Westfield AeroRace 2008 Build Manual Download Page 70

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Revision 91

Chapter 11

Engine & Associated Systems

Contents

INTRODUCTION .............................................................. 1

Tools Required ................................................................ 1

Standard Parts ................................................................ 1

Parts Required ................................................................ 2

FITTING OF ENGINE AND SYSTEMS .................................. 3

Fitting – Chassis Mount ........................................ 3

Assembly – Radiator ............................................ 3

Fitting – Radiator Brackets ................................... 3

Preparing – Engine .............................................. 3

Fitting – Engine ................................................... 4

Fitting – Cooling System ...................................... 4

Fitting – Expansion Tank ...................................... 5

Fitting – Sender Wires ......................................... 6

Fitting – ECU & Relays ......................................... 8

Fitting – Oil Catch Tank ....................................... 8

Fitting – Fuel Hose .............................................. 9

Fitting- Exhaust ................................................... 9

INTRODUCTION

A 2000cc Zetec engine is supplied along with throttle bodies, ECU and a type 9 gear box. The engine is supplied complete and ready to fit. This
chapter also covers fitting of the cooling system, engine wiring harness/ECU and exhaust system.

The cooling hoses supplied require cutting to length this can be achieved with a hack saw.

Tools Required

Engine Hoist

13mm Socket x2

17mm Socket x2

8mm Spanner

Rivet Gun

Torque Wrench

Ratchet

Flat Blade Screw Driver

Rivsert Tool

4.1mm, 5mm, 7mm, 10mm Drill Bits

3mm Allen Key

Standard Parts

M8 x 25mm Set Screws

M6 x 16mm Set Screws

M6 x 20mm Set Screws

M5 x 16mm Set Screws

M10 x 50mm Set Screw

M10 x 25mm Set Screw

M6 Spring Washer

M5 STD Washer

M5 Nyloc Nut

M6 Nyloc Nut

M10 Nyloc Nut

40mm Jubaliee Clips

30mm Jubaliee Clips

25mm Jubaliee Clips

10mm Spacer Tubes

Summary of Contents for AeroRace 2008

Page 1: ... Suspension Steering Differential Rear Brakes Flexible Brake Hoses Fuel Tank Supply System Prop Shaft Steering Column Body Work Rollcage Engine Systems Final Fittings Optional Anti Rollbar Suspension Set up Pre Start Checks Introduction BUILD MANUAL ...

Page 2: ...All rights reserved Apart from any fair dealing for the purposes of private study research criticism or review as permitted under the Copyright Design and Patents Act 1988 no part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by means electronic electrical chemical optical photocopying recording or otherwise without prior written permission All en...

Page 3: ...al construction The whole point of the building a Westfield is to realise a vehicle what will fit the purpose for which it is intended With many thousands of satisfied owners both here and abroad we believe that at Westfield we have accomplished that objective It is in our best interest to deliver to you the means of building a car simply and quickly with a minimum of complication and a maximum am...

Page 4: ...hat are designed specifically for the purpose and are available from the factory 4 DO NOT use bricks building blocks or wooden packing cases Bricks and building blocks are not suitable as they are liable to topple Wooden packing cases are not suitable as they are liable to crush as the weight of the car increases during the build process 5 DO NOT connect the battery positive lead until the wiring ...

Page 5: ...9 Top Ball Joint Nut To Upright M12 x 1 5 25 34 10 Shock Absorber To Chassis Mounting Bolts 7 16 UNF 30 40 Component Thread Lb ft Nm Notes 11 Upper Steering Column Mounting Bolts M8 x 1 25 20 27 MAX 12 Steering Column Universal Joint M8 x 1 25 20 27 MAX 13 Steering Rack Mounts M8 x 1 25 20 27 MAX 14 Steering Wheel Nut 9 16 UNF 35 47 Component Thread Lb ft Nm Notes 15 Propshaft To Differential Bolt...

Page 6: ...a setscrew is threaded along its whole length The length of a bolt or a setscrew is measures from the underside of the head The diameter of a bolt is measured across the plain non threaded section for a setscrew measure across the top of the threads 60mm 55mm 50mm 45mm 40mm 35mm 30mm 25mm 20mm 16mm 2 3 4 3 2 1 2 2 1 4 2 1 3 4 1 1 2 1 3 8 1 1 4 1 3 1 4 3 1 2 4 3 3 4 M5 M6 M8 M10 M12 7 16 Plain Sect...

Page 7: ...id conditions Do not store bodywork in direct sunlight in greenhouses or conservatories Westfield Sportscars will not accept warranty claims for damage to bodywork where the damage has been caused by any of the above conditions Support During your build you may from time to time require further support in addition to this manual Westfield Sportscars prides itself on its industry leading customer s...

