DexterZX2 Project Log - 6/13 Front bumper fitment!!! | Page 4 | Ford Escort Owners Association (FEOA)
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DexterZX2 Project Log - 6/13 Front bumper fitment!!!

Discussion in 'Photo Forum' started by DexterZX2, Aug 5, 2010.

  1. madmatt2024

    madmatt2024 FEOA Member

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    Your shifter looks like its backwards.
  2. white-lightning

    white-lightning FEOA Member

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    TWM ftw. I love mine, I have had it for about 1-1/2 years.
  3. DexterZX2

    DexterZX2 New Member

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    I noticed that after I installed it and took a picture. Since then I've switched it around. Thanks for keep an eye out though, lol.
  4. DexterZX2

    DexterZX2 New Member

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    4/12/11

    Quick update, I just ordered my new tires from Discount Tire. I also got a confirmation e-mail back from my first sponsorship company. My parts from them are on the way. This is exciting news, and I couldn't hold it in any longer. I just had to share this good new with my fellow TeamZX2 members. Here's a little teaser pic for you all.

    Photoshop of one of many parts to come from Mishimoto, my new sponsor.
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  5. omanthegiant

    omanthegiant New Member

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    that is so sick! i'm so jealous
  6. DexterZX2

    DexterZX2 New Member

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    ^^ Wait till you see what else I got from them. I'm so excited.
  7. 98EscortDude

    98EscortDude New Member

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    My guess is an oil cooler.
  8. DexterZX2

    DexterZX2 New Member

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    Already have one of those. I'll have pictures up tis weekend of everyting I got, and hopefully an update of the motor going back into the car.
  9. DexterZX2

    DexterZX2 New Member

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    4/22 - 4/23 Update

    "Good Friday" took on a whole new meaning for me this year. It was the day that my motor was finally set to rest back in my car. Before I get into everything that happened on Good Friday, I have to go back to the weekend before. I was origionally going to re-install the motor and trans on the 16th of April, but I ran into some complications. I first had to remove the old oil pan and install the new one that had an oil return line welded into it.

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    After that was installed was ready to put the flywheel and clutch back on. I had the motor up in the air with the cherry picker and off the engine stand. I got the flywheel on and torqued all the bolts down to spec. Then it was time to put the clutch on. The only problem was I didn't have the clutch alignment tool. Well the motor had to go back on the stand till I could source an alignment tool from someone. Luckly I contacted CJW and he had a couple lying around the garage I could borrow.

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    This brings me back to Friday now. After getting the clutch on properly and torqued down to spec, it was time for the bell housing to get attached. Once the transmission was mounted and the motor in the air I could finally get this motor back in the car. Just a reminder, installing a motor is a job suited for two or more people. I had my buddy Earl over to help get it back in, and it wasn't easy. We had to take our time and make sure we didn't bang it against anything inside the engine bay. Once it was lowered into the bay and the top transmission mount was attached the motor could rest on the brace below the transmission. You then have to put a jack under the transmission in order to adjust the positioning to get the lower transmission mounts bolted up. then all you have to do after they are bolted is attach the motor mount on the passenger side of the bay. It took about two hours to get the motor correctly fitted back into the engine bay.

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    After the motor was back in the car, I decided the next step would be installing all my new front suspension parts. I cleaned up the steering knuckles and taped them up for paint. I applied 3 coats of black to the knuckles, and decided to let the paint cure overnight in my dad's paint room.

    The next day started with a trip to my Advance Auto Parts store. I picked up a new set of axles, tie rod ends and lower ball joints for the front suspension. When I got up to the garage, my painted knuckles were cured and ready to go. I started taking apart the passenger side axle. I had to seperate the stock axle from the mid-shaft, which turned into a PITA since it as removed from the car already. Once they were separated and the new axle was in place I installed them into the tranny. At first I couldn't get the driver's side axle to lock in place, so I took a brass rod and hammer and gently tapped on the end of the axle until I felt it click. After that, the lower ball joints and tie rod ends where attached. Once everything was ready I attached the knuckles to the ends of the axles and bolted the ball joints to the control arms.

