Oscar of Markoz

"On todays episode of Australian Cortina ...."
I finally finished the battery cover. Well just a few more areas need rewelding to fill up some holes, but otherwise done.
I made the whole thing from sheet metal, folding and shapeing as I went, using cardboard templates helped somewhat also. Constant measure and remeasure of the original to get the right heights and slopes etc.
Using a tool I made to get the swageing right and trying to replicate the originals swages in the same places.
I also made the lip just like the original to make it look like the battery covers lip is the original, but really the original is under it.
I made up some brackets out of sheet metal also and put some rivnuts in them to secure the cover to. Theres one towards the centre of the firewall on the lip, then one on the back of the firewall on the curve and another behind the bonnet hinge bracket. So they'll all technically be hidden. Either by the Firewall plate that I have to make up, the engine itself or the bonnet bracket.



It was by far the hardest thing I've done on this car so far but I'm very happy with the end result.
I'll have to make a recess of some sort for the intake manifold but I'll work that out once I've tacked up the intake manifold together. That could also cause issues getting it in and out, but I'll see how I go when I get to that. Its a battery cover after all, so should only need to come off when changing batteries.
Next up, the firewall plate and tacking the intake manifold together and full welding the exhaust manifold.

"On this episode of Australian cortina ..."
Pottsie came round and we bent up the new fuel lines which I bought from Rocket Industries. They are 3/8 aluminium. I bought some pipe benders on ebay for $20 and they were pretty easy to do. Worked a treat. Also bought a pipe flaring kit, which does single and double flares. So I double flared the pipe ends nearest the fuel tank to mount the rubber fuel lines too. I also bought some cushion mount clamps which are big enough to run both lines, plus the charcoal canister line which I made from the old plastic fuel line. Cleaned it up and it looks great. The screws that are used for the cushion clamps will be changed as I want to run some nut serts. So I'll replace them later.


I started cleaning up all the bolts I need to get zinc coated also. So I wirewheeled them for now, but I'll deoxidine them all later and get them done. But for now, this is what they'll look like basically. Here is also a close up of the straps for the tank where they needed to be modified to suit the cortina mounting system.

I had to cut more out of the filler neck hole for the boot floor as they breather pipes didn't quite have the clearance I wanted. So I cut it out and touched up all the paint. I cleaned up some vacuum hoses to use for the vapour seperator pipes and got some neat little clamps for them. I ran the overflow pipe also and clamped that up also. Looks really nice I reckon. Although I'll be making a cover for this area to keep any chance of fuel vapour and smell out of the boot area.

And last but not least, this is the fuel tank mounted into its place. The straps run the commodore rubbers to mount it onto the tank. I also searched the wreckers and found a Diahatsu Charade fuel filter mount was the best for my situation. I bent one of the legs on it at a 45 degree angle and mounted it onto the edge of the boot floor and diff hump area. I need better screws for this, as they are still too loose. I'll use more nut serts here. But you get the idea. So thats the tank in place, and the rubber fuel hose to the filter and the return line run. Which still need one more cushion clamp to mount it to the diff hump top. Looks really nice though, like it was meant to be for a cortina. I bought new clamps for the fuel lines but the system used to choose the right size is way off in my books. They are at their max thread and still too loose for my liking. So new clamps have to go on there.


So next up I'll be sorting the bolts and sending them away to get zinc plated. Along with putting together my front suspension. WOOHOO!

Nar its ok. I thought it was more like the rocker cover. But its a different pattern. I just knew that somewhere in my head I had this image of it and I thought it was more like the rocker pattern. Thanks anyway.
I think I'll just get a rocker cover and cut it up to use as my air box top.
 
Thanks guys

Nar its ok. I thought it was more like the rocker cover. But its a different pattern. I just knew that somewhere in my head I had this image of it and I thought it was more like the rocker pattern. Thanks anyway.
I think I'll just get a rocker cover and cut it up to use as my air box top.
 
Thanks guys

More like not enough. hahaha

that looks a bit less complex. and easier to work on by the looks also.
 
been watching too much project binky perhaps? 

I couldn't look at the damn thing anymore, so I made up a new bracket. Much cleaner and simpler.
The stupid things you do when you over think things. 


Alternator bracket next

Great job, as usual. Loving this build.

a couple pics of Tony's N/a 250 leaving the line on its way to 10.90 👍🏻👌🏻💪🏻💪🏻💪🏻

"On todays episode of Australian Cortina ...."
I bought a set of EL Falcon thermofans and after much trimming and cutting of the shroud, along with some plastic welding of spare plastic to create a new shape on the sides, it now fits.





Next up, alternator and electric water pump

I bought some alloy bends, silicone hose bends and t-bolt clamps from Aeroflow to make the Intercooler Piping. Some careful measureing and cutting, some tig welding and here is the end result. 
Here is the video of it
https://youtu.be/4IV5Vhu8TMo

The cortina top mounts (standard) are like that also. They are welded to the top of the radiator and then claw over and get bolted down. I didn't want any mounts to be seen in that radiator support area at all so I went with the different route.
Leo sadly is flat chat with school, even filming he was only able to help me for a small while. I will get him back in there soon though. He has a model car build of his own that he'll be doing soon.
 

"On this episode of Australian Cortina ...."
Bought a new alloy radiator, its a VR VS Commodore unit. Just removed the brackets and plates for the standard commodore thermos. Welded on some brackets to mount it up onto the end tanks.
Also cut out the standard cortina radiator mounting area at the bottom towards the front apron lip and made a new one which sits the new radiator further down. Made some pedestal mounts for the radiator dowels and it works like a champ.
Here is a video showing the whole process

"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. 




Next up, cooler piping and mounting the radiator

"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.







Next up, mount the radiator.

The youtube videos are a completely different ball game compared to the photos. Believe me the videos are much better

"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. 





Next up, The dump pipe and wastegate pipes.

I bought some alloy bends, silicone hose bends and t-bolt clamps from Aeroflow to make the Intercooler Piping. Some careful measureing and cutting, some tig welding and here is the end result. 
Here is the video of it
https://youtu.be/4IV5Vhu8TMo