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Find a glass place that caters to Semi trucks. They will be accustomed to working with flat glass, and will have the right laminated material available. Randall

I'm re-reading all your clues, and am confused. You are using a stock sensor and Fidanza flywheel, yet your ECU is set to 36-1. Is your sensor on the flywheel or on a 36 tooth wheel (minus one) on the crankshaft?

Are you sure you have the right sensor housing for your car? The Zetecs had different housing for automatic vs. manual transmissions. See here, for example http://www.locostbuilders.co.uk/viewthread.php?tid=66152

Sold, pending funds transfer.

Yes, it is. Randall

It's still available.

+1

I don't have my notes handy, but from memory, they're from a '89-ish VW. Randall

Bump

Bump

Yes, it is. Randall

bump

I've got the same height/long torso issues. In a standard Birkin S3, the windshield frame is about in the middle of my visual field. I solved the issue by cutting the floors and installing dropped pans so the bottom of Birkin's plastic seat shells could be below the original floor. Now I look through the middle of the windshield and have no issues with head versus weather hood/roof. I'm not especially near you, but my car's for sale and I'd be happy to let you sit in it. Randall

I set the rev cut-out at 7200rpm in the Emerald. Also, I forgot to add that I have a set of corner weighting scales available with the car. Randall

I never thought this day would come, but it is time to sell my Birkin. I just don't get enough opportunities to drive it here on the North Olympic Peninsula. This is a 2001 BIY component built car with 23,000 miles. I've been its caretaker for over ten years, and upgraded nearly every system in the car. When initially tuned, it made 178 HP on the wheel dyno. Sadly, I've never tracked this amazing car. $26,000/OBO Engine: ZX3 Zetec block Ford Racing Head Crower stage 3 cams Eagle Rods Probe 10:1 pistons CFM 65mm billet throttle body High output Bosh injectors Raceline oil pan Raceline water rail Birkin sump guard High output radiator fan remote oil filter Emerald K3 ECU Transmission: typical Ford T-9 box Fidanza flywheel Quaife ATB differential Suspension: Woody's radius rod rear end Birkin wide front end kit 4 pot Outlaw brakes in front .750 brake cylinder Hawk brake pads Interior: lowered floor sections Birkin “competition” seats with padded inserts 5 point harnesses removable steering wheel Mirrorsforsevens wide mirror The car has a full hood with side curtains and a half-hood (Birkini). I also have a spare wheel carrier and a bolt-on rear cargo rack that go with the car. Potentially available, as well, is a 7x14 enclosed trailer with ramp gate and interior tie-downs.

I would think that there are any number of talented fabricator/welders in Seattle. It shouldn't be too hard to make a new one, since you have the original for a pattern. Randall

I have a vague recollection of using either GTI or Golf rotors for my 2001. I had to turn the central hole a bit larger to fit the hub, but otherwise fit was no problem. Randall

I should have added, I've never heard of anyone having problems with zippers and sometimes wish I had them. But it's not a big deal without...it just takes a couple seconds longer. Randall

The upholsterer who made my half-hood flatly refused to put in zippers. He felt the stresses in the installed hood would destroy the zippers fairly quickly. Instead, I installed nylon buckles in the rear mounting straps. for ingress/egress, I un-clip the buckle (and sometimes one or two snaps on the windshield) climb in, then reach around behind me and re-clip the buckles and any snaps. Easy enough. I can do the same for a passenger, too. Randall

Tom, curious that your experience is so opposite what was relayed to me by some top tuners over the years. Perhaps the people I've talked with used Ti retainers made from the wrong alloy. They related sudden failure after mere hundreds of hours. Randall

Stay away from Ti retainers, unless you plan to replace them as a regular maintenance item. They have a shockingly short life span. Randall

With Motul, I wonder where the other lobe wear you mention came from. I vote for a complete tear down. Something major isn't right. Sorry, I don't have Duratec experience, so I can't recommend a spring compressor. Randall

Compressed air into the sparkplug hole will hold the valves closed while changing springs or seals--if you have good valve seats. What kind of oil were you running? Randall

It was several years ago, when Zetec parts were more easily sourced. It was/is a "Ford Racing" part that I sourced from Ford Performance. Randall

I suspect the check valve in your oil pump is scored. I had a bit of grit, or something, do that to mine and had the same low pressures until I changed the pump. No pressure problems, since. Randall