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Goodwood
by waikiore - 19/09/26 02:50 PM
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Jun 14th, 2026
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OP
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Apparently there have been cases with the 4 cylinder Zetec, where water has come in through the louvres and caused a misfire. Although the Roadster coil pack is high up at the front of the engine bay, any water which gets in can run down the HT leads and may cause a misfire. So for a while I've been wondering if a coil pack cover is feasible.  In the end I turned to Origami......  Next I turned to the scrap box where I'd salvaged some aluminium from an old shower. Out came the snips, and hey presto.........  Then came the tough part - the folding. I must be getting better, because one attempt produced this:  The centre fold will locate between the two rows of HT lead caps. Next, after some shaping with a hammer, and a trial fit:    Next the lining. 4mm standard density neoprene over the centre fold to locate the shield, and 3mm on the horizontal sections. There is a slight overlap all the way round. No chance of an HT short with this insulated lining.  Another trial fit..........   More to follow>>>>>
DaveW
'05 Red Roadster S1
'16 Yellow (Not the only) Narrow AR GDI Plus 4
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Next I applied the outer cover, using high density neoprene,which keeps the shape better..... using aerosol adhesive. This overlaps the aluminium former by quite a margin as you'll see next.  Underneath - where the 'overlaps' will be subject to engine heat I've applied Reflect-a-Cool adhesive heat barrier, and you should know by now where I get this stuff. It's looking quite good........  A final trial fit:    It's a push fit, and holds in place very well, but next a road test is needed to make sure it stays put, and doesn't get too hot. 
DaveW
'05 Red Roadster S1
'16 Yellow (Not the only) Narrow AR GDI Plus 4
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South Wales Correspondent Talk Morgan Expert
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South Wales Correspondent Talk Morgan Expert
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Dave,
AS soneone who has had water ingress problems with a 4/4 Zetec, I read the post and the pics with interest. Looks a great idea.
regards,
G
GLLHG
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Talk Morgan Enthusiast
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Dave, nicely done, my HT leads look a bit naked now, I'll have to get snipping.
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No water ingress with my 4/4 Zetec as it only has 12 louvres per side!
What about a deflector plate fixed to the underside of the bonnet, under the louvres to channel water to the sides, rather than over the cam cover?
Nigel
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Dave,
AS soneone who has had water ingress problems with a 4/4 Zetec, I read the post and the pics with interest. Looks a great idea.
regards,
G Try the shropmog website it has a fix. I never bothered but I know water always got in there. http://www.shropmog.co.uk/ See the Technical section
JohnV6
2022 CX Plus Four
2025 Renault Scenic Alpine etech "Yvette"
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Roadster Guru Member of the Inner Circle
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Post Photobucket Reboot from March 2010:Apparently there have been cases with the 4 cylinder Zetec, where water has come in through the louvres and caused a misfire. Although the Roadster coil pack is high up at the front of the engine bay, any water which gets in can run down the HT leads and may cause a misfire. So for a while I've been wondering if a coil pack cover is feasible. thinking In the end I turned to Origami......  Next I turned to the scrap box where I'd salvaged some aluminium from an old shower. Out came the snips, and hey presto.........  Then came the tough part - the folding. I must be getting better, because one attempt produced this:  The centre fold will locate between the two rows of HT lead caps. Next, after some shaping with a hammer, and a trial fit:    Next the lining. 4mm standard density neoprene over the centre fold to locate the shield, and 3mm on the horizontal sections. There is a slight overlap all the way round. No chance of an HT short with this insulated lining.  Another trial fit..........   More to follow>>>>>
DaveW
'05 Red Roadster S1
'16 Yellow (Not the only) Narrow AR GDI Plus 4
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Joined: Dec 2008
Posts: 22,385 Likes: 358
Roadster Guru Member of the Inner Circle
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OP
Roadster Guru Member of the Inner Circle
Joined: Dec 2008
Posts: 22,385 Likes: 358 |
Post Photobucket Reboot from March 2010:Next I applied the outer cover, using high density neoprene,which keeps the shape better..... using aerosol adhesive. This overlaps the aluminium former by quite a margin as you'll see next.  Underneath - where the 'overlaps' will be subject to engine heat I've applied Reflect-a-Cool adhesive heat barrier, and you should know by now where I get this stuff. It's looking quite good........  A final trial fit:    It's a push fit, and holds in place very well, but next a road test is needed to make sure it stays put, and doesn't get too hot. 2017 Note: This is still in place and doing the job.
DaveW
'05 Red Roadster S1
'16 Yellow (Not the only) Narrow AR GDI Plus 4
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