Moondust K-Reg MK3 2.3 Duratec-HE Turbo. SOLD on 26/06/2011

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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Fri Nov 21, 2008 7:56 am

FRSJON wrote:lovely progress mate...sorry about the sig..a mate of mine on there did it for me.. if i knew how to change it i would.... :rolleyes: :bonkers:


Hi Jon, I was only kidding mate :wink: Back working on the car again this morning - will have the MK4 Fiesta brake linkage bar fitted today and refit all the steering column again
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby luca on Fri Nov 21, 2008 10:01 am

Coming along nicely mate, that engine is one nicely designed set up.

Colour looks good to on the rocker.

Come on get on with it im bored at work and need another update :lol:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Fri Nov 21, 2008 1:21 pm

luca wrote:Coming along nicely mate, that engine is one nicely designed set up.

Colour looks good to on the rocker.

Come on get on with it im bored at work and need another update :lol:



Wish I could mate! - in the process of buying a bigger house and still got loads of crimbo presents to get so nothing expensive is being bought until the new year now.

I'll still be getting on with fabricating etc though - Pedal linkage is now all fitted, I had to fit the small bar that joins to the MK5 brake pedal to the cross-linkage bar from the MK3. It was a bit fiddly but it's all done now :aviator:

How come you changed your username? :-? Thought you were a newbie until i saw the siggy pic! :lol:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby luca on Fri Nov 21, 2008 1:37 pm

jimmyesh wrote:
luca wrote:Coming along nicely mate, that engine is one nicely designed set up.

Colour looks good to on the rocker.

Come on get on with it im bored at work and need another update :lol:



Wish I could mate! - in the process of trying to buy a bigger house and still got loads of crimbo presents to get so nothing expensive is being bought until the new year now.

I'll still be getting on with fabricating etc though - Pedal linkage is now all fitted, I had to fit the small bar that joins to the MK5 brake pedal to the cross-linkage bar from the MK3. It was a bit fiddly but it's all done now :aviator:

How come you changed your username? :-? Thought you were a newbie until i saw the siggy pic! :lol:



Yes I have the same situation, have some new ideas for the car but I have hung my modding overalls up for a few months to catch up with the real world :lol:

I changed my name as I wanted something a little more me, Its far easier saying Hi im Luca RATHER than Hi Im M4dyeti rahhhhhhhh! :rolleyes:

Christmas time wooo hoooo!
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jmeBDC on Fri Nov 21, 2008 2:41 pm

Loving the cam cover colour! And agreed polish that inlet! :aviator:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Fri Nov 21, 2008 5:39 pm

jmeBDC wrote: polish that inlet! :aviator:


I'll see how much energy I have left once the car is done first! :aaah: I'm really not into (insert ghey rap term) shiny bits everywhere but yeah perhaps I should spruce it up a bit! :wink:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby FRSJON on Fri Nov 21, 2008 6:16 pm

definitely polish at least the top of it...will look lovely...or cover it in carbon.... :Q :Q :Q
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jmeBDC on Fri Nov 21, 2008 6:29 pm

jimmyesh wrote:
jmeBDC wrote: polish that inlet! :aviator:


I'll see how much energy I have left once the car is done first! :aaah: I'm really not into (insert ghey rap term) shiny bits everywhere but yeah perhaps I should spruce it up a bit! :wink:


Quite true. I dislike shiny bits everywhere too, but thats just crying out for it :lol:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby Jam_84 on Fri Nov 21, 2008 7:10 pm

what an excellent project. look forward to seeing this done. was also quite impressed with the MANJ too :D


Keep up the good work. if nothing else it makes for excellent reading :D :Q :lol:


Ben.
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Sat Nov 22, 2008 2:25 pm

Bloody hell, why wasn't this little beauty for sale when I started this project?! :rolleyes: Would have saved me some serious time and perhaps some cash - would make an awesome tranplant into a MK6 Fiesta ST though don't you reckon? :-?

http://cgi.ebay.co.uk/2008-MAZDA-3-6-FO ... 240%3A1318
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby Ram on Sat Nov 22, 2008 3:00 pm

pedal box looks :Q as does green rocker cover. this is looking like one serious project with lots of one off's. well done :)
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby Ruishy1 on Sat Nov 22, 2008 3:53 pm

i seen that auction a couple of days ago, was gonna post it but didnt want to depress you :lol:
His ad is full of s**t though, i wanted to message him and take the piss, but tbh would not have been worth my time :P
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby FRSJON on Sat Nov 22, 2008 6:03 pm

cheeky engine that mazda one... :oooh: ... still think yours is more up to handling the power... :Q ... sig's been edited... :D
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Sat Nov 22, 2008 9:03 pm

FRSJON wrote: sig's been edited... :D


Lol cheers Jon I'm not really that sensitive buddy! :lol:

Yeah that Mazda lump will already have a stronger bottom end and maybe variable cam-timing when compared to a N/A Duratec but the ultra-high pressure fuel direct fuel injection system would be Bic™ to get working in a MK3 Fez I reckon :-?

