Jump to content


Photo
- - - - -

My TF Cortina Project


  • Please log in to reply
194 replies to this topic

#181 Outback Jack

Outback Jack
  • Member
  • PipPipPip
  • 1117 posts
  • Reputation: 277
  • Location:South West
  • State:WA
  • Car:XG Outback Ute

Posted 13 December 2015 - 09:57 AM

Awesome work mate.
Everytime I check in something cool is happening.

Sent from my GT-S7583T using Tapatalk


5f0679eb-c1e0-42e1-b938-f63b5cd59a98_zps

 

 

 


You Can't park that Holden in MY Driveway.......................This is Ford Country.

 

 

I had my Ute raised when everybody was lowering theirs so I could drive over shit.

A Country Ute need to actually be able to get over a speed hump... or it's no good for the farm.

 

 


#182 MNTL.XD

MNTL.XD
  • Member
  • PipPipPip
  • 721 posts
  • Reputation: 984
  • Car:XD Fairmont/ XB

Posted 21 December 2015 - 07:53 PM

I love this build. The work done so far is awesome! You almost make it all look too easy mate!

#183 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 02 March 2016 - 03:53 PM

"On todays episode on Australian Cortina ....."
 
Ok, work around home has been very busy since starting up Tough Garage. Been doing a heap of work on a MK2 Escort. It pays the bills (for the cortina) so no use complaining.
 
But I did manage to get some tedious work out of the way and that was to full weld and smooth the turbo merge collector. After Tig welding and MIG welding to fill in small area and then deburring it all, I have a finished product and it looks awesome.
 
I welded all the inside joins and smooth them off and all the outside also, then made some clearance for the bolts and nuts that go through the flange. Took alot of time, but I'm very happy with how it turned out.
 
turbomergecollector1.jpg
 
turbomergecollector2.jpg
 
turbomergecollector3.jpg
 
turbomergecollector4.jpg
 
turbomergecollector5.jpg
 
Now, I can move onto full welding of the rest of the turbo manifold. I managed to get a mate who works at Plasmaman, to help out with a custom fuel rail as modding the one I had turned to **** and I wasn't 100% happy with it.


#184 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 25 September 2016 - 02:27 PM

"On todays episode of Australian Cortina ..."

 

Finally finished full welding the turbo manifold. I made it harder for myself (rookie mistake) because I didn't allow that much pipe coming off the header flange plate. So getting the tig into the back of it was really tight. I ended up having to buy a long thin alumina cup and that got the job done.

For added security and to smooth off the outlet I welded the header flange to pipe edge from the inside of the pipes also as the pipes were just alittle smaller than the header plate port sizes.

I smoothed all the welds off and it should look the goods in heat coating once I'm all done.

 

turbomanifold12.jpg
turbomanifold21.jpg
turbomanifold31.jpg

 

The lack of updates is of course due to me being flat out with Tough Garage jobs now. But its good when I find a spare moment here and there to work on my own car.

 

Next up, pressure test the intake manifold, make the throttle body elbow, mod the new fuel rail, make the dump pipe and external wastegate outlets. Should be fun.



#185 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 01 November 2016 - 04:12 PM

"On todays episode of Australian Cortina ..."
 
Managed to finish modding the fuel rail. Cut off the old feed and return pipes and blocked them off with very small peices I cut out and tigged on. 
Cut the 2 ends off and welded on some weld on male bungs. Turned out really good. Will probably re-tig weld the slight sink back that the weld left behind and regrind it to make it look smooth and factory.
Another peice to the puzzle.
 
fuelrail1.jpg
fuelrail2.jpg
fuelrail3.jpg
 
Next up, finish the throttle body elbow.


#186 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 15 February 2017 - 04:26 PM

"On todays episode of Australian Cortina ...."
 
Made a Throttle Body Elbow. Bought some cast alloy elbow at the closest size I could get to the throttle body. Then bought some 10mm alloy plate. Designed some templates out of cardboard to great the flanges. Took quite a bit of work to shape these. Between hole-sawing the centre holes and cuting it out and filing them to shape. Then Drilling and taping threads to suit some grub screws which I then cut down as they were too long.
Once the flanges were made, I had to make a small cut on the elbow peice and tigged the lot together. Then filled smooth the welds to give it that factory cast look. Needs alittle filler welding here and there but otherwise its done. I'll also weld the inside lips and burr them smooth to give a smooth transition for the air.
 
TBE1.jpg
TBE2.jpg
TBE3.jpg
TBE4.jpg
TBE5.jpg
 
Next up, I'll either mod the Throttle body and have it ready to go with all its fittings etc or make a start on the Dump Pipe.


#187 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 31 May 2017 - 09:08 AM

 
EP6
 
Check out the other videos in this series.


#188 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 20 July 2017 - 07:20 PM

 
EP7


#189 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 04 September 2017 - 03:48 PM

"On todays episode of Australian Cortina ...."
 
I bought a CX Racing intercooler a while back and I was at the stage where I could install it. 
I had to cut some metal away from the support braces for the radiator support so that the cooler ends would clear as well as the silicone hoses. 
I made some pedestal brackets to mount the bottom bolt bungs into, so that it sits in place the same as a radiator would. 
I used some 1" grommets so that theres no metal on metal on the pedestals. For the top I bend up some 4mm alloy into Z shapes and used some rivnuts to secure them to the bottom of the radiator support. Its solid as a rock and works a treat. 
 
intercooler1.jpg
intercooler2.jpg
intercooler3.jpg
intercooler4.jpg
intercooler5.jpg
 
Next up, The dump pipe and wastegate pipes.


#190 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 15 September 2017 - 03:03 PM

"On todays episode of Australian Cortina ...."
 
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
 
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.
 
dumppipe1.jpg
dumppipe2.jpg
dumppipe3.jpg
dumppipe4.jpg
dumppipe5.jpg
wastegatepipe1.jpg
wastegatepipe2.jpg
 
Next up, mount the radiator.


#191 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 25 September 2017 - 03:00 PM

https://youtu.be/bHrjbBVeQY4

 

EP9



#192 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 05 December 2017 - 07:41 AM

https://youtu.be/M9NmxP78VfA

 

EP10



#193 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 12 December 2017 - 12:11 PM

https://youtu.be/6Y59YxnHr2s

 

EP11



#194 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 04 January 2018 - 05:16 PM

"On todays episode of Australian Cortina ..."
 
Did some modifying of the Throttle Body. It had these 2 pipes coming out of it which were for vacuum signal and sucking engine fumes from the rocker cover to the throttle body. 
I deleted them and also needed to fatten up the inlet area as the silicone hose reducer was alittle loose for my liking. Plus the T-bolt clamp was wider than the standard lip area of the throttle body.
I ended up buying a small peice of 2mm thick alloy tube, sliced it in half cause the diameter was too small. Added 2 small filler peices and welded it onto the throttle body. 
I added a bead of weld to the end of it so it stops the chances of the hose coming off 
under boost. 
 
TB1.jpg
TB2.jpg
TB3.jpg
TB4.jpg
 
Next up, cooler piping and mounting the radiator


#195 Oscar of Markoz

Oscar of Markoz
  • Member
  • PipPipPip
  • 132 posts
  • Reputation: 122

Posted 15 February 2018 - 02:29 PM

 
Video on the Dumppipe and Wastegate





0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users