Page 8: ...c film All the panels are CNC cut and ready drilled for easy installation In some cases it may be necessary to trim or bend returns on some panels usually the tunnel inner sections This is not undertaken at the factory to prevent damage to the other panels during packaging All the panels are attached to the chassis using 4 1 mm closed aluminium rivets and sealed using silicone sealant If you have ...

Page 9: ...quired A Inner Tunnel Panels B Rear Bulkhead Panel C Flat Floor Panels D Exterior Panels E Bulkhead Panels F Scuttle Panel G Drivers Side Inner Footwell Panel H Passenger Side Inner Footwell Panel I Tunnel Top Panel A B C D E F G H I ...

Page 10: ... the inner tunnel panel is bent around the chassis using a soft mallet see image below The rear of the panel fits inside of the chassis tubing so the rivets can be fixed from inside of the tunnel see image below 6 Carefully place the panel on to the chassis and place rivets in the holes ready for final fitment Fig 1 4 1 4 7 Pull up the rivets with a rivet gun 8 Remove any excess sealant with a cle...

Page 11: ... scuttle panel F repeating the process used for the tunnel NOTE This panel does not cover the driver s footwell see image below 6 Panelling Exterior Side 1 Fit the side panels D repeating the process used in the tunnel panels NOTE Due to the size of the panel it is useful to use panel clips to hold the panel during fitment see image below 7 Panelling Floor Panels 1 Locate and fit the two floor pan...

Page 12: ...g a brake bias bar This allows the brake proportioning bias to be adjusted from front to rear The brake bias system requires two circuits one for the front wheels and one for the rear wheels Brake bias set up is covered in chapter 14 Tools Required A 10mm spanner B 13mm spanners x2 C 22mm spanner D 5mm Drill Bit E 4 1mm Drill Bit F Needle File G Mini Pipe Bender H Copper Grease I Rivet Gun J 2 5mm...

Page 13: ... C Brake and Fuel Pipe Set D Accelerator Pedal E Clutch Pedal F Clutch Bush 31mm G Brake Bush 31mm H Accelerator Bush 21 5mm I Clevis Pin 6mm x 20mm J Split Pin 1 5 x 20mm K Brake Pressure Switch L Accelerator Trunnion M 3 Way brake Union N Clutch cable A c C B D E K M N L F G H I J ...

Page 14: ...to the clevis pin ensuring the washer is between the pedal and the split pin 6 Apply copper grease to the 31mm steel bush F 7 Insert the bush into the pedal Fig 1 2 8 Locate 1 M8 x 70mm stud and screw an M8 nyloc nut on to the end leaving approximately 5 clear threads Slide a washer on to the stud pushing it up to the flat side of the nut 9 Offer up the pedal to the uppermost hole on the clutch pe...

Page 15: ...he balance bar It may be necessary to remove the master cylinder dust clip to enable the push rod to rotate Fig 2 4 2 4 NOTE The locking nut is used to screw the pushrods in or out of the clevises Screw the nut on until it locks against the shank of the pushrod A spanner can then be used to rotate the push rod and thus screw it in to the clevis 11 Hold a straight edge against the brake and clutch ...

Page 16: ...ivets are used in the tunnel P clips are secured with a 4 1mm closed rivet 1 Position the front 3 way union to the underside of the front chassis cross member Fig 4 1 4 1 2 Secure to the chassis with a M6 nyloc nut 7 Nm 5 ft lbs maximum torque NOTE The pipe runs along the round tubular triangulation brace Secure with four push in style clips The pipe then runs along upper cross member to the front...

Page 17: ...welded to the chassis 1 Place 1x10mm copper washer on to the thread of the pressure switch 2 Screw the brake pressure switch into the middle of the three way brake union applying a maximum torque of 7 N m 5 ft lbs Fig 5 1 5 1 3 Fit the union to the chassis using an M6x30mm set screw and a 6mm steel washer either side of the union 5 2 NOTE When correctly fitted the copper washer should be slightly ...

Page 18: ... should be mounted 35mm away from the upper wishbone mounts on the top face of the chassis rail Fig 6 6 7 Fitting Fuel Pipe NOTE The fuel pipe used measures 8mm diameter They are routed through the tunnel with the rear brake line Two hard lines required providing a return feed and return The pipes are held in place using the 8mm P clips Remember that the P clips can only be fitted when the fuel li...

Page 19: ...the previous and bend in the same plane and direction at 57 12 Put a mark 460mm from the previous and bend at 8 in the horizontal plane towards you 13 Put a mark 680mm and bend 90 towards you 14 Bend the pipe 90 in the opposite direction as close to the end of the previous bend as possible The result should be a kink towards you of approximately 25mm with the pipe traveling in the same direction a...

Page 20: ...nnel spacing distance must be reduced so the loom is fitted securely Please note Westfield Sportscars accept no responsibility for damage caused by modification to supplied STD looms Modifications to wiring looms are done at the customer s discretion and alteration of supplied Westfield parts voids any warranty associated with the product Before you start remove the loom from its packaging taking ...