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    It was time to get the new BC Racing coilovers out of the box and attach them to the steering knuckles. I have to source some bolts from the junk yard cause mine need replaced. Right now the coilovers are set the way they came from the manufacturer. Once the car is back on the ground I'll start adjusting the ride height. The next part to install to my front suspension was the Wilwood Big Brake kit. This kit actually started off being a kit for a Honda Civic, but what makes it work for the ZX2 is the caliper mount bracket. It's a piece that has two sets of holes. One set mounts to the calipers, and the other set mounts to the factory caliper brackets. The rotors for the big brake kit measure 12.5" dia. The calipers for this kit a 4 pison calipers. With the BB kit mounted up all I have to do is run the brake lines and tighten up the axle nuts.

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    Finally I leave you all with one more thing. My parts from Mishimoto showed up. Now I can tell you what all I got from them for my ZX2. Parts included a carbon fiber oil catch can, universal radiator, carbon fiber rad. cap, flexable radiator hose and black front mount intercooler. I mocked up the intercooler so you can see what it'll look like.

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    My new tires were also delivered last week. I got a set of Kumho Ecsta AST's in 215/35/18. They weren't teh Falken's I origionally wanted, but they should provide an agressive tread pattern, and good tread ware. They were a little bit cheaper in price too.

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  10. 98EscortDude

    98EscortDude New Member

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    Wow some nice new toys you got there! Thats a big intercooler what is your power goal for this build?
  11. white-lightning

    white-lightning FEOA Member

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    I have the same tires in 205/50/R15. They stick pretty good, as I have yet to have them break loose in a corner.
  12. DexterZX2

    DexterZX2 New Member

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    4/30/11 Update

    My plan for this weekend was to get my rear suspension completed and back on the car. I first had to remove the lower control arm bolts from my rear cross member and the new disc brake spindles. I took everything down to my buddy's garage since he had a torch there. we heated up the two spots where the bolt connects to the spindles until they were glowing red. With some PB Blaster applied and a few hits of the hammer, the bolts were free. I am able to reuse the bolts that came from my car when I go to install the disc brake spindles. I will have to replace the rummber bushings that burnt up during the bolt removal though.

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    I then headed back to my garage to clean up and paint the rear disc spindles. After taking the wire wheel to them, and a few coats of black paint, here are the results.

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    While in between paint coats and waiting on my welder buddy to show up I started putting more parts into the engine bay. I ended up getting my intake manifold, fuel injectors and fuel rail installed. With the size of the new injectors being so much bigger than the factory ones, I couldn't make use of the clips that attached them to the rail. The good news is with the rail bolted down and the injectors seated correctly, I don't need the clips to hold them.

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    I would've installed my throttle body, but I'm having that sent out to get powdercoated along with my new valve cover. I did however start working on the location and how I plan on mounting my radiator and intercooler. I plan on relocating the radiator to the outside of the front frame rail. To do this I have to trim out the inner part of my header panel. I still have a bit of trimming, but the radiator fits in place.

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    Well my friend showed up with his portable welder around 6 that night. He got to work right away with fitting the plate in the trunk. He had to hammer the plate to fit the contours of the floor. Then he spot welded at every hole to attach to the existing floor. Under the car he welded a piece of 3/4x3/4 angle to add some support. I picked up some 2 part epoxy to run along the edge of the plate to create a seal which I still need to do.

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    When he was done my other friend and I started on another project. All this work being done to the trunk and rear bumper is prep work for my new exhaust system. I picked up a carbon firber rear diffuser for the latest generation WRX STI. It measured up perfectly to my rear bumper. The only thing is I have to trim my rear bumper to make it fit.

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    This is how my rear bumper looked before the diffuser.
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    Here we are cutting away at my rear bumper.
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    Here you can see the diffuser piece mocked up to the bumper.
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    Here's the plan to attach to diffuser to the bumper. I'm going to get some flat 1" wide aluminum and make brackets to attach the center of the diffuser to the car. Then I'll mask around the bumper with tape and trace the edge of the diffuser. After that, I'll remove the rest of the bumper up to the line. Once that's removed I'll make some angled brackets to epoxy to the inside of the bumper and diffuser. It's gonna take some patients to get it cut right, but doing it this way the diffuser won't be going anywhere.

