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Zetec conversion

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Zetec conversion
#1
  This topic is about my 1959 Morris Minor 1000
Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
Hi!
I'm upgrading my Minor from Minor 1000 to Minor 2000.
I understand it's a quite common conversion in the UK but I'm probably first in Sweden with this setup.
I've chosen the Mondeo Zetec 2.0 connected to a Scorpio MT75 gearbox to get rwd.
Its a new project so I havent done much yet but today I dropped the engine in place to measure what must be modified under the hood.
My car is pretty rotten so I have lots of welding to look forward to but the engine swap seems to be a pretty simple modification on the Minor...
It would be nice to get connected to anyone who has done this conversion, I have a feeling that questions will come later on :-)

Regards Rikard

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rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
Rikard,

A couple of years ago I had one of the first Ford Escort SE's with the Zetec motor and 5 speeds. The little car was great on MPG and could cruise at 70 MPH all day ...

Wish I had it now : -( I would turn it into a donor for my '60 Morris 4 door.


Best of luck with the conversion, please keep the forum updated with details /photos.

Maybe I'll find another Zetec someday ...

Cam

jlhminors Jonathon Heap
Warwick, UK   GBR
If of interest we manufacture a full fitting kit for the Zetec into the Minor using the Type 9.

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Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
After getting connected to Jonathon at JLH Minors I´ve studied some more about how to do this conversion and learned that "slip in" IRL means "not so" slip in :-)
Some modification on the original engine bay is a "must do". However.... at last I´m understanding what to do and its all downhill from here.
But still got a lot of rust to care about..... Darn "Chucky"! Why have You allowed yourself to be so rotty!


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rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
Is that area below the battery box in the fire wall balkhead ???

The enclosed photos really show the amount of work need to convert over the engine bay . and the location of the reservoirs for the brakes and clutch ..

What do you figure the total cost to make such a change ??

Cam

Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
Yep correct its below the battery tray.
First picture shows how the modification of front beam will be done, first I will cut out and replace the front part with a profiled steel pipe and then cut away the part marked with X.

I´m in for a budget engine conversion doin it all by myself, no extreme performance and (for now) a good second hand engine/gearbox (200$).
It has taken me a lot of time studying pictures on the web that shows how the "proffessionals" makes it work. Here in Sweden I dont know anybody that has made this on a moggy so a visit to get advice is off the chart.

The "expensive" parts for me will be inlet manifold with carbs or throttlebodys, ignition, exhaust manifold and water side rail. Somewhere around 2000$ for them parts...
But the big money will be spent on the rest of the car: brakes and handling, interior, paint job and wheels etc.

My intention is to build a Minor that works well in modern traffic with good performance and handling, not a race machine as my family wants to ride it too :-)

//Rikard

rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
Rikard,

Thank you for the details and the photos. Not sure that a stock engine and trans ( in running condition) could be found for $200 (USD) - 1648.8 SW.Krona

So the Scorpio MT75 gearbox instead of the T9 is the way you plan to go - interesting??

Well you be swapping out the rear gears as well?

You mentioned a "... first I will cut out and replace the front part with a profiled steel pipe and then cut away the part marked with X. "/..... was for strengthening the front end bracing to prevent the frame from twisting?


Cam

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jlhminors Jonathon Heap
Warwick, UK   GBR
This is similar to our mods too


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Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
Thank's again for Your useful pictures Jonathon, beautiful work!

Cam: Yes I dont want to take any chances for the chassies members to bend during the reinforcement procedure.

I bought my engine and tranny at a carsalvage thats about to shut down, so their prices are looow now :-)

I haven't really decided what to do with the rear end, I have got an Sierra differential with 3,62 ratio on my shelf so that is one alternative. A Scorpio Cosworth diff is also avaliable...
It would probably be easier to install a rear axle from a Cortina/Taunus but they might be too wide for the Minor and Escort rwd axles are rare now...
I don't know what they use in the English conversions but im afraid the Morris axle will say goodbye rather quick..?

//Rikard

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rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
There's a few Pick and Pull salvage yard with 30 mile of my home. But having gone to them in the past, most of the usable parts are gone and what remains are hulks that people rip-up out of spite for some darn reason. They need to turn the dogs loose on those jokers ...


Do you have the wiring harness to plug in all the bits ??

The additional photos of the White Morris front end is really helpful. Do you have measurements on how far back you had to cut the firewall and trans tunnel?

Cam

Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
Hi!
So much to do and so little time to do it.....
I recently discovered "Project Binky" on Youtube where Bad Obsession Motorsport transforms a tired Mini into something spectacular.
Their project gave me lots of ideas and inspiration how to continue my "Chuckie-thing".
So... I have now disassembled most of the car and found out that the common thing with Chuck and Binky is the amount of "dark matter" that kept the cars together.
Well tinworm is not an issue, after all it's a lot of steel to cut out anyway to make proper reinforcements for the increased power and proper handling.
I have now welded about a mile of pipes inside the car to prevent it from bending when it's time to "fire up" the grinder.
Next step for me is to replace inner sills and boxing the sills with a steeltube inside( there's nothing wrong with stealing good ideas, huh?)
After that I'm going to replace the floor pans and the chassies legs.
"Binky" made me consider boxing a-pillars and other parts of the body that will be handling increased amount of stress with thicker steel than original and so it will be done :-)
I also remembered that I have a rear end from a Supra Mk2 with LSD hidden in my dungeons and maybe it will be an alternative to the Sierra rear end, time will tell.

I wish You alla nice weekend!


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rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
Rikard,

Any new photos of you progress ??


Thanks
Cam

Lordhelmet Avatar
Lordhelmet Rikard V
Jönköping, Jönköping, Sweden   SWE
Hi Cam.

Not so much photos regarding the engine conversion at this moment, I'm deeply into replacing all rusty panels now for a unpredicted time ahead.
Maybe I started this thread to early.... But on the other hand it will show all modifications that will be made instead eye rolling smiley

Inspired by the Binky project a lot of new ideas has appeared.
I will try to fit Citroën gas-hydraulic suspension in Chuckie instead of the leaf-springs and torsion-bars.
I'ts to much of a lottery to gamble with coilovers or ordinary macperson struts suspension as I dont know the weight of the finished car.
I want a smooth ride but firm when needed and my experiences of Citroëns suspension are good, like a "flying carpet".
The gas-hydraulic suspension doesn't take to much space either so a individual rear axle will be possible.

Attached pictures is from today, I've taken all the glass out and removed the kick-panels to be able to modify the sills.
I've also removed the headliner and the attached mouse-nest... no as a matter of fact not a nest, a mansion!

Now it's time to strangle my wallet to be able to order some replacement panels, they as much else will be bought from England.

Regards Rikard


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rusty bucket Avatar
rusty bucket Cam H
Baltimore, MD, USA   USA
Rikard,
Happy Saturday to you !.. Thanks for the update, so soon!!

A few months ago, I found the Project Binky on you tube and was amazed at the work the two guys put into that car. They sank a LARGE amount of $$ in to it also..


They are seriously talented guys. and they have a very well equipped machine shop.

Good Luck with you car and hope you can come up with the $$ for you UK parts. (post Brexit ;-( )

.. Cam

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