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Post by ArtfulHussy » Sat Jul 16, 2016 3:05 pm

Wish I had even a fraction of your knowledge and skills.
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Post by McCloud 85 » Sat Jul 16, 2016 3:44 pm

ArtfulHussy wrote: Wish I had even a fraction of your knowledge and skills.
Thanks very much
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Post by Wild E. Coyote » Sat Jul 16, 2016 6:16 pm

Always insipirational and aspirational read :wink:
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Post by McCloud 85 » Sun Jul 17, 2016 10:31 am

Wild E. Coyote wrote: Always insipirational and aspirational read :wink:
Thanks very much, I'm sure you're giving it more credit than it deserves. It's a dam headache most of the time!
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Post by tuonokid » Sun Jul 17, 2016 10:44 am

They all are Dan! I thought I'd got mine ready for Fordfair and the boot actuator has just packed up....oh bugger!
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Post by grayfox » Sun Jul 17, 2016 11:44 am

This is what you call a proper project thread. I wish I could get so involved with such a project with the knowledge and skills you've proved! Love the above shot showing as you say just how wide she is!
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Post by McCloud 85 » Sun Jul 17, 2016 6:55 pm

tuonokid wrote: They all are Dan! I thought I'd got mine ready for Fordfair and the boot actuator has just packed up....oh bugger!
Barry
It's always the most daft things that go wrong isn't it! Painful! :lol:
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Post by McCloud 85 » Sun Jul 17, 2016 7:00 pm

grayfox wrote: This is what you call a proper project thread. I wish I could get so involved with such a project with the knowledge and skills you've proved! Love the above shot showing as you say just how wide she is!
Thanks very much for your comments. You'll be far richer if you don't get involved with a project like this! I just got a price for 5m of 25mm oil hose for a breather pipe and it's £80! There's always something to buy.
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Post by grayfox » Sun Jul 17, 2016 7:35 pm

McCloud 85 wrote:
grayfox wrote: This is what you call a proper project thread. I wish I could get so involved with such a project with the knowledge and skills you've proved! Love the above shot showing as you say just how wide she is!
Well there's that but then there's paying for labour! Lol


Thanks very much for your comments. You'll be far richer if you don't get involved with a project like this! I just got a price for 5m of 25mm oil hose for a breather pipe and it's £80! There's always something to buy.
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Post by red » Mon Jul 18, 2016 8:43 am

Glad to hear the tank all got sorted :grin: good work mate.
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Post by Brian' » Mon Jul 18, 2016 7:54 pm

She's screaming for a front splitter! :P Well done on the progress, keep it up and really looking forward to see this at Ford Fair :-D
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Post by McCloud 85 » Tue Jul 19, 2016 10:33 pm

Brian' wrote: She's screaming for a front splitter! :P Well done on the progress, keep it up and really looking forward to see this at Ford Fair :-D
I know! At some point it will have the front splitter put back on (a replacement as the original is knackered) and I'm also thinking the F2 spoiler will go back on to to balance the car's look. Yeah will be at ford fair so come and say hello!
red wrote: Glad to hear the tank all got sorted :grin: good work mate.
So am I! At least in not driving around in a bomb now!
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Post by McCloud 85 » Tue Jul 26, 2016 8:12 pm

Little update..

Whilst the car was up on the stands I did a little job that I'd been meaning to get around to for a while. Had bought a strengthening plate for the front diff so it was about time it got fitted. Also gave me the opportunity to get a drain plug fitted like the rear

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Diff plate

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All fitted and back together

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I also at this point changed the engine oil and moved on a FUCHS 15w50 ester oil. Was running a 5w50 before which I believe was a little thin, if nothing else it smells nice!

With that done went out on a drive and car seems nice and smooth still and this time with no burning rubber smell!! So the doughnut is behaving.

Seem to have a wobble on the steering wheel under braking which I don't remember before. I have just had the wheels balanced as a weight must have come off and was giving a wobble between 45-70mph, that's now gone but have noticed this new one. Could be discs but I think unlikely, could be tracking so will investigate.

That's all for now.
2 x

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