    I didn't get the finish the rear suspension this weekend. I still have to rebuild the rear calipers, clean them and paint them. I also have to seal the edges of the new trunk floor and paint the rest of the underbody. Once that's done I can re-install the rear cross member and bolt up the disc brakes. Then the rear coilovers can go back in and my wheels can be installed. After all that, the car will be back on the ground. I have some bigs plans for next weekend, so stick around to see how it all goes.
  13. juggalo

    juggalo New Member

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    THAT'S LOOKIN F*CKIN FILTHY!
  14. twobit

    twobit FEOA Member

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    TOTALLY Jealous ... vary nice build man!
  15. DexterZX2

    DexterZX2 New Member

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    5/7/11 Update

    The day started off at 7:30am when I dropped my wheels and tires off to get mounted. Whiile they were getting done the g/f and I took another trip to the junk yard. I needed to pick up some bolts and a starter. An hour of tearing apart a ZX2 in the yard and I finally got the starter out. Getting the TB and IM out of my way was a PITA. We left the JY and headed back to the shop to get my wheels.

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    Here's the starter back in my engine bay after I cleaned it up a bit.
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    Over the past week I decided to scrap my 97 Escort LX RDB set-up cause I came across a whole rear from a ZX2 S/R.

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    The S/R rear just needed some rust removal, cleaning and a couple coats of paint to look nice again. I spent most of the afternoon cleaning the parts with a wire wheel and brake-kleen. While I was working on getting the rear suspension ready for paint, my g/f was back under the car to finish painting the underside. Now that the trunk plate is welded and sealed, the rest of the underside could be painted. After the underside was finished, she moved onto the rear fender wells.

    After everything was cleaned up on the crossmember, I removed the calipers and rotors. The S/R set-up has the rotors screwed to the spindles. I could use and ordinary screwdriver to remove them, so I borrowed my dad's impact screwdriver. A couple hits of the hammer and they were out. With all the parts cleaned and taped up, they were ready for paint. I got two coats on everything and then ran out of paint. I have to order some more from Eastwood to finish the underside of the crossmember and calipers. I'll have pictures when the painting is complete.

    Since I couldn't finish painting this weekend, I didn't reach my goal of installing the rear crossmember and getting the car back on the ground. I decided to spend the resh of the evening finishing up my front brakes. I first had to re-install the front brake lines. I then installed my SS brake lines after fishing the hard lines back into the engine bay. I still have to clip the lines into the brackets on the coilovers, but the hard part is done. I also installed the clutch hard line to the clutch slave cylinder.

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    Just before the night was over I wanted to get a wheel on to see how the BBK looked behind my wheel. I still have to tighten the axle nut. I need to borrow my buddy's torque wrench because mine doesn't go high enough.

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  16. Bomdoutscort

    Bomdoutscort FEOA Member

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    Nice work on all the parts you fabbed up to work.
  17. DexterZX2

    DexterZX2 New Member

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    Thanks, but I'm not done yet. I still have a few more interesting modifications coming.
  18. twobit

    twobit FEOA Member

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    Completely in awe.. love how in detail you get with everything.. cant wait to see it done!
  19. DexterZX2

    DexterZX2 New Member

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    This past weekend saw a lot of progress being made to my car. To sum everything up I created brackets and mounted up my Mishimoto radiator, installed the rear suspension, installed my coil pack and bracket, finished cutting and fitment of the rear diffuser and started to install my engine bay wiring harness. At the end of the weekend when everything was cleaned up, my ZX2 started to look like a car again.

    5/21/11

    The day started off with a trip to Lowe's. I had to pick up hardware for mounting purposes along with a strip of aluminum and an aluminum angle. The strip of aluminum was used to make the radiator mounting brackets, and whatever's left over will be used to make clip angles for the diffuser. Returning to the garage, my buddy and I started the final trimming of my rear bumper. With the edges of the bumper and diffuser taped up we traced a line to cut along. After the bumper and support were trimmed, we were able to put the diffuser in place and tape it to the bumper. The seam is all but flawless. Now all I need to get is some SEM epoxy to run along the inside seam and make a few 1" x 1" angle clips that will give the diffuser some added stability. It'll take 24 hours for the SEM epoxy to cure, but once it does the bond will be as strong as concrete.

