rzempel Posted October 27, 2009 Share Posted October 27, 2009 For all those considering, thinking about, planning, or starting to upgrade your LSIS, I offer these words of warning.... This past February, I installed Woody's radius rod kit in my Birkin's rear suspension. The improvement was dramatic. So, I started thinking about the reportedly fantastic improvement I could get by installing the wide front end kit. As I began thinking about that, I also started wondering what it would take to get a a little bit more power from my series 2 Zetec--the one with the awkward exhaust cam smog thingy. I knew that the ZX2 motor wasn't easily upgradeable, but I expected I might be able to find a cheap ZX3 motor from which to scavenge the head. So, I poked around on Craig's List a little bit...which turned out to be like being told by a girlfriend, "I'm a little bit pregnant." Immediately, I spotted an ad for a fully built Zetec race motor with all the right bits. The price was ridiculously low, compared to the individual parts: Ford Racing head, Crower Stage III cams, Probe 10.2:1 pistons, Eagle rods, ARP bolts, straightened crank, Fidanza flywheel, Ford Racing manifold, and Ford Racing 72mm throttle body. I convinced myself that I'd never see a deal like that again, and that it would be an easy engine swap to get all the power I'd ever want. So, I made the deal and had the motor shipped from New York to Los Angeles. Once the motor was on the way, I decided to do everything at once--wide track front end, Outlaw brakes, Emerald ECU, Wide-band O2 sensor, lowered driver's floor, better seats, and a bunch of little things to get it sorted. For awhile it was like Christmas every few days as packages arrived, were opened, and carefully stacked around the Birkin. Once all the parts I had ordered, including the motor, were in place, I took a deep breath and started cutting wires and disassembling my car. That was March. I figured that I ought to be done in two or three months...easily before summer driving season. It's now almost November, and I'm not driving my car. What went wrong? First of all, none of the existing sensors were correct for the new motor or the Emerald ECU. So, I spent days combing the local wrecking yards for suitable sensors--what can I say, I'm cheap, I'd rather spend a few hours and a couple of bucks than shell out hundreds for things like MAP and air temp sensors. Having to re-wire the new sensors into the loom gave me the opportunity to completely rewire the car from the fire-wall forward. That was entertaining. Also entertaining, was pulling the motor five times. First, the Fidanza flywheel was about 50 thousandths too big to fit inside the Birkin bellhousing. My "clever" solution to that was to put a carbide straight fluted bit in my router and carve away, using the steel spacer plate as a template. that worked, but I combed aluminum bits out of my hair for days. Next, I had a leak between the engine block and the oil pan. 'What do you mean there's no gasket...does Ford really say lay down a huge thick bead of goo, that can easily squeeze into the oil pan and block oil passageways? Yup, they really do. Finally, the Fidanza clutch didn't work with my Birkin clutch actuating system. There wasn't quite enough throw to completely disengage the clutch, and no more adjustment range. I decided the best way to fix that was to re-design the geometry of the throwout arm. After I did that, I discovered that a previous owner had cut the actuating rod short. If I had seen that first, I could have probably just replaced the arm. As I discovered the hard way, not all of the parts I had fit either inside the cramped engine bay, or with each other. The nice Ford Racing manifold, for example, won't clear the diagonal frame member alongside the motor. Without the Ford manifold, the 72mm throttle body was useless. So, I checked around and found a 65mm body at Central Florida Motorsports. Sure, I could've gone the traditional route and ordered Jenveys, but haven't I already mentioned that I'm cheap? With the engine finally sorted, I installed the wide track front suspension and new brake calipers. That was entertaining. To accommodate the new upper shock mount, one of the existing suspension holes needs to be widened, and there's no template. I wasn't happy to make blind cuts in the skin of my car, but I managed. The new bits went together fairly well, with only a few holes needing re-drilling for alignment. I did find the two upper rear bolts were too short, though. I got the right length bolts, and discovered that I had to disassemble the whole wide track kit to change the bolts. Like I said, entertaining. Next on the list were the seats. After much research, hand wringing, and teeth gnashing, I ordered a set of the new Birkin "racing" seats, sight unseen, from Dick Brink. As it turned out, they are far more comfortable that the vinyl covered plank that passed for seats I originally had. And, the shape of the bottom lent itself well to lowering through the floor. I measured very carefully, and cut holes in both driver and passenger side floors. With the seats on new frames that I welded up, I can now sit in the car without my head sticking far above the roll bar. I riveted some pans up underneath the car to cover the holes, and everything looks great. I even replaced the out-of-date harnesses with spiffy new ones...and, made up some new brackets so they could be mounted correctly. At that point, nearly everything was done. I still have a fuel swirl pot to install, but that can wait. I had chosen the Emerald ECU because it's more user friendly than others. It has, purportedly, such an ease of use that just about anyone can get their car running and tuned fairly well just by driving it. Ha! I actually did get the car running, and was working on tuning. But, I knew the MAP sensor I had chosen wasn't working correctly so I changed it for the right one. Tuning went downhill from there. I couldn't get any repeatable results, and finally I threw in the towel. The car is now at JBA Racing in San Diego for dyno tuning. One of these days, I expect to finally drive my Birkin again. Will somebody, please, hit me if I mention that I'm thinking of upgrading anything in the future...? Link to comment Share on other sites More sharing options...