Page 21: ...Wiring loom B Engine Loom C Dash Loom D Sub Loom E 4 1mm Rivets F Cable Ties G Loom saddle s H Starter Cable I Battery Cable J Earth Cable K Dash Board L Digital Dash M Analog Clock Set N Webcon Engine Harness K L A B C D E G H I J M N ...

Page 22: ...ss Main Chassis Harness WIRE COLOUR CODING G GREEN WG WHITE GREEN N BROWN LGW LIGHT GREEN WHITE B BLACK WN WHITE BROWN R RED GU GREEN BLUE W WHITE NY BROWN YELLOW U BLUE RU RED BLUE P PURPLE WR WHITE RED WB WHITE BLACK GP GREEN PURPLE RU RED BLUE ...

Page 23: ...Wiring Loom 3 4 Wiring Schematics Analogue Dash Harness Westfield Zetec Harness ...

Page 24: ...ess Ignition Starter Harness Analogue Dash Harness WIRE COLOUR CODING G GREEN WG WHITE GREEN N BROWN LGW LIGHT GREEN WHITE B BLACK WN WHITE BROWN R RED GU GREEN BLUE W WHITE NY BROWN YELLOW U BLUE RU RED BLUE P PURPLE WR WHITE RED WB WHITE BLACK GP GREEN PURPLE RU RED BLUE ...

Page 25: ...les 1 Drill and rivet three saddles on to the underside of the tunnel section 1 they are mounted on the driver s side Fig 1 1 NOTE All the saddle fixings are mounted on the right hand side of the tunnel Black dots show position of the saddles See below 1 1 1 2 2 Drill and rivet three saddles to the section 2 of the tunnel Fig 1 2 3 Drill and rivet two saddles on the section 3 of the tunnel Fig 1 3...

Page 26: ...wires are not stretched 4 Using the fuse box as a guide mark the position of the holes on to the scuttle panel 5 Drill two 7mm holes in the position marked 6 Secure two M5 rivserts into the scuttle panel Fig 4 2 4 2 7 Locate two M5x20mm dome headed screws from your parts along with two spacers M5 IDx10mm long 8 Push the screws through the fuse box holes fit the spacer and secure to the rivserts Fi...

Page 27: ...ted under the tunnel cross member until other parts of the loom have been attached 6 1 2 Separate the wires for the starter solenoid Brown Black and White and crank position sender black sheathed from the rest of the harness Fig 6 2 6 2 3 Run them down the tunnel side of the passenger bulkhead and attach to the saddle clamps pull the wires through to leave as much slack as possible 4 The water tem...

Page 28: ... There position should be on top of the scuttle panel If not run them up through one of the grommets 6 10 16 Run the three master switch wires to the driver s side of the scuttle GRP body part Along the scuttle panel see wire loom layout at the beginning of the chapter Secure with saddle clamps and cable ties NOTE Any earthing straps that do not reach a specific earthing point should be fixed to a...

Page 29: ...he ON OFF and FOG switches 8 Connect the dash harness to the ignition start harness with the 16 pin plug 9 Connect the Ignition start harness to the main chassis harness with the 12 pin plug 10 Offer the dash board up to the scuttle and temporarily fix in place 11 Secure dash panel to the scuttle by drilling five 5mm holes through the dash panel and into the scuttle 12 Enlarge the holes in the scu...

Page 30: ...m 3 11 9 5 NOTE The fitting of the ECU and connection of the sender wires will be covered in the engine chapter Fitment and connection of the light units and master switch will be covered in the body work chapter ...

Page 31: ...dependent front and rear suspension featuring unequal length adjustable wishbones aluminium uprights adjustable dampers and ride height Tools Required A 5 8 Spanner x2 B 13mm Spanner x2 C 17mm Spanner x2 D 19mm Spanner x2 E 26mm Spanner x2 F 13mm Socket x2 G 17mm Socket x2 H 19mm Socket x2 I 26mm Socket x2 J 5 8 Socket x2 K Torque Wrench L Ratchet M Thread Lock N Ruler Tape Measure Standard Parts ...

Page 32: ...s D Upper ball joints E Track Rod Ends F Front Damper x2 G Front Spring x2 H Steering Rack I Track Rod Lock Nut x2 J Rack Mounts K Rack Rubbers L Front Upright Assembly M Lower Rear Wishbone x2 N Upper Rear Wishbone x2 O Rose Joints Inserts x4 P Rear Damper Unit x2 Q Rear Uprights A B C E D G F H K J I M N P L O Q ...

Page 33: ...ully tightening one at a time 5 Screw track rod lock nuts I on both sides of the rack arms 6 Screw the track rod ends E on to the arms until there is about four or five threads left showing on the arm Fig 1 2 1 2 NOTE Do not tighten locking nut at this stage 2 Fitting Front Wishbones 1 Position the front lower wishbone A on to its mounts at the front of the chassis Fig 2 1 2 1 NOTE With the wishbo...

