BA DOHC 4 - Power Steering Bracket 1

Got home from work yesterday at 3.30pm, and got stuck in to more bracket fabricating.

Power Steering Pump this time.

Using the top plate left over from the leaf spring shackle, I used mans favourite tool, (shed tool, not bed tool LOL) and used the angle grinder and a 1mm cutting disk to shape up the bracket. A bit of measuring, a few strokes of the . . . . drill press, and a bit of tidying up with the bench grinder I had a nice bracket. I dug around in my spare bolt bucket and was ready for the final fit.

Not to shabby I reckon.



Power Steering Pump bolted up. Looking Good!



Lines up beautifully with the exisiting pulleys. Threw on a spare serp belt for a look.


BUGGER!!!!!!

The inside edge of the belt just touches the top sloping edge of the timing cover LOL.

Not too hard to fix. I will use the first bracket as a template for the new one, and will lower the pump mount holes by 10mm. That should still give the bottom of the pump enough clearance above the water pump for a hose and clamp to fit nicely.

Once that is done, I will need to make up a bracket for the back of the pump.

I have to say, that this design and fabricating stuff is quite satisfying work.

Cheers
BenJ

Last edited by BenJ on Sun Oct 30, 2011 11:44 am, edited 1 time in total.

BenJ,

Very nice work dude! It is satisfying when it all starts coming together, and even more so when you finally have it running & can say I did that, making modified brackets to make it all work!

Cheers

ToranaGuy

are the fittings on the back of the pump the same on a eb as the ba?

Nice work Benj the eb is coming along nicely!

just one problem insurance must be a pain in the a**.

use a B series pump and modify the hose?

why fabricate a bracket that doesnt need it

The primary reason for making the power steering pump bracket is because I don't have a BA Power Steering Pump, but have a couple of spare E Series ones.

Ash, good thing you mentioned the bonnet clearance for the p/s pump. I will have to check into that.

Cheers
BenJ

heres one for 45 bucks on ebay
http://cgi.ebay.com.au/Falcon-BA-BF-4-0 ... ccessories

nice engine stand by the way!

LOL, yep, I always knew the stand would come in handy one day.

I have that BA Pump on my watch list.

Cheers
BenJ

This is a massive step forward Ben J using B series power- good luck to you

Just had a quick squiz and measure, from the top of the cap on the power steering pump sits 110mm below the top of the head. Just thought you may like to know.

Not really if your over 25 & get it engineered.

Cheers

ToranaGuy

BA DOHC 5 - Progress

Front Dress Complete



I acquired an alternator from an AU, which bolted up, giving me the last component needed. The serpentine belt used here is from the EF-EL. The BA belt tensioner has about 5mm more movement to allow the belt to be slid on. While I could use the EF-EL belt, I will see if I can source one that is 10mm longer for daily use.

**************************************************************
Having exhausted my non existent supply of suitable material to fabricate brackets from, I had two ideas. One was to visit Pick N Payless and grab some lower leaf spring support plates, and the other was to have a look around at Bunnings.

Bunnings was closer, and I found several suitable candidates in the building area.



The components on the right are all 5mm thick and the two plates are 3mm thick. The big U shaped bracket (designed to go on the bottom of a post) is around the $8 mark, just to give you an idea on how cheap these are as donor parts.

Now for some fabricating fun.

Power Steering Pump Brackets

As I need to remake the power steering pump bracket and lower the pump 10mm, I started there first.

I cut one long side of the U shaped bracket and then using my first attempt as a template I was able to plan the new bracket.


After much action with the angle grinder, bench grinder and drill press I ended up with this.


And mounted to the BA Bracket.



Now I could bolt the pump in place and start on the rear support bracket. Not having a welder to hand, I had to be a little inventive.


This photo shows how the rear bracket attaches to the block.


A couple of pics of the pump bolted in place.



There is approx 3mm clearance from the serpentine belt to the timing case cover. Hopefully the belt won't shake that much under use. I can't lower the EL pump any further than it currently is.


As you can see there is only just enough room now for the radiator hose and clamp to slide in.


Air Conditioning Pump Bracket

Now that I was able to run a belt across the pulleys, I could now work out how to locate the bolt holes in the adaptor plates. Through a fair bit of trial and error, educated guessing and a try-it-and-see approach, I marked and drilled the bolt holes. I then shaped the plates a bit and bolted it all together.

The shaped plates.


Due to needing clearance for produding bolt heads I useds oversize nuts as spacers to give me the required room. The bottom forward bolt head that attaches the plate to the BA Bracket, was also ground down 2mm, as it was protruding to far and hitting the side of the pump. The bolts are standard EL A/C pump bolts, and I will cut them a bit shorter, or source new replacement bolts.





I was a bit concerned that the pump may now be too far away from the engine and could possibly foul on the chassis, but it lines up with the outside edge of the BBM.


I guess we will see when I go to drop it in the EF.


SWC is coming over tomorrow and can critique my handiwork.

Next thing to look at is the heater pipes.

Cheers
BenJ

Last edited by BenJ on Sun Oct 30, 2011 11:47 am, edited 1 time in total.

WOW! That's juse sexy dude!

I really should make my modified alternator bracket to fit the EF/EL alternator into a EA-ED neater.

Cheers

ToranaGuy

Toranaguy,
If you're going to use the Ea-Ed belt, here's a piece of ancient history.
eb2-ed-i6-alternator-upgrade-t57831-20.html?highlight=alternator
Looking good Ben and our gas car's going, Near new engine and a 327 LSD! Hope to soon be ready for Sydney run. Talk to you later this week.
Cheers,
Mac

hey benji...with the heater hoses theres um a guy on here that did it...u use the usual ef/el heater hose thing on the bbm side and join the other side at the back of the block with a rubber hose...bit confusing but hard to explain.....search.. ba motor into 5 speed eb or bf turbo into 5 speed ed.. it has the pics there for it.. hope it helps