Kitcat Posted October 27, 2009 Share Posted October 27, 2009 I am exhausted just reading about this! We all can identify with your problem tho. I think bankruptcy is the only proven cure. Should be quite a car when you are done. How much hp are you hoping for? Mike Link to comment Share on other sites More sharing options...
Boxologist Posted October 27, 2009 Share Posted October 27, 2009 ttiwwop Link to comment Share on other sites More sharing options...
gpennino Posted October 27, 2009 Share Posted October 27, 2009 That happened to me during last 6 month when I painted the whole car. I planned 1-2 month and took me 6! But after finishing, all I can say is I would do it again... :hurray: Link to comment Share on other sites More sharing options...
rzempel Posted October 27, 2009 Author Share Posted October 27, 2009 How much hp are you hoping for? As John D. Rockefeller allegedly said when asked, "How much money is enough?" Just a little more. :-) Right now, it's 178hp at the wheels, and 152 torque. I suspect I'll be happy with that, when the current non-start issue is solved. Link to comment Share on other sites More sharing options...
rzempel Posted October 27, 2009 Author Share Posted October 27, 2009 ttiwwop OK. I didn't take many pictures, since the parts pretty much look like, well, parts. Here's one I snapped with my phone during the wiring phase. Link to comment Share on other sites More sharing options...
catracer Posted October 27, 2009 Share Posted October 27, 2009 OH my, BRG TR 250? or a TR4 for next door neighbor? Raced a 4 for a while. Talk about dropping a boatload of bucks.... Link to comment Share on other sites More sharing options...
rzempel Posted October 27, 2009 Author Share Posted October 27, 2009 1964 TR4. I've had it since 1980, though it's now parked at my Dad's house. I had to clear a space for my wife while I work on the Birkin, and it was either the TR4 or my '60 TR3. When I raced motorcycles, I discovered the secret to making a small fortune from racing...start with a big one. ;-) Link to comment Share on other sites More sharing options...
Kitcat Posted October 27, 2009 Share Posted October 27, 2009 Your hp is almost double mine and mine is still pretty speedy. When you factor in the perception of speed (wind, noise, vibration, people pointing in amazement, etc.) 50 mph feels like 100. So it's never dull. Great looking bunch of cars, BTW. The Birkin will definitely push the performance envelop up a notch! Mike Link to comment Share on other sites More sharing options...
catracer Posted October 27, 2009 Share Posted October 27, 2009 So true. This madness started in 1975. Graduated from college, sold the VW microbus for $600 bought a TR3-A for $375. Picked up the 3 and drove home from NoVa in a pouring rain with no 1st or 3rd gear. heater not working, steamed up inside, I-64 rush hour......wipers marginal...water coming in through the numerous rust holes in the floor, screen and sidecurtains. Survival was so unexpected that the hook was forever set. I've had a TR3, or at least enough boxed parts to claim a car, ever since. The current is actually running/driving, for now anyway. Link to comment Share on other sites More sharing options...