Page 34: ...shbone using M10x25mm bolts securing with M10 metaloc nuts The nuts should be on the bottom of the wishbone Torque to 38Nm 28ft lbs Fig 2 3 2 3 7 Position the front upper wishbone B on to the chassis brackets NOTE The upper wishbone is not symmetrical It should be fitted so that the ball joint tube is off set towards the rear 8 Locate two 7 16 x2 bolts from your parts place a standard washer on ea...

Page 35: ...acket See exploded view NOTE Position the damper with its adjustment knob on the inside and the adjustment thread at the lower wishbone end 4 Fit a washer on each bolt and secure with a nyloc nut do not fully tighten at this stage Fig 3 1 3 1 5 With the second bolt position the lower mount of the damper to the lower wishbone repeating the process for the upper mount Fig 3 2 3 2 6 Repeat the proces...

Page 36: ... will not go in use a vice to gently push it in Ensure the bush goes in square Fig 5 1 5 1 2 Put a lock nut on to the rose joint thread 3 Screw a rose joint into each lower wishbone M complete with locking nut until there are four threads showing Fig 5 2 5 2 6 Fitting Rear Lower Arms 1 Position the lower wishbone between the lower chassis brackets Fig 5 2 The rose joint is at the back of the car i...

Page 37: ...our parts place a standard washer on each 3 Insert the bolt through the bush placing washers between the damper and the bracket See exploded view Fig 8 1 8 1 4 Secure the bolts with 7 16 nyloc nuts do not fully tighten at this stage 5 Repeat the process for the other side NOTE The bottom of the damper is not attached at this stage 9 Fitting Rear Uprights NOTE The Westfield uprights are supplied as...

Page 38: ...e mechanism Rollcage Support Side Impact The full rollcage fitted requires 18 mounting points Four of these points do not intersect the chassis so in order to fit the cage two additional support bars are required The nature of the fitment means that they must be fitted before the body work is fitted Hence the reason for fitting them in this section not the rollcage section Tools Required A 5 8 Spa...

Page 39: ...Differential and Rear Brakes 5 2 Parts Required A Rear Brakes Discs B Rear Calipers C Differential Unit D Left Drive Shaft E Right Drive Shaft F Stabilising Bracket G Rollcage Support A C B E D F ...

Page 40: ...Revision 37 ...

Page 41: ...Differential and Rear Brakes 5 2 ...

Page 42: ...0mm stud all the way through 11 Place a M12 washer on to both ends of the lower differential stud 12 Secure with M12 nyloc nuts Torque to 54Nm 40 ft lbs and torque the top bolts to 40Nm 30 ft lbs Fig 1 3 1 3 13 Locate the stabilizing bracket F from your parts It is mounted on the rear of the differential housing and is secured to the chassis via a metalastic bush Fig 1 4 14 Attach the bracket to t...

Page 43: ...if preferred Ensure the disc is completely clean and dry before fitting the calipers 1 Position the brake disc over the wheel studs and against the hub Fig 3 1 3 1 2 Offer the caliper B up to the hub ensuring that the bleed nipple is at the top Fig 3 2 3 2 3 Locate two M10x45 cap headed set screws from your parts place a M10 spring washer on each 4 Insert the two set screws with thread lock on eac...

Page 44: ...DUCTION The flexible brake hoses come in pairs two front and two rear The rear hoses are longer than the front two The hoses are supplied with locking nuts attached The hoses fit directly into the calipers and do not require any adapters or hard lines Copper washers are required to create a seal between the caliper and the lines Tools Required A 13mm Spanners x2 B Spanner C 7 16 Spanner ...

Page 45: ...Flexible Brake Hoses 6 2 Parts Required A Flexible Rear Brake hoses B Flexible Front Brake hoses A B ...

Page 46: ...e and do up pinch tight 1 3 NOTE Do not over tighten It is better to have it too loose at first and then tighten more later if a leak is detected 8 Repeat the process for the other side of the car 2 Fitting Rear Hoses 1 Locate the two rear hoses A from your parts The end of the hose without locking nuts are the ends that fit into the caliper 2 Remove the dust caps and ensure that the copper washer...

Page 47: ...d When fitting these components care needs to be taken in order to prevent damage or leaks from the parts It is also essential that the fuel hoses used confirm to the British Standard BS AU108 2L4 C4 R The Tank is fitted to a frame This frame is mounted to the upper rear wishbone mounts The fuel pump and filter are mounted at the rear of the car behind the fuel tank Do not use metal clips to attac...

Page 48: ... Mount Straps x2 D Screw in Pipe Unions E H P High Pressure Fuel Pump F Fuel Filter G Flexible Fuel Pipe H Foam Tape I Aluminium Boss O Ring J Ventilation Union K Gauze Filter L Fuel Pump Bracket M Fuel filter Bracket N Swirl Pot O L P low Pressure Pump O B A M L I J K C D E H G F N O ...

