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TimmyA's 93 ED Falcon 

 

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 Post subject: Re: TimmyA's 93 ED Falcon
Posted: Sat Apr 29, 2017 12:35 am 
Technical Contributor
Offline
User avatar

Age: 27

Posts: 3704

Joined: 27th Sep 2006

Gallery: 20 images

Ride: ED Falcon

Power: 133 rwkw

Location: Leeton
NSW, Australia

Better late to reply than never!

The bland door is the motorised door that does the hot/cold control... I don't have the motorised blend door because I hate the automatic climate control... Wife's BF turbo has it and it's more a PITA than a help...

I repaired the recirc flap... If that's what you're talking about, then the only way to get it out is to remove the dash... In an early E series it's pretty easy to get the dash out, I can probably get one out by myself in 45 mins... Not sure about ef/el as I've never done one of them...

Yeah there is a mismatch in travel, this is for a reason but, it ensures that the actuator is alwasy trying to close or open the door, so that it keeps the door firmly against it's wall and prevents any air leaking from the undesired direction... The steel unit that me and my old man made is lifetime and has never me an ounce of grief... I also have a plan for the windscreen/feet diverter flap should it break on me again...

Signal for the coil comes from the hall effect, gets filtered in the TFI where it is sent to the EEC for processing... It works out the advance required and delays a signal to the TFI again, where the TFI handles the dwell and then sends a pulse to the coil to fire... I think... It's a pretty overly complicated system in order to gain computer advance control for the fuel injection... Can't take too much credit for the est unit... I did quite literally "photocopy" the Ford issued special tool...

The issue with leaving the TFI is the heat generated by the block... 3 litres of wiper fluid (when full) is going to have a hard time trying to convection cool the alloy dizzy that is in a motor with 9 litres of coolant trying to get it to 92 degrees being forced around by a centrifugal pump... The TFI does make heat, my heatsink got slightly warm to the touch... Not enough to require water cooling on it's own... It's the motor cooking it that is the issue... Hence the class action lawsuit against Ford in america (same TFI system over there that regularly fails) that the people won... This is when the heatsink was invented and used on some american vehicles...

Cheers,
Tim

 

_________________

93 Red ED 5spd Manual Build Thread

Performance: Complete AUII VCT Wiring & Power Train, Pacey Headers, 2.5" Exhaust, Exedy Clutch, DBA Rotors
Visuals: FG XR Wheel, XR Front, 17's, BA 5 Spd Shifter, BA Ghia Window Switches, NL Cluster
Tunes: 8" Pioneer Sub, JBL Speakers, Clarion Double DIN Headunit

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 Post subject: Re: TimmyA's 93 ED Falcon
Posted: Sat Apr 29, 2017 1:18 am 
Technical Contributor
Offline
User avatar

Age: 27

Posts: 3704

Joined: 27th Sep 2006

Gallery: 20 images

Ride: ED Falcon

Power: 133 rwkw

Location: Leeton
NSW, Australia

Well... Update time...

Been a hugely busy start to the year... Been a million places for work and staying away from home, had weddings, holidays, and all sorts of other time consuming events to attend to... Getting back into car stuff nowish, and these are the bits and pieces I've made up since the last posts... Bought a cheap a** CBR125 to save money on fuel for around town errands and to/fro work travel... Super fuel efficent... So it's received some treatment... Bit of TLC and a power pipe... It'll make it easier when the red car comes off the road to strip and fit to the silver body... It also came in handy when the wife's BF s**t the turbo on the way home from the South Coast... Rear bearing collapsed and wheels hit the casings... Made a horrible noise when I went to accelerate off... Got towed home (long day)... All fixed now... But she was in the red car for the week while I was on the bike... Thinking because the old owner hacked the metal oil line to make it "easier" to change the block filter, he got steel into the restrictor and started the end of it's life... It did 230,000km...

Intake elbow flange and pipework Mach I... Involved cutting up a an aeroflow 4" 135degree ally elbow and ally pipe to make the following... Once I started sitting bits together I realised the tb end was too tight and tried to shorten the radius up a bit to allow more clearance for the tb blade... I got what looked like a good amount of bits tacked together and took them for proper finish welding...

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Once I'd had it welded and polished up I decided I still wasn't happy with the TB end... It looked pretty horrid and that's the part you'll see on the motor so set about fixing it... Used a half donut from aeroflow as the radius is much tighter than a mandrel bend... It's being finish welded now... Enter Mach II (note the comparison photos of old to new)

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So that's where that stands... Will get it back and grind the welds down again... Fix a couple of damaged parts on it... Sort out a throttle cable mounting and get it welded on... We'll get there...

