Building A Cosworth Powered Kit Car

Brake & Fuel Lines

The next Section of the build manual was the brake and fuel pipes. I had borrowed a pipe bender, pipe cutter and pipe flaring tool from Richard at Tremona Garage. One neat feature about the Xtreme is that most fixing holes are already laser cut meaning the fitting the brake and fuel lines was a simple case of pushing the clips in the holes and carefully bending the supplied copper nickel pipe in to shape. Note the word "carefully" as I had to go down the motor factors and buy some more copper nickel pipe after kinking the difficult to bend fuel lines.

The fitting of the brake pipework to the rear basically followed the build manual. As I did not know exactly what my pedal box was going to look like. I left the a long length of the front part of the brake line unfinished until such time as I knew where to locate it.

As I was intending to use a balance bar for the brakes, I also now required a second T piece for the front brakes. The T piece will be fitted near the laser cut hole on the offside front of the chassis where the offside front brake line passes through. This means only 1 length of brake line needs to come from the pedal box to the front T piece. Then 1 short length of brake line goes from the front T piece to the laser cut hole on the offside front and another length of brake line travels across the front crossmember to another laser cut hole on the near side front. Luckily, I was able to utilise most of the laser cut fixing points that would be used for fitting the conventional brake line setup.

At this moment in time, I had no idea on where the fuel pump will be fitted, was it to be an Escort Cosworth in tank item or a Sierra Cosworth externally mounted gravity fed item? Was I going to use an internal or external swirl pot?, so again I routed the fuel lines down the transmission tunnel but left plenty of fuel line spare at each end to allow me to route it to the correct pace later on.