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 Post subject: Weber Carby Upgrade Instructions suit any 4 cyl carby motor.
PostPosted: Sun Jan 15, 2006 7:30 pm 
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Joined: Wed Oct 05, 2005 5:58 pm
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Location: Ballarat
After a lot of people telling me i needed a bigger carby I decided to go for the ford 2ltr cortina/escort weber carby. Here's what i did to install it and I haven’t looked back...

First of all rebuild the carby or get a kit and do it yourself if your game! I sent mine to a bloke in Baccus Marsh and he did it for $240. While it with him he removed the choke and the whole choke mechanism ( a few clips and split pins).
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Once home I unbolted the old cable mechanism off the old nikki and replaced the weber one with it.
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With the carby off I took off the inlet manifold, and got a hacksaw blade and cut the center out of the manifold then with some steel grinders i set to work porting the carby inlet to suit the weber. This is how it finished up looking
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Along with the carby I got the adapter plate ( $35 at Autopro/Autobahn ) and the new studs and bolts to go with it.

All studs on the manifold have to come out and the two closest to the rocker cover replaced with longer ones to accommodate the adapter plate and weber. On the outside of the adapter the two bolts that are supplied with the kit i screwed in where normally the studs are for the nikki. These were a 7mm hex key to fit.
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Some windscreen silicon between the manifold and adapter plate sealed it and with that I put on the adapter plate. More sealer and I put on the weber on top making sure there was enough sealer to seal it properly.

Tighten nuts onto the 4 studs that are protruding through the weber to secure it properly.

Connect the main fuel feed (the bigger of the two hoses). Some webers have a return line also ( the smaller of the 2 hoses ) if it doesn’t then just put a bolt into the return line running from the petrol tank and put a clamp to make sure it doesn’t leak.
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To attach the accelerator cable I had to make up a bracket shown below, I'm handy with a mig welder and an angle grinder so it took me about 10 mins to build. To bolt it on i used the screws that normally hold the choke on and to hold the cable, I cut the piece off the standard carby and welded it on.
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You are now ready to tune your weber and test it out. YAY!!!

Once finished you can either whack the usual RAMFLO filter
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onto it or you can go and modify a stock gemmy filter to hide the weber to avoid trouble with the cops. Pics of it are below. It a few hours work and a bit of patience but well worth it and it covers the weber perfect and looks neat, which is wat the police are looking at when they check your gemmy.
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Side Notes:

1. As an after thought I have also set up a blow though supercharged setup using this carby and found that it's quite a reliable and good carby to work with. Also

2. After some looking and learning I have discovered that by putting a few washers under the driver's side engine mount you can actually tilt the motor over a bit and avoid the problem with the choke hitting the brake booster. This will avoid all the problems related with starting and it idoling while the motor is cold.

3. After more research I took off the cold air intake as it actually resricted the air flow to much and now just use a ram-flo filter.

4. Sorry to dissapoint anyone but I know use an EFI setup on my g200 and an EFI 13b rotary turbo in my other gem, but for those trying to get that little bit more out of your old 1600 the weber is yoru answer.

Hope this helps some people!!

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Last edited by Buggzy on Tue Jun 27, 2006 6:58 pm, edited 1 time in total.

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 Post subject:
PostPosted: Sun Apr 02, 2006 1:49 pm 
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Location: SA - The Boring State
How much tuning did it need?

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 Post subject:
PostPosted: Sun Apr 02, 2006 2:13 pm 
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actually dude i soldered up the jets and redrilled them all at 1mm, then i tuned it using the nikki carby tuning instructions in the gregory manual. and it was sweeet as.

