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Motor & Gearbox
I have bought my motor / wreck.  Its a Duratec from a Ford Focus 2L.

Ah my lovely wreck.  My wife doesn't understand the attraction of a wrecked car and the magical Duratec just sitting there without a scratch.

It's just about ready to Pluck the motor out.  Thanks heaps for Deans help who had the wreck moved to his house and did heaps of preparation work before I arrived to strip the big bits out.  Thanks heaps mate your help was absolutely invaluable.

Dean is also Making a FMS clubbie with a Duratec, however he has decided to incorporated a Silvia LSD IRS.  hmmmmm :-) IRS.

When friction is your friend.  The wife is less than half the weight of the motor and gearbox, and I was needed to guide the motor down the ramp and into the shed.  Also being on the alert if it decided to do anything it wasn't supposed to. 

Ah look at that.  The duratec can't wait to jump into the front of the Clubbie.

I saved the tyres from the wreck as well.  They had only done 12500 Km so are OK for my first rego.  Lots of other bits were also salvaged.  Some things like the struts, power steering rack, electric power steering motor and pump etc. will be "Swapped" for bits that i need from the wreckers.  That's the theory anyway.

Mystery #1

This was in the top of the gear box.  Don't know what this does yet. 

Motor speed sensor.

Don't need it.

Mystery #2

The one down the front was connected to the Gear selector.  Thus it's going to send info to the ECU about the gear selection, starting in neutral or Park and not allowing starting in 1,2 or Drive. 

Don't plug it in, you don't want to send any info to the ECU about the Gear Box.

 

Mystery #3
Now if you have a look at the top there is another plug.

Don't plug it in, you don't want to send any info to the ECU about the Gear Box.

 

Mystery #4

OK this one I think is the speed sensor to feed the vehicle speed back to the ECU and then the Dash.

Yes it's the speed sensor.  Runs off a 26 tooth sprocket.

Here is some information about the size of the duratec.

 

 

   
This gear box is actually from a Toyota Corona.  Believe it or not it actually is the same gear box the Toyota Supra. It's a W58 and the ratios are great.  Nice spread low with a very all 5th for cruzing.

 

All wreckers know the supra boxes are great and are priced accordingly, usually $660.  However some wreckers don't know that the Corona Box is the same.  I picked this one up for a fraction of that price and the shift feels nice :-) .
Click on the gear box thumb nail to see the approximate dimensions.
Chassis Mods for the motor and the Gear Box.  

 

 

 

   
   
   
Standard old motor mounts.

Mackay mounts and 3mm wall with 25 X 50 RHS.  Motor is very firm when all welded up.

 

Passengers side misses by at least 1mm after I rerouted the dipstick.

 

Making the Engine Mounts

I don’t have drawings however I’ll go through the process I used.

Making the 6mm flat plate Engine mounts.
Take the dip stick out of the engine block
I used paper over the bolt holes and a pencil and did a rubbing over the actual positions of the bolt holes.  Like you did as a kid with a coin under paper to get the etching of the coin on the paper.
This gives you an exact representation of the bolt holes positions.
Then I drew a shape around them that looked as though it would work ensuring It would leave enough material for the diameter of the bolts plus approx 6-10mm more.  (Technical Hay) 
J
At this point I fiddled with the Position of the dip stick tube and “made my template work around it”.

RHS
The RHS is 50 * 25 * 4 wall to memory.  It is think walled anyway.

Mackey Mounts.
The Mackey mounts are used by many and readily available at any “Blackwoods” or similar shop.
I simply turned the round steel to a size that it would both          
-Suit the Mackey Mount
-Suit the 25mm width and allow for the weld.

Putting It Together
OK now I put the motor and box in the chassis in position.
Bolted the engine plates into position.
Put the Mackey mounts and round steel and bolts on the chassis mounting plates.
Did a few length calculations and Angle calculations.
Cut the RHS, and ground to suit
Stuffed one side and repeated process

Welding
Tack welded “IN THE CAR”
Removed and welded it completely.

The start of the Fuel Tank.

It's only 25L to keep the weight down and eliminate Fuel Surge.  May have a problem with the Targa Tasmania or the 12 hour Bathurst races.  Ah well what's the likely hood of that really being a problem anyway.   :-)

What a pain in the but.  I have to dodge the Panhard Rod. get the angles correct and allow for the Focus Fuel pump that is approximately 150mm at the top.

Yes it looks bent and it is.

Your friend and mine the grinder with the aluminium cutting blade.

 

It's a bit deceptive.  The tank has moved forward.  I have approximately 25mm clearance from the Panhard Rod to the tank when the tank has 10mm cushioning under and behind it.