Page 49: ...and filter F from your parts 5 Wrap both the filter and the pump with foam tube 6 Place the bracket L over the pump 7 Place the bracket M over the fuel filter NOTE The filter is mounted to the tank mounting frame B And the H P high pressure pump E is mounted on the upper chassis rail 8 Mark two points 82mm apart on the underside of the tank mounting frame 80mm from far left of the mounting frame F...

Page 50: ...he lower mounting hole on the longitudinal chassis rail according to Fig 3 2 3 2 6 Drill a 7mm hole at the point marked and secure an M5 rivsert into the hole 7 Screw the remaining rubber bush into the rivsert 8 Locate three M5 nyloc nuts from your parts 9 Position the swirl pot on to the three mounting bushes and secure with nyloc nuts 4 Fitting L P Pump 1 Locate from your parts the Facet L P pum...

Page 51: ...d in chapter 2 section 7 Use the lower line for the FEED and the upper for the RETURN 6 Assembly Fuel Tank 1 Locate the fuel tank A from your parts along with the two unions D J the aluminium boss I O ring and gauze filter K 2 Wrap PTFE tape round the small union D and thread it into the small threaded insert on the swirl pot Fig 6 1 6 1 3 Insert the gauze filter K into the swirl pot it needs to b...

Page 52: ...e front face of the chassis tube not all the way through 9 Remove the strap and enlarge the hole to 9mm 10 Fit an M6 rivsert into the hole and secure 11 Refit the strap with M6x25 bolts spring washer and standard washer Fig 7 3 7 3 8 Fitting Fuel Hose 1 Fit a length of fuel hose from the large union on the tank to the free side of the L P fuel pump ensuring there is enough length to secure the hos...

Page 53: ...nd with a four bolt flange connection is fitted to the differential The sliding coupling will be fitted onto the gearbox output shaft during the engine and gearbox installation The steering column consists of two separate bearings mounted to the chassis which support the column Tools Required A 13mm Spanner x2 B 8mm Spanner C 13mm Socket x2 D Ratchet E Torque Wrench F 6mm Drill Bit G 3mm Allen Key...

Page 54: ...Prop Shaft Steering Column 8 2 Parts Required A Propshaft B Steering Column C Spacer Plate D Bushes E Bush Housing F Steering Wheel A C B D E F ...

Page 55: ...r the car ensure it can not fall of its stands 4 Temporarily secure the other end with a cable tie until you are ready to fit the gearbox Fig 1 3 1 3 2 Fitting Steering Column 1 Locate the steering column B from your parts along with the spacer C and bolts required 2 Locate from your parts the column bushes D and the bush housings E The bushes need to be pressed into the housing If it is not possi...

Page 56: ...r face of the wheel with masking tape leaving a small patch for the center point to be left showing 3 Using the diagram below mark a 50mm PCD Pitch Circle Diameter with three holes evenly spaced 4 Drill three 6mm holes through the steering wheel Be careful to drill the holes accurately 5 Repeat the process for the flange on the steering column being careful to get it centered correctly 6 With both...

Page 57: ...known as gel coat Scratches can be polished out as with conventional painted finishes or if the scratch is deep additional gel coat can be added and blended into the original by sanding and polishing The body can be waxed as with conventional finishes to help protect it from the elements Tools Required A 4 1mm Drill Bit B 5mm Drill Bit C 6mm Drill Bit D 8mm Drill Bit E 10mm Drill Bit F 12mm Drill ...

Page 58: ... 2 Parts Required A Rear Section B Rear Arches x2 C Scuttle D Bonnet E Nose Cone F Nose Cone Bracket G Over Center Catch x4 Bonnet Catch H Rear Light x2 I Dzus Fastener x2 J Rear closing panels A D C B E F G H I J ...

Page 59: ...not fit any rivets at this stage just use clamps to temporarily hold the panels down 2 Placement Scuttle Bonnet 1 Place the scuttle D in position onto its mounting blocks There are two on each side of the side panels Fig 2 1 2 1 2 Place the bonnet E on to its locating blocks Fig 2 2 2 2 3 Check the fit and gaps of the panels to each other also check that the all the panels are centered to the chas...

Page 60: ...oles drilled and secure with 4mm counter sunk rivets 4 Fixing Rear panel NOTE Before removing the scuttle it is advisable to mark the position of the front edge on the side panel Use either masking tape to draw on or use a china graph pencil to mark the body work Do not use felt tip pen on the body panels 1 Remove the scuttle Create 16mm clearance holes through the side panels so that the rivserts...