I'm more than happy with my own engine's progress though - If Mazda's emissions-friendly lump makes 260-odd Bhp & 280 lb/ft then there's no excuse for mine not making 300BHP+ comfortably (could be the bloke who built it's fault if it doesn't though! :P )


Yeah his Ad is full of sh*t :lol: :rolleyes:
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Re: MK3 2.3 Duratec-Turbo MK5 Hydraulic Pedal Box fitted!

Postby jimmyesh on Mon Nov 24, 2008 7:35 pm

Hi everyone, got bored in my lunch break today so thought I'd tackle a niggly power steering issue :)

As you know, I have the PAS pump which is standard fitment on 1.8/2.0 Duratec Mondeos, 1.8/2.0 Duratec Focus and Fiesta ST (That's the one I have). The problem is that the Fiesta Si high-pressure PAS pipe won't fit the PAS pump of the Duratec and the Duratec pipe wont fit the PAS rack of the MK3.5 fiesta! :oooh:

The Mondeo MK3 rack high-pressure inlet connection is just a "push-in" type that has a plate which bolts it on to the rack, the fiesta one is a more conventional swivel-ended screw type that screws into the rack.

Therefore I carefully cut the Mondeo push-fit end off that pipe, (keeping the flat "collar" that's on the pipe to allow for a stronger base to weld to) did the same with the Fiesta screw-fit end from the Fez pipe, cleaned the faces up then carefully welded the Fiesta end to the Mondeo Pipe. A small bar was inserted into the pipe to keep alignment correct throughout.

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The finished article - later on I painted any exposed metal as the pipe is steel and I want it to last at least a year! :rolleyes:
Fits a treat too :Q

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Not the most exciting update I know but it's one of those crappy little jobs that I didn't want to do at the end.
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby FRSJON on Mon Nov 24, 2008 9:10 pm

well a updates a update.... :bonkers: ... i take it thats kinda the same as what i have going over the cam belt cover??.. need to change/ hide it some how...not the nicest looking thing... :oooh: :lol:
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby jimmyesh on Mon Nov 24, 2008 9:28 pm

FRSJON wrote:well a updates a update.... :bonkers: ... :


:lol: Fair one, I know it's not exactly an earth-shatteringly exciting update! Just though I'd try and show every hurdle that you can come up against when doing this conversion and how they're overcome...

FRSJON wrote: i take it thats kinda the same as what i have going over the cam belt cover??.. need to change/ hide it some how...not the nicest looking thing... :oooh: :lol: :


Yeah sort of mate except the metal part of mine does not go "over" the cam cover, the black rubber part merely sits in p-clips that bolt to the cam-chain cover so it looks a bit neater :)
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby FRSJON on Mon Nov 24, 2008 9:32 pm

nice.. can i fit one the same as yours to mine??..as im painting the rocker cover and going to get a vernier pulley on the exhaust cam i dont really want it sat where it is at the mo... :)
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby Alan12112 on Thu Nov 27, 2008 2:28 pm

Progress is coming along nicely Jimmy

I'm still on the lookout for one of those inlets for my turbo but they seem to never come up for sale :x
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby HCS PIMP on Thu Nov 27, 2008 4:05 pm

looking good admire the extra work ur takng out i went for the more simple si 2.0 but ive had it sat for a week as i need the 2.0 ecu arggg
2.1 Went BANGGGGG now a Ghia 1800
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Re: MK3 2.3 Duratec-Turbo Update 24/11/2008

Postby jimmyesh on Thu Nov 27, 2008 6:03 pm

Bit of progress today :D Got my sump back from my mate, Frenchie, at work who's kindly TIG welded my -10 turbo and -6 oil catch-tank oil returns which I bought from Earls hoses. The sump was cleaned of swarf and rubbed down, followed by a couple of coats of gloss black engine enamel. Sump and dipstic were fitted this afternoon :)

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He also fitted some new brackets that I made for the GRS intercooler (the old ones had seen better days...)