 

Thickening plates for threads and you can see the baffle in the top that will be slot welded.
Testing the tank.

20psi. plus.
5% expansion allowed.
Tig Welded.

You can see the plumbing coming together here.

And the steering as well.

Duratec

Dellow

Supra is a reality

 

CLUTCH STUFF
I decided I wanted a very simple clutch arangement and didn't mind adjusting it when required.  So I went about manufacturing a simple bell crank and pushrod assembly.  Of cause it uses Spherical bearings, and ball bearings on the centre bolt to keep it all smoooooth.  The bell crank has adjustment if I require more throw.

 

 

I also had to shorten the original Y arm in the gearbox to make it work with the Dellow ball pivot position as it has now been moved from the original Toyota position.
In the top shot you can see the filler.  I've put in inside the rear compartment for the moment.  Mainly for ease of filling and manufacture at the moment.  The clamp came from the Donor Vehicle.

You can also see the charcoal canister and the fuel tank in the back ground.

 

Love my EuroSpeed Oil Filter housing.

From Brisbane.

The original sender won't fit.  Just pop down to supercheap and grab one off the shelf.  I went to Enzed to get the plug for the other hole.  Perhaps later, it will go to a sender for a oil pressure gauge.

 

Oil filters are any that take a 20mm thread.

Thanks very much for that.. its nice when people appreciate the trouble we go to on these parts.

The thread is 20mm, you should be fine with any of the following filters:

Ryco part

Height Overall

Seal Diameter

Seam Diameter

Thread

Z142A

80mm

66mm

87mm

M20-x1.5-6Hmm

Z155X

83mm

98mm

105mm

M20-x1.5-6Hmm

Z411

86mm

66mm

71mm

M20-x1.5-6Hmm

Z429

86mm

66mm

71mm

M20-x1.5-6Hmm

Z436

66mm

66mm

71mm

M20-x1.5-6Hmm

Z445

65mm

63mm

68mm

M20-x1.5-6Hmm

Z495

76mm

63mm

82mm

M20-x1.5-6Hmm

Z547

86mm

63mm

68mm

M20-x1.5-6Hmm

Z57A

79mm

85mm

97mm

M20-x1.5-6Hmm

Z79A

76mm

63mm

82mm

M20-x1.5-6Hmm

 

 

 

 

 

 

 

 

   
   
A better view of the set up.

Everything is also sealed up for good.

 

Gearing Calculator                
                   
Tyre width   205 mm     Blue areas are calculated   Diff 4.11 Nissan Pintara  
Aspect Ratio   60 %     Yellow fields are entered   Gear Box W58 Supra or Corona
Wheel Diameter   15 inch              
Tyre Diameter   627 mm              
Motor Speed Gear Gearbox Ratio W58 Driveshaft Speed Diff Ratio Wheel speed Wheel Circ Road speed Road Speed  
rpm     rpm   rpm m metres/min kph mph  
2000 1 3.28 609.76 4.11 148.36 1.970 292.20 18 11  
  2 1.86 1075.27   261.62   515.27 31 19  
  3 1.27 1574.80   383.16   754.65 45 28 At 100 Km/Hr. RPM in
  4 1 2000.00   486.62   958.41 58 35 fifth gear will be 
  5 0.78 2564.10   623.87   1228.73 74 46 2713
                     
4000 1 3.28 1219.51   296.72   584.40 35 22  
  2 1.86 2150.54   523.25   1030.55 62 38  
  3 1.27 3149.61   766.33   1509.31 91 56  
  4 1 4000.00   973.24   1916.82 115 71  
  5 0.78 5128.21   1247.74   2457.46 147 91  
                    K/hr split
6000 1 3.28 1829.27   445.08   876.59 53 32 difference from gear prior.
  2 1.86 3225.81   784.87   1545.82 93 57 40
  3 1.27 4724.41   1149.49   2263.96 136 84 43
  4 1 6000.00   1459.85   2875.23 173 106 37
  5 0.78 7692.31   1871.61   3686.19 221 137 49
Top Speed (Ignoring Drag !)                
6500 5 0.78 8333.33   2027.58   3993.37 240 148  
                   
Speedo Drivegear Calculator              
(using tyres/diff from above)         Worm Drive      
Axle revs/km   Driveshaft Revs Speedo rating   gears ratio    
revs/ km   revs/ km   rpk ratio          
507.73   2086.79   637 3.276   5x19 3.80    
        675 3.092   6x20 3.33    
        1000 2.087   6x22 3.67    
            Best Match?