big block to go in ashley's zephyr

[mygasser]

today we welded the coilover brackets to the axle as well as tabs for the rear brake pipe and flexi's. the across the axle hardline was made and fitted, we just have to bleed the brakes now and that's another job finished. we also sorted the setup for the alternator which will be almost the same as when i fitted the first ford v8 in this car, a 351 cleveland. we drilled the lug nut holes to 19mm/3/4" to match the fronts and the existing wheel nuts ash' has. we're pretty much at the point of making 'the list' of jobs left to do. we must be getting there, lol.
neil.

[mygasser]

the exhaust 'u' bends arrived today so getting the exhaust started was first on the list. the flanges needed the slotted holes slotting some more inwards to line up with the manifolds. then the 'u' bends are 2 1/2" and the manifolds/flanges are 2" so after cutting the angles for each side they needed reducing by 1/2". some thin pie cuts and welding later they were welded to the flanges. we retrieved the exhaust system we took off 2 1/2 years ago (it pays to be a hoarder) and ash' hung it back in place leaving just a short section to be made to join the new and old. ash' filled the rear axle with lsd additive and gear oil. after finding a long bolt the alternator was hung on the side of the engine and slid back til the pulleys all lined up and a measurement could be taken for the spacer it needs. the adjuster bracket we found here will bolt straight to a threaded boss on the water pump as if it was made for it and a short bit of flat bar will provide support for the long bolt so it's doesn't bend.
we then made 'the list' which surprisingly was only about a dozen items left to do.
neil.

[mygasser]

we got the downpipes made today, well almost. we're waiting for a pair of 2 1/2" flanges for the driver's side, one for the downpipe and one for the system. they come as a pair with a gasket and nuts and bolts for under £11 so not bad. also the alternator brackets are made so we can measure up for a fanbelt now. 11 jobs left on the list.
neil.

[mygasser]

the last 2 flanges arrived today so the exhaust is now done, tick. we sorted through my 'pile' of fanbelts and found a new one that fits, tick. the rocker covers, rockers, pushrods and inlets are stripped off of both engines and all the gasket faces are cleaned up on ashley's ready for new gaskets and the weiand inlet to go back on, 1/2 a tick lol.
neil.

[mygasser]

after flipping the weiand inlet over today we realised it's one of those small runner inlets for 'economy'. except it's not really as the small ports only go about 2 1/2" in then there's a rounded step up to the full runner size. so we cleaned the gasket faces and drew the gasket port size on it. bl00dy hell, the head/gasket ports are just over 1/2" taller and 1/4" wider. also the ports squeeze in about 3/4" in where the pushrods go through the inlet casting. after checking there's loads of 'meat' there so 2 hours later the ports are full size which must increase power by about 30hp without the extra it being a 'performance' inlet to start with. definately worth the effort. here's some pics today including ports before (showing the sharpie line where the gasket is) and after porting. oh, and a few coats of silver wheels and it'll be easier to keep 'nice'.
neil.

[mygasser]

today we took the exhaust downpipes off and wedged them up ready for paint. from experience the method we use is to get it vertical-ish, jam my heat gun in the bottom then start spraying the heat proof paint after 30 seconds or so. it get's baked as it's applied, and seems to last a lot longer. the white painted headers on my anglia stayed nice and bright white the whole time i had it.
also ash' set to on the edelbrock chrome rocker covers with some autosol so they're nice and shiny now along with a test go on one of the back wheels. the new conversion uj arrived but when the large side was offered up it seems the cups are 1350 size, doh! so the plan is use 2 cups from a 1330 joint i have but swap in all the new needles from the wrong size cups. what a palava.
neil.

[ScottyDave]

Is it one week left?

[mygasser]

Is it one week left?

we have loads of time, it's not one week until tomorrow
neil.

[mygasser]

lots of reassembly this afternoon. it's looking much better, we now have to decide if we use the ready made fe plug leads as is or cut them to proper ocd lengths and recrimp them, lol.
neil.

[mygasser]

just thought, it's a close run thing but this is the biggest of it's 3 v8's.... so far. it's had a 350, a 351 and now a 352, lol.
neil.

[mygasser]

my ocd couldn't handle those too long plug leads so i've ordered a pack of 9 (one spare) terminals from ebay for under a tenner so they can be cut to length.
neil.

[mygasser]

IT'S ALIIIIIIVE! WOOHOOHAHAHA!
we got lots done today and there are more ticks on 'the list' which is always good. we have added to it though as we thought 'fit the flip front and reconnect the lights is kind of important, lol. ash' is still out there painting the rear axle so it's dry for tomorrows session. radiator fitting and propshaft making are the 2 'big' things left to do. we'll know once the rad's bolted in place if we have what's needed hose wise, if not it'll go silicone hoses from rally design on monday. oh and ash' has to get an urgent order in to real steel for a carb kit (it's leaking everywhere as the seals have gone hard) an air filter and one other thing i can't remember what......... lol.
anyway it runs and sounds really sweet so a good £450 worth, as long as the box works of course
neil.

[mygasser]

the new rad's mounted and it clears the flexfan by a good 1/2". the back of the fan's about 1/8" from the crank bolt and alternator pulley but as revs pick up the blades flatten so those gaps will increase. we measured up for silicon hoses (black) and ally joiners so i'll get them from rally design. we even found a steering wheel boss that can be turned down and threaded for ashley's red flake steering wheel he got for his birthday 2 years ago, lol. lastly today we bled the brakes, now we can free off the front calipers.
neil.

[mygasser]

today we got the propshaft made, the new conversion uj fitted and then painted it. then the 'found' boss was turned down, drilled and tapped for the 3 retaining bolts (stainless allen bolts of course) and then fitted with the new red flake wheel.
neil.

[mygasser]

the silicone hoses are cut as required and fitted, then the system was filled with water (it'll be swapped for antifreeze after running up to temp' to check for leaks). the pcv valve and grommet from the old rocker cover is now fitted and after adding a vacuum fitting to the inlet a hose was connected up. we fitted the propshaft and lastly bolted the horns and relay back in place.
we now have the carb to rebuild, the flip front to fit and connect the lights, cut the ht leads to neat lengths and check the trans' fluid once we've run it through the gears a couple of times. oh and ash' will get all ocd polishing the body and wheels..... because he can, lol.
neil.