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    In between cutting the bumper, I finished the final coats of paint to the underside of the rear cross member and brake calipers. I also painted my strut tower bar and coil pack bracket. Once the paint was dry I brought the cross member into the garage to install my 19mm rear sway bar, Energy Suspension end links and ss braided brake lines. I still need to pick up new bolts to install my rear tie bar. With everything installed on the cross member we bolted it back in place under the car.

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    5/22/11

    Sunday started with making brackets to mount my Mishimoto sponsored radiator. Since I relocated the radiator to the front side of the frame rail, the old mounting points wouldn't work. The new radiator also sits lower that the factory unit. I had to make two "step down" brackets that got rubber gromets in them for the pegs on the bottom of the radiator to sit in. These brackets would attach to the bottom side of the frame rail.

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    The passenger side bracket had to be bent at an angle to have a level mount point on the frame.

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    To keep structural stability through the rail I placed steel sleeves into the bolt holes.

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    The top brackets were next on the list to make. These would be simple 90* angles. With the proper holes drilled into the angles, the radiator was ready to be mounted. With all four points attached and tightened down, this radiator is solidly in place. The next test was fitting up the header panel. A few weeks back I started removing some of the panel that would interfere with the radiator. I had to finish trimming the panel up. I would've just cut the whole center section out of the panel, but I needed to keep the center bumper mount. After trimming the panel up and removing a section for the radiator cap, the header panel fit like a glove.

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    I also took the time to mount my MSD coil pack and bracket to the motor.

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    With the radiator mounted and secure, I spent the rest of the day finishing up my rear suspension. I installed the rotors to the hubs, attached the calipers and ran the brake lines. I still need to pick up a set of rear disc brake pads for my S/R set-up. I also need to pick up a set of e-brake cables for the S/R set. The trailing arms were the next items to attach. After everything was secure, I slid my BC Racing coilovers into place and bolts them up. Once all the suspension components were in place I decided to fit up my wheels, (this also frees up some more space in the garage).

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    One last thing to do for the weekend. I placed my CWQ3 pcm in it's proper location. Then I fed the main engine bay wiring harness through the firewall. I attached the harness to the pcm inside the car. Next time I'm in the garage I'll start hooking up the harness to what's available.

    After all the hard work was finished and the garage was cleaned up for the night, I took a few current pictures of my ZX2. It's starting to look like a car again. Shouldn't be too much to do to finish this project.

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  20. DexterZX2

    DexterZX2 New Member

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    6.13.11 Update

    It's been a awhile since I had anything to update in this thread. That being said, I had a day off yesterday and wanted to do some quick fitment checks. I picked up a set of black housing inner turns from SoBe-it (TeamZX2 member), at the All Ford show to replace my stock chrome set. I took a razor blade to remove some excess epoxy around the edges. I then bolted them to the front bumper. Then I mounted my ZXtuner black housing headlights to the header panel. Once they were in place. I mounted my front bumper onto the car. I took a quick measurement and confirmed that I have a good 5" between the bumper and the radiator. That's plenty of space to fit my intercooler between. Now I just have to figue out how I'm going to mount it. After the bumper was mounted I ran into a small issue. The inner turn bulb harness's don't fit due to the new radiator location. In fact, even without the bulb harness in place the passenger side light hits the radiator.

    I have two options to create a fix for the problem.

    1. I could shave the back of the inner turnsignal housing so it doesn't make contact with the radiator. Then I can make custom bulbs from the flat LED's and rewire them.

    2. I can make new upper brackets for the radiator to pull the top back enough for the lights to fit.

    I'm not sure which option would be better yet. If I move the top of the radiatior back, I might have to eliminate the hood latch and run hood pins. This would also make it easier to make a custom radiator cover plate. On the other hand, making new blubs and re-wiring the inner turn harness's could end up being a PITA. That's something I'll have to address next time I'm in the garage. Here are a few pictures from the test fitment.

    Here you can see that the inner turn signal housing is pushed out due to contacting the radiator.
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