Page 61: ... rear arch to hub centre NOTE It is ultimately best to fit the rear wheels to gain a full perspective of the fit 10 Drill six 4 1mm holes spaced at 40mm through the body in to the sections of tube welded to the bottom of the chassis cross member 11 Secure with six 4x16mm large headed body rivets 7 Fixing Bonnet Nose 1 Locate the bracket G for the lower nose cone from your parts 2 Locate two M6x45m...

Page 62: ...s where the over latches are to be positioned to prevent scratching of the panels 3 Using a catch as a template mark the five holes to be drilled 4 Remove the catch and drill five 4 1mm holes NOTE The top of the catch unit needs to be level with the top edge of the side panels Ensure there is sufficient tension in the catch to hold the bonnet securely The catch should also be fitted 50mm from the ...

Page 63: ...fire extinguisher pull cord They are mounted to the driver s side of the scuttle 1 Tape off the area where the master switch is to be fitted with masking tape 2 Using the master switch as a template mark out the positions of the holes 3 Using a 22mm hole saw drill the center hole and an 8mm hole to drill the fixing holes 4 Secure the master switch with M6x20mm setscrews and nyloc nuts 5 Mark the p...

Page 64: ...Secure the outer two panels one at a time to the GRP rear section with clamps 3 Drill four holes round the lip of each alluminium panel through the GRP rear section 4 Secure in place with 4mm large head rivets NOTE The middle panel requires a strip of aluminium along the rear bulkhead The middle panel slots under the lip 5 Position the lip over the rear bulk head and note the rivets required to ho...

Page 65: ...car 2 Cover the rear section of the bonnet with masking tape 3 Mark out the cut required according to the diagram Fig 15 1 15 1 4 Using a 50mm hole saw cut the four holes required in the bonnet according to the diagram 5 Remove the material between the holes using a jig saw or similar with a fine blade 6 Finish the edges off with 400 grit wet and dry paper ...

Page 66: ... high grade M10 bolts It is bolted directly to the top of the rear bulkhead and to the side of the chassis through spacer tubes to clear the body work The cage is also fitted to the lower rear chassis via adjustable rose joints to ease fitting Tools Required A 5mm Drill Bit B 11mm Drill Bit C Marking Tools D Masking Tape E 17mm Socket x2 F 5 8 Socket x2 G Touque Wrench H Ratchet Standard Parts A M...

Page 67: ...Rollcage 10 2 Parts Required A Rollcage Kit ...

Page 68: ...body being squashed when tightening position the bolts so they are flush with the side panel for now 3 Repeat the process for the other side 4 With the aid of another person lower the cage over the car The horizontal flat plates on the rollcage locate to the flat plates behind the bulkhead Fig 2 1 2 1 5 Locate four M10x25mm setscrews place a standard washer over each setscrew 6 Insert the four set...

Page 69: ...tscrew and secure with a nyloc nut 3 1 9 Repeat the process for the other side 4 Fitment Final 1 Check the alignment of the cage and all of the bolts to ensure they are correctly fitted 2 Now that all the bolts are fitted torque them up to 38Nm 28ft lbs ...

Page 70: ...te and ready to fit This chapter also covers fitting of the cooling system engine wiring harness ECU and exhaust system The cooling hoses supplied require cutting to length this can be achieved with a hack saw Tools Required A Engine Hoist B 13mm Socket x2 C 17mm Socket x2 D 8mm Spanner E Rivet Gun F Torque Wrench G Ratchet H Flat Blade Screw Driver I Rivsert Tool J 4 1mm 5mm 7mm 10mm Drill Bits K...

Page 71: ...Harness F ECU G ECU Brackets H Oil Catch Tank I Expansion Tank J Kinked Water Hose K 90 Water Hose L Aluminium Water Pipe long M Aluminium Water Pipe short N Large P Clips x2 O Jubilee Clips x8 P Exhaust Manifold Q Silencer R Fan S Fan Mounting Bracket T Fan Switch U Reducing hose V Small Bore Hose N O J K L M N O P Q A B C E F G D H I R S T U V ...

Page 72: ...kets 1 Locate from your parts the two aluminium radiator brackets B along with two M6x16 dome head set screws 2 Place a spring washer on each set screw 3 Fit the aluminium brackets to the radiator with one M6x16 cap head screw for each bracket Fig 3 1 3 1 NOTE The aluminium brackets need to be fitted to the radiator before they are riveted to the car 4 Attach the radiator to the lower mounting bra...

Page 73: ...mount first then lower the engine down onto its engine mounts Fig 5 2 5 2 NOTE The mounts come with the nyloc nuts fitted to them so they need removing before lowering the engine on to its mounts 5 3 5 Fit the nyloc nuts on to the engine mounts with a plain washer and tighten to 47Nm 35ft lbs 6 Fitting Cooling System 1 Locate the hoses J K and aluminium pipes L M from your parts ready to hand 2 Cu...