Win on the AU2 booster... Grabbed the alloy spacer of one of my spare XR dual diaphragm ED boosters to see how close the AU2 one was to fitting the ED holes... Turns out not much... Two holes on the spacer were slotted and I never knew why, turns out they suit the AU booster... So this bracket will make the perfect template to modify the ED firewall to suit...

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Starting to think about engine mounts... These are some Imprezza bushes that matched the measurements of some heavy walled pipe I had lying around, according to the Whiteline site at least)... Turned up and they're 4mm bigger OD than what the website says, rendering my pipe useless... So I went to an engineering shop and they had this bar/pipe offcut, so old mate was kind enough to part off two rings on the lathe and charge me nothing because it was an offcut of useless steel... Winning... Nothing will break these engine mounts when they're done... Will make up some block plates out of some spare sheet I have and use the silver car to drop the au motor in and make up the rest of the mounts for a true good fit...

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On top of that there is the useless house renos... A bedroom nearly done... Then the front wall of the house and ensuite next... First child is due mid August... So all in all, no shortage of things to keep doing... Been kid proofing the house a little and generally cleaning up and getting organised... New temporary kitchen is in... Bought a Kaboodle (flat pack) Bunnings kitchen over 2 months as we could afford it and I must say, if you're on a budget, they're a pretty good kitchen system for the money... Do a little every week yourself as you can afford it...

Until the next time!

Cheers,
Tim

 

_________________

93 Red ED 5spd Manual Build Thread

Performance: Complete AUII VCT Wiring & Power Train, Pacey Headers, 2.5" Exhaust, Exedy Clutch, DBA Rotors
Visuals: FG XR Wheel, XR Front, 17's, BA 5 Spd Shifter, BA Ghia Window Switches, NL Cluster
Tunes: 8" Pioneer Sub, JBL Speakers, Clarion Double DIN Headunit

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 Post subject: Re: TimmyA's 93 ED Falcon
Posted: Thu Aug 10, 2017 12:51 am 
Stock as a Rock
Offline

Age: 29

Posts: 116

Joined: 19th Jan 2016

Ride: G6e

Location: Adelaide
SA, Australia

TimmyA wrote:
Advances this weekend is I am now running an EL 3.45 LSD diff...

Lokka is gone now... So much nicer to drive... Can actually go around a corner now without having to clutch it... And no more noise... I couldn't count how many people have pulled me up and told me the a** end is about to fall out of my car...

Wasn't too bad a task...

The ED lines, where the "T" is on the diff, missed the EL breather by about 3 inches so I welded a bolt to the diff and bolted the T there... Weld three tabs on in the same spots as where the ED has them and folded them over the lines, The passenger side line need to be re-shaped a tad to miss the breather...

Kitted the rear calipers... Gave them some Brembo red too... Looks good... The caliper brackets got a hit with the acid and the alloy looks like brand new... Backing plates are as black as black can be after a good clean... Incredible looking a** end now... If only you could see it...

So if anyone wants a Lokka there will be one for sale sooner or later... They're a great idea... Just not for me I think... Quite happy with an LSD for my use thanks...

3.45 over 3.27 seems to have made a tiny tiny improvement to the torque off the line... And with me guessing what "feels" like 50 km/hr when I look down I'm doing 58 so will check that with the gps and then fit the 22 tooth gear and see if make much improvement...

Other achievements is the completion of the NL cluster loom... So it is finished... Just gotta put some resistors in the door ajar one so it stops flashing at me... Got the LCD to illuminate now.... And just gotta change out the oil pressure sender... Will fit it up again tomorrow and put some LED's in it and see how it goes at night... I'll get some white faced dials made up for it too once I sort out what it is that I want...

Programmer turned up for my J3 chip... Knocked the idle down from 850 to 700 and tripled the dashpot figures... Again much nicer to drive now with those figures adjusted...

Fairly happy driver for now... Will get some picks of the NL cluster loom tomorrow and some of the FG wheel I'm slowly making up too...

Cheers,
Tim



Hm dash pot figures trippled ? Is your idle speed controlle still ok ? As ive heard of them in the us dieing with huge figures not sure what the duty cycle you'd be running but looks like i wont be shy to adjust more help from your thread i seem to be stealing ideas left and right
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