Well I started this project in 2006 and its still a work in progress. Here is the original thread: http://www.sxoc.com/vbb/showthread.php?t=231035 (please don’t bump the old thread and if mods could close it please)
I thought I would start a fresh one with a few more constant updates lol.
The plan is to finish the build before my sister’s wedding on the 30th July! The odds are against me but gonna do my best
The original plan was to use a SR20DE engine I had from my Silvia project but due to compatibility issues it was a lot easier and cheaper to use a 2L Zetec. Managed to get the engine and gearbox from a chap who works as Morgan cars in Malvern, the engine was an ex development engine, had never been run and was used only to size it up.
I decided to not use the injection side and the engine is now running a set a twin 45 Webber carbs with Dunnell manifold and management system.
The gearbox and diff are from an XR4i. The gearbox is using a bell housing from a Granarder, we did this as it moves the starter to the other side and runs a cable clutch! This is a lot easier to work with.
The rear driveshaft’s had to be custom made due to running the more modern XR4i diff and the car being designed for a more classic pinto setup, with push in shafts at the hubs and bolt on at the diff. This was done by a local engineering firm who have been very helpful thought the project so far.
We had a lot of pissing around with the engine and gearbox mounts as the chassis was designed for the pinto but with the angle grinder we soon managed to alter the mounts and weld them in place! Also a few structure bars had to be cut out from the chassis to make the engine fit but they will be replaced once the exhaust is in and we know where we have room.
Once the engine was in the project was put on hold for a while due to my job not being secure! I had thought about selling the car but was convinced to just put it on hold until funds became available.
Over the next few years I brought parts as I could afford them! The brakes were first on the list with a set of reconditioned Cortina callipers at the rear with new pads and disks and some new front sierra callipers with grooved disks and green stuff pads at the front. Braided hoses and brake pipes had already been fitted by the previous owner.
With the brakes working the next was the fuel tank and pump! The tank was brought new from Westfield and the pump had already been supplied. This was an easy fitment to do as all the fittings where included with the kit and mounts already on the car.
With the rear end now complete it was now back to the engine bay. The next things to look at was the alternator, had to fabricate a alternator bracket (thanks dad) this hold the original Zetec alternator, it is a lot bigger than needed but it was a new one with the engine so thought best use it and I’m not overly worried about the extra weight lol.
Looking at the starter I had managed to get a sierra one but this was a large starter and did not fit as it interfered with the sump! I had thought about getting a smaller starter but with people telling me horror stories about hitting the sump and loosing oil I decided to look at replacing it with a shallow sump.
There was quite a few available and not a lot of difference in price but I decided to go for the Dunnell one, this was one of the most expansive but it was designed for the lager starter that I already had and used the original oil levels so not pissing around with marking the dipstick etc....
This has taken a while to get sorted due to money and time but I have sent the original off now and I’m expecting the new one middle of next week
Next was the radiator we had to make up some brackets but this was not to challenging and managed to find a use for an old fan from my old S15
That’s all up to date so far. Have more pictures to add but need to get them uploaded.
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being fibreglass it’s not a perfect fit! But we shifted it around and got everything within about a 5mm difference and it’s come out very well 