Page 74: ...r radiator outlet Secure with the remaining jubilee clip 15 The two aluminium pipes require securing to the chassis this is done with large P clips N 16 Position a P clip over the upper hose near to the nose end of the nose cone Fig 6 6 6 6 17 Line the hole in the P clip up with the center of the cross member and drill a 5mm hole into the chassis 6 7 18 Enlarge the hole to 7mm fit a M5 rivsert int...

Page 75: ...rge upper main pipe with cable ties 13 Locate the small silicon bung from your parts 14 Fit the bung to the spare union on the thermostat housing Secure with a 25mm jubilee clip Fig 7 5 7 5 8 Fitting Sender Wires 1 Locate the coil plug on the wiring loom it should be exiting the offside of the tunnel and is marked coil Fig 8 1 8 1 2 Plug the connector in to the coil which is located at the rear of...

Page 76: ...8 9 15 Locate the oil pressure wires White with black sheath from the loom which should be routed along with the alternator wires 16 Connect the eyelet to the oil pressure sender mounted on the nearside of the engine by unscrewing the plastic nut Fig 8 10 8 10 17 Locate the water temp connector for the ECU Blue and Black It should be run along the offside of the chassis with the alternator wires 1...

Page 77: ... panel where the wires are not stretched 8 Mark the position of one of the pre drilled holes in the bracket onto the tunnel top 9 Drill a 4 1mm hole in the tunnel top and secure the plastic bracket to the tunnel top with a rivet 10 Fit the relays to the bracket and secure any loose wiring with cable ties and saddle clamps Fig9 3 9 3 NOTE Ensure that all the cables and wires are secured properly wi...

Page 78: ...The Webcon throttle bodies come complete with fuel hose attached already The hoses need to be attached to the hard lines exiting the tunnel NOTE As set up in chapter 7 the lower of the two fuel lines is the feed to the engine 2 Locate the hose that is attached to the fuel regulator route it neatly under the throttle bodies to the hard lines Fig 11 1 3 Offer the hose up to the return line and cut t...

Page 79: ...ncer bracket from your parts and bolt it through the hole drilled previously using M10x50 set screw 6 Apply some silicone exhaust paste to the end of the manifold about 25mm feed the silencer Q on to the manifold with the exhaust clamp fitted first Fig 12 3 12 3 7 Secure the silencer to the rubber mount with the nut fitted to it Be careful not to twist the rubber mount when tightening Fig 12 4 12 ...

Page 80: ...em but require refitting to change the seating position as a seat runner cannot be approved for racing A plumbed in fire extinguisher is also supplied in the kit This is activated by remote pull cords mounted to the scuttle and on the dash so that in the event of a fire a marshal or the driver can activate the extinguisher Tools Required A Rivet Gun B 4 1mm Drill bit C 5mm Drill bit D 10mm Drill b...

Page 81: ... Parts Required A Fire Extinguisher Set B Seat x2 C Seat Bracket Bracket x4 D Harnesses set x2 E Front Cycle Wings F Wing Mirror x2 G Mirror x2 H Aero Screen I Aloy Wheels x 4 J Ducted Nose Panels N O H J A B C D E G F I H ...

Page 82: ...ss straps in before the seat is sitting fully on the floor 3 With the seat sitting on the floor of the car position the seat and test its position to see if you can operate the controls properly 4 Insert four M8 cap head bolts from inside the car through the seat brackets and through the floor Fit a washer before fitting the bolt 5 Secure the bolts with Nyloc nuts and washers NOTE The rear bolts a...

Page 83: ... fitting method for the scuttle pull cord is described in the body work chapter 1 Locate the other pull cord from your parts and mount it to the dashboard where the driver can reach it Fig 4 1 2 Route the cables back to the extinguisher from the pull cords 3 Push the inner of the cable through the union and then through the other part of the handle 4 1 4 2 4 Locate the outers in their unions Pull ...

Page 84: ...rrors are attached to the front of the rollcage 2 Offer the mirror up to the pre drilled holes in the rollcage 3 Insert the two M6x16 counter sunk set screws through the mirror bracket and rollcage Fig 7 1 7 1 4 Fit a M6 washer on to each setscrew and secure with nyloc nuts Fig 7 2 7 2 8 Fitting Aero Screen 1 Locate the aero screen H from your parts 2 Position the screen on to the scuttle so that ...

Page 85: ...fer the assembled ducting up to the front of the radiator 4 Locate four M6x16mm dome head screws along with four std M6 washers 5 Place a washer on each set screw 6 Fix the ducting to the radiator using the set screws Fig 9 2 9 2 ...

Page 86: ...ting Rear Roll Bar 3 3 Torque Setting 4 INTRODUCTION An anti roll bar is available from Westfield Sportscars as an optional extra If you wish to purchase this option please contact the parts department for further information If you have not specified an anti roll bar proceed to the next chapter Tools Required A Metric spanner set x2 B Knife C Sand paper D Copper grease ...