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Another niggly problem - The EGR valve needed removing as I'm not intending on routing exhaust gasses back into my inlet to save the planet! :rolleyes: (Looks awful too!) Here's the offending item...

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Using the old gasket as a template I made a blanking plate out of aluminium, here it is shown before I cleaned the mating faces and fitted a new gasket, along with some shorter bolts.

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Still waiting on my turbo manifold - it's been nearly 2 months now and I need that all fitted before I dummy-fit the engine :rolleyes:

Bye for now! :)
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby Ruishy1 on Fri Nov 28, 2008 12:38 am

lovely mate, cant wait till its finished :Q
Bit of a bugger with that manifold, you been on to the blower trying to sort it out ?
If you dont get any satisfaction how about getting one form a mazda 2.3 turbo................... :lol:
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby Captain Tightpants on Fri Nov 28, 2008 8:06 pm

Again cool mate. :)

I hate pissing around modding things like PAS pipes. You ever bought a new one? I retrofitted a FRST with PAS a couple or three years ago, I went to Ford and bought some 16v ones. Seriously overpriced! I ended up making some stainless solid ones in places anyway! :lol:

Looking good still mate, I always make sure I check on your thread. Always a good read,

Steve
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby jimmyesh on Fri Nov 28, 2008 9:20 pm

Captain Tightpants wrote:Again cool mate. :)

Looking good still mate, I always make sure I check on your thread. Always a good read,

Steve


Cheers Steve :D

I always try to keep costs down by fabricating in-house where I can.

Excursion kindly told me that my EGR blanking-plate is too thin and has to be at least 10mm thick (when made with Ally) - Something else to crack on with next week.

Also I'm tring to blag a trolley from work that I can place my engine on whilst fitting the flywheel & clutch, before fitting the transmission. That way I can move it all easily to the other end of the workshop where the crane and ramps are for dummy fitting over Christmas leave.

Come on Pumaspeed, hurry up with my manifold!! :aaah:
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby Captain Tightpants on Fri Nov 28, 2008 11:16 pm

Fair comment from Mark to be honest. Fair gap between those mounting holes by the looks of it. Is there a couple of core plug sizes that would fit?

Steve
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby jayrs on Sat Nov 29, 2008 1:59 am

come on nicely since i last looked in mate :Q
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Re: MK3 2.3 Duratec-Turbo Update; Thu 27/11/2008

Postby jimmyesh on Sun Nov 30, 2008 5:15 pm

Hey everyone, good news! :D

Got lucky on Ebay today and bought a Focus RS Gearbox (so much for not touching the Christmas spends! :rolleyes: )

As most of you know, the Focus RS Gearbox already has a Quaife ATB Diff fitted as standard, along with shot-peened gears and stronger bearings. Seeing as the Quaife is £520 + Vat (so more like £600) new on its own I've basically paid half price for it and it comes with an uprated gearbox too! :aviator:

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I'm aiming to collect it on Friday, once in the workshop I'll take the FRS "Zetec" MTX75 bellhousing off and swap it for my mondeo "Duratec" MTX75 bellhousing. I'll fit the flywheel, clutch and gearbox to the engine the following week when I'm on leave again.

Bye for now!
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby FRSJON on Sun Nov 30, 2008 5:51 pm

nice one mate... coming along nicely... :)
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby jayrs on Sun Nov 30, 2008 5:56 pm

nice little buy there mate :Q
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby Smo on Mon Dec 01, 2008 12:28 am

Wow, bargain with that gearbox! :D
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby Captain Tightpants on Wed Dec 03, 2008 9:13 am

Remember to put the magnet back in upon rebuilding!

I always forget and end up pulling it apart again!!! :lol:

Steve
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby jmeBDC on Wed Dec 03, 2008 12:55 pm

Bargain!
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby jimmyesh on Thu Dec 04, 2008 11:18 am

Captain Tightpants wrote:Remember to put the magnet back in upon rebuilding!

I always forget and end up pulling it apart again!!! :lol:

Steve


Magnet?! :-? Crikey I didn't even know there was one in there! :oooh: Every day's a school day ,eh? :lol: :P

Cheers Steve.
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby D.J on Thu Dec 04, 2008 11:30 am

Started reading through this last night and finished off this morning.

My God, what a job you are doing here!!! :o

Keep up the good work, and keep the updates coming...
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Re: MK3 2.3 Duratec-Turbo. I've now got a Focus RS 'box!

Postby binno on Thu Dec 04, 2008 2:33 pm

Huge transformation from when you got it, especially keen on the colour, looks great.
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