On our Zetec Engine, what do we do with the output from the PCV (Positive Crankcase Ventilation) oil separator and the cam cover breather?  In the good (or was it bad) old days these pipes were fed back in to the air filter input but you cant do that on a Westfield.  We asked Chris Masters the Question. "Route the pipes across the engine bay  and down the RHS space frame and vent to atmosphere was the answer". "DO NOT connect the two together or you will blow the clutch oil seal". ( I presume the one at the back of the flywheel).  "Or you could fit and oil catch tank".   Now you are talking.  We are not keen on dumping oily fumes over the inside of the engine bay or on the Queen's highway.

We began by searching the Westfield sites on the Internet. Most catch tanks seem to be DIY solutions ranging from tonic water bottles to old fire extinguishers.    Next the after sales and add on suppliers such as RaceTech and Demon Tweaks, as well as some local suppliers.  The going price ranged from around £45 to £65 + VAT.  The size was around 2ltr , which  seemed a bit large for our purposes, after all we don't expect to dump much oil, but it has to do with race regulations

We decided to try Westfield.  They should know how big it needs to be and where is the best place to fit one.  I was at the factory picking up some bits and asked to see one.  Andrew  (Westfield Parts dept) went an produced a used one. Where does it fit?  "Right hand side in front of the master cylinder"  "How much"?  I asked. "£45 + VAT".  I ordered one on the spot they take about 2 weeks to make and should be ready at the same time as I pick up the seats.   True to their word the tank was ready in two weeks.   I took the opportunity to examine a car at the factory to see where the tank fitted. Chris Masters wasn't there but I spoke to Chris Ball who took me to see the guy's on the shop floor.  They did not have one fitted, but said,  "Put a couple of brackets across the lower chassis members in front of the master cylinder and behind the engine mount and just bolt the tank to it"-…….Simple.  Of we went happily waiting the arrival of the catch tank.  I picked it up at the same time as I collected the seats.

Back at the garage we attempted a trial fit. The tank doesn't want to fit.  It is too long to go between the master cylinder and the RH Engine mount . The tank was approx 6.5 inches long, including the mounting brackets, and the space to fit it in is just less than 5 inches.  If you try to fit the tank transversely (another Westfield suggestion) it is too tall to go under the lower steering column.  Andrew is convinced that we have the wrong tank.   So I called Chris Masters.  Chris says it is tight, but is adamant it will fit.  Andrew is unconvinced.    

We discussed possible ways of fitting the tank using bridge type brackets to span the end of the master cylinder and the engine mount and even using the engine mount.  (When asked about this. Chris Masters said it was OK, and not an SVA problem as long as the tank was firmly secured.) We don’t like any of these solutions. Andrew is still not convinced we have the correct tank.  I think it is the only tank that Westfield supply and that whilst the design may work with other engines and master cylinder combinations it is not right for Zetec based installations

We continued to discuss possible solutions whilst we worked on the engine and engine testing.  Andrew remained unconvinced about the correct tank. Eventually before Christmas he called Chris Masters himself and got exactly the same story as I got.  We thought we could engineer a better solution with a custom built tank.  For example, if Westfield turned their tank on its side, it is narrow enough to fit in the designated space between the master cylinder and the engine mount and low enough to go under the steering column with   plenty to spare all round.  The inlet tubes, drain plug and site tube would need to be repositioned but it would make a good solution. We considered an "L" shaped design, to solve the clearance under the lower steering column, and took it to a local engineering firm for an estimate.  £85 + VAT.  At that price the Westfield tank WILL FIT.

Back to square one.  We set about making some mounting brackets to bridge the master cylinder and the engine mount.  We had tried earlier but were dissatisfied with the result.  We then realised that with major surgery to the tank we could get a better quality fit.  We removed the mounting brackets welded to ends of  the tank with a hacksaw and an angle grinder. We moved our brackets further in, away from the master cylinder and engine mount so that the tank would sit on top. We adjusted the height of the brackets to lower the tank leaving plenty of clearance.  We marked the points on the brackets to drill the tank and chassis mounting points.  The base of the tank was drilled and rivnuts inserted sealed with Hermetite (orange).

The tank was then painted, silver ant the brackets satin black.  Andrew found some heater pipe elbow fittings 5/8", in Halfords,  which were a good push fit over the pipes in the top of the tank. However they were, as expected, a tight fit in 1/2" rubber hose. However with the aid of some washing up liquid and some WD40 they were persuaded to fit and secured with Jubilee clips.  The pipes on the top of the tank and the elbow connectors were trimmed to give maximum clearance above the tank and the neatest hose run between the engine and the tank.  The tank was then mounted in place before we put the body on. We don't expect to collect much oil but it does neaten up an otherwise an untidy part of the engine installation.