Page 87: ...s Required A Front Roll Bar 29650 B Rear Roll Bar 40402 C Mounting Blocks Rear D Mounting Blocks Front E Steel Brackets F Upper Clevis Front G Upper Clevis Rear H Drop Link I Lower Clevis Front J Lower Clevis Rear A B C D E F H I J G ...

Page 88: ...1 The new bolt goes on the other way around to the standard bolt 12 Fit a washer and secure with a nyloc nut 13 Locate the upper clevis front F from your parts 14 Slide it on to the anti roll bar and position it 158mm from the centre line of the roll bar 15 Locate the drop links F from your parts Assemble them so as each rod is fitted with two rose joints and a locking nut at each end NOTE The lon...

Page 89: ... of the roll bar 9 Fit the drop links H between the roll bar and the lower wishbone There is no clevis required on the rear as the lower wishbone has a mount built into it 3 Torque Setting 10 When the anti roll bars have been fitted sit the car on the ground 11 Torque the bolts up to the settings listed in the torque chart at the beginning of the manual ...

Page 90: ...g up your car can be time consuming but is an important part of the build to get the most from your car The dimensions given are a base setting that we have developed As you become accustomed to your car you may wish to alter the settings to match your driving style If you do not own any equipment for setting up your car you may wish to purchase some or entrust Westfield Sports Cars to do the job ...

Page 91: ...Suspension Set up 14 2 N O ...

Page 92: ...r can be set in to the upright to get a larger contact patch under cornering Too much camber increases tyre wear Camber is adjusted by altering the length of the top wishbone on a Westfield 7 Check the camber angle that is currently set on your car 8 Slacken the ball joint locking nut 9 Remove the metaloc nut on the upper wishbone ball joint 10 Detach the ball joint from the upright Use of a ball ...

Page 93: ...ull rotation of the rose joint equates to 1 3mm of movement into or out of the bottom wishbone 1 Check the toe angle that is currently set on your car 2 Remove the lower upright bolt connecting the wishbone to the upright Adjust both sides of the car not just one side 3 Screw the rose joint in or out as required to achieve the toe on the set up sheet listed on the previous page 7 Notes 1 If you ma...

Page 94: ...crewed over towards the front master cylinder This will transmit more force to the front brakes Fig 8 2 8 2 5 The diagram below shows rear bias with the bias bar screwed over to the rear master cylinder this will apply more force to the rear brakes Fig 8 3 8 3 6 The brakes should ideally be set up on a rolling brake test machine as used by MOT stations 7 The bias should be set in the central posit...

Page 95: ... Harness Buckle Covers 4 5 Rear Number Plate 4 6 Hood Mounting Covers 4 7 Steering Wheel Cover 5 8 Head Lamp Covers 5 9 Head Lamp Raiser 5 10 Bonnet Catch Covers 5 11 Damper Covers 5 INTRODUCTION To prepare your car for SVA there are several covers that require fitting in order to meet the requirements for external projections Tools Required A Sharp Knife B Silicone Gun C Silicone Sealer ...

Page 96: ...racket GRP x2 G Rubber U Section H Cover Bonnet Catch x2 I Leveling Bracket Rev Fog Lamp x2 J M14 Hex Head Bolt Covers x2 K Cap Windscreen Cover x4 L M12 Hex Head Bolt Covers x8 M Cap Hood Frame x2 N M8 Hex Head Bolt Covers x4 O M10 Hex Head Bolt Covers x10 P 7 16 th Hex Head Bolt Covers x4 Q Harness Buckle Cover x2 R Steering Whell cover Not in SVA kit x1 A B C E J L N P D F H I K M Q R ...

Page 97: ...ve Fig 1 4 1 4 7 Slide the sleeve over the track control arm and refit the track rod end Fig 1 5 1 5 8 Slide the cover over to protect the locking nut 9 Locate from your parts one M10 bolt cover O Fit the cover over the nut securing the track rod ball joint to the steering arm Fig 1 6 1 6 10 Locate from your parts two M10 bolt covers O Position the covers over the two bolts securing the lower ball...

Page 98: ...r parts 2 Push the covers over the lugs on the A post covers Fig 3 1 3 1 3 Repeat the process for the other three lugs 4 Harness Buckle Covers NOTE The buckle covers require 15mm cutting off the pointed end so they can slide over the eyelet 1 Locate from your parts the four harness buckle covers 2 If necessary remove the buckles from the eyelets 3 Push the small end of the cover over the eyelet tu...

Page 99: ...pacers D from your parts 2 Remove the headlamps from the car 3 Refit the head lamp with the spacer positioned on the threaded section of the mounting point Fig 9 1 9 1 4 Secure with the original nut 5 Repeat the process for the other lamp 10 Bonnet Catch Covers NOTE Two covers are required for the bonnet catches if you are not running locks The covers are similar to the ones used for the A pillar ...

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Westfield AeroRace 2008, Build Manual

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