rzempel Posted October 27, 2009 Author Share Posted October 27, 2009 Great looking bunch of cars, BTW. The Birkin will definitely push the performance envelop up a notch! I should hope so! :-) The Birkin already made this one (my daily driver) feel fat and lazy. I'm anxious to test the difference with more power, better brakes, and superior suspension. Link to comment Share on other sites More sharing options...
soareyes Posted October 27, 2009 Share Posted October 27, 2009 After reading your story, I think I like my Birkin exactly the way it is now. Of course that won't be true anymore once you get yours running and you leave me in the dust on our next drive! Think you'll have it ready for Gert's Thanksgiving blat? Link to comment Share on other sites More sharing options...
slngsht Posted October 27, 2009 Share Posted October 27, 2009 good job! If you're gonna upgrade, you might as well jump in head first. Link to comment Share on other sites More sharing options...
rzempel Posted October 27, 2009 Author Share Posted October 27, 2009 I sure hope so, though I'm starting a week-long road-trip to Northern California on Sunday before Gert's blat. I'm hoping the Birkin will be done and it will only be a weather question if I drive it or a car with a fixed top. The motor is fully tuned, and runs great once started. It has a vexing cold start problem, though...when fully cooled, it won't start. I've become convinced that your method for upgrading was the least painless, and perhaps I should have done it that way, too. Link to comment Share on other sites More sharing options...
7evin Posted October 28, 2009 Share Posted October 28, 2009 I agree with Mazda, If your going to do it do it full on..... Of course that is sure not the painless way... It is defiantly a sickness.... But I can think of allot worse things that aren't near as fun. The reward you receive in the end completely out weighs the challenge.... It is going to be an awesome ride when the kinks are worked out..... Link to comment Share on other sites More sharing options...
Mondo Posted October 28, 2009 Share Posted October 28, 2009 I started my sportscar lineage with a Lotus Europa (Renault motor). Loved the handling but not the motor or the fact that I was literally only protected by 1/4in of fiberglass. Then got a restored TR6; best sounding car ever (when carbs were synched), should of never sold it. But is was a semi-daily driver and showing up places soaked in sweat due to no A/C was an issue. Several dirt bikes & a sportbike later, I think the S2K will be around for quite a while. As far as the disease.... I think the car has most the little bugs worked out but I have a daughter going to college next year so the supercharger is on hold:( Link to comment Share on other sites More sharing options...
7evin Posted October 28, 2009 Share Posted October 28, 2009 My first car was a 1972 914 porsche that I bought when I was 14 for $1200. Bought it from the money I saved from 2 years of tobacco crops. From age 16 to 18 I lost my lic 3 times.....always testing and tuning in the wrong place. I still have the car. Some things get in your blood and thats it Link to comment Share on other sites More sharing options...
Alaskossie Posted October 28, 2009 Share Posted October 28, 2009 rzempel, I do feel your pain.... take a look at the thread on this list titled "I've thrown in the towel," starting 7/17/09. My upgrade-itis began even before my assembly of the 2007 Caterham kit was started, let alone finished. As a result, after more than two years of long commutes and mounting frustrations, my car is now being completed by ace ex-Caterham UK engineer Nathan Down in Colorado. His help has been invaluable. He informed me that my chassis, intended for the Duratec engine from Cosworth USA, was shipped from UK with a Zetec wiring loom. As a consequence, Nathan has had to pull 54 additional feet of wire into the loom to make the Duratec work with the Zetec sensors etc. as well as to accommodate some of my upgrades. The upgrade-itis pandemic is an equal-opportunity affliction, but it hits the inexperienced (like me) the hardest. Good luck with your car -- sounds like it's mostly downhill from here on out. Someday, you'll be able to have a laugh over your experiences (I hope -- for both our sakes). Link to comment Share on other sites More sharing options...
BusaNostra Posted October 28, 2009 Share Posted October 28, 2009 I'm the other way, "fabrication has no rules: I love to tackle the impossible and make it possible. It's a challenge, food for the brain. Source are people. If you talk to someone, he/she will lead you to a promise land. "No man is an island" Link to comment Share on other sites More sharing options...
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