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 Post subject:
PostPosted: Sun Apr 02, 2006 3:01 pm 
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Let me buy it off you :P

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 Post subject:
PostPosted: Sun Apr 02, 2006 3:58 pm 
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Location: Ballarat
ashzz/z wrote:
Let me buy it off you :P


you have pm :D

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 Post subject:
PostPosted: Sun Apr 02, 2006 8:08 pm 
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Joined: Wed Mar 29, 2006 8:13 pm
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Location: tasmania
that is the best idea. love it :lol:


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 Post subject:
PostPosted: Wed Apr 05, 2006 10:46 pm 
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Location: Caldwell, ID, USA
i never thought of getting rid of the material from the center of te intake inlet. gonna have to do that to my intake when i swap my g200 in my truck.


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 Post subject:
PostPosted: Thu Apr 06, 2006 12:05 pm 
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Location: Eaton
use some die grinding/cutter bits to get a better finish. might as well match port the manifodl while you ahve it off aswell

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 Post subject: Weber
PostPosted: Thu Apr 06, 2006 1:12 pm 
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Joined: Thu Mar 02, 2006 1:45 pm
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Location: Darling Downs West Qld
Buggsy

Thanks a treat, I liked the std air filter adaption?

I am putting a V6 Capri Web on me gem and will hide it likewise?

Good on Ya :lol:

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 Post subject:
PostPosted: Sat Apr 08, 2006 6:13 pm 
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Joined: Thu Mar 30, 2006 9:12 pm
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Location: Brisbane
I cant f*#cking believe this is on here!!!!

My internet has been down for the last few days and i just put a weber on my car that i got off a 2L CORTINA ... and i had to do ALL of this s*#t as the problems arised...

I should have waited and checked this!!! LOL

I took all of the choke mechanism out of mine though... where as you jsut pinned it open...


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 Post subject:
PostPosted: Sun Apr 09, 2006 12:31 am 
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Theres no choke on that weber...The choke hits the booster reservoir.

I tried fitting one yesterday, big flames came out of it when i went to start it...came off pretty quick.

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 Post subject:
PostPosted: Sun Apr 09, 2006 12:39 am 
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Location: Brisbane
i jsut meant the butterflies on the top there that have the wires holding it open.. i took of my choke mechanism too cos itw as some water controlled one... took it off..and took out the butterflies too... THATS what i meant by the choke..

EDIT. and after another look at the photo's in the second to last pic you have actually removed the butterflies all together... which is exactly what i did with mine.


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 Post subject: ..
PostPosted: Sun Apr 09, 2006 12:34 pm 
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Joined: Mon Mar 27, 2006 1:26 pm
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Location: Melb/Vic
ey, i just put a weber on my gem, havent made the accel cable yet, but its not running properly, i still got the choke on there, coz if i pit it open the car conks out i tryed clocking the hole a bit with my hand and it was running allrite, so i tightend the choke back on, it runs ok, but when i rev over 3000rpm it cuts out, like it hasnt got enough fuel? why? with the fuel line i done like u said "Connect the main fuel feed (the bigger of the two hoses). Some webers have a return line also ( the smaller of the 2 hoses ) if it doesn’t then just put a bolt into the return line running from the petrol tank and put a clamp to make sure it doesn’t leak. " Could u take a close up pic of all the other lines and how u connected them?


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 Post subject: ..
PostPosted: Sun Apr 09, 2006 2:33 pm 
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Joined: Mon Mar 27, 2006 1:26 pm
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Location: Melb/Vic
another thing.. do i have to connect any electrical wires to it?
and it backfires really bad, lol.. is that normal? when its idling and i accel a bit harder..?


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 Post subject:
PostPosted: Sun Apr 09, 2006 2:50 pm 
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Location: Brisbane
i pulled off all the choke stuff..with the electrical crap... the wires you unplugged from yoru nikki are for the electric choke...the weber doesnt have an electric one so those wires are useless...

the weber is only a basic carby, make sure you have blocked off ALL unused hoses, and check the around the carby for leaks...spray some brakeclean or WD40 or something like that around the joins and s*#t..and if it makes the car run s@*tter, then you have a leak there.... make sure it is perfectly air tight, apart fromt he top hole... lol.

mine ran like a bag first off too... but that was because i had an open pipe that i missed blocking off.


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