fiestaturbo.com

[black2]

Yeah will prob have a look & see whats gone in there. These boxes prone to this? Only reason i ask both mine & my brothers FRST's have pumped considerably more power & torque through their boxes and never had any problems. **touch wood**.

Gareth.

[jayrs]

the main weak point is the main shaft bearing, but if a old box is used and abused then its gunna $hit it self.
high power and low ratio boxes dont go well together though
i was just wondering if you were gunna strip it as i'll be interested to see what broke thats all mate.

[black2]

the main weak point is the main shaft bearing, but if a old box is used and abused then its gunna $hit it self.
high power and low ratio boxes dont go well together though
i was just wondering if you were gunna strip it as i'll be interested to see what broke thats all mate.

Well you make a good point there and its one that ive been thinking about. This box came from a 1600 fiesta si which was a chaved up example so i should imagine that its not had the easy'est of lives, lol When i picked said si up the clutch was slipping so bad that it was only just driveable.

Im going to whack in one of my spare xr2 boxes and see what thats like. Only thing is I loved that si box the ratios were stacked real tight and it was great for acceleration & its been so long since i drove an xr2 i forget what the ratios are like on them?

Gareth.

[jayrs]

bung the xr2 box in mate, you wont be disapointed
im sure there the same as the si too thinking about it, would have to check on that if you want

[sk8xtrm]

sorry to here about that mate! my si box blew before they really are not up to much at all! im running a diesel box and i cant recommend it enough very similar ratios to the si just strong! its doing me well thats for sure.lol Also i hear another good box is rs1800 but dont know myself.

Just to point out tho i dont know what the ratios are in the xr2 box apart from it woll do 100mph in 3rd and the si box is only capable of 80 - 85 in 3rd.

Just my input

Again sorry to hear about the box buddy!

[black2]

Yeah i will miss the ratios from the SI box.

Tomorrow night i shall be starting to strip the broken one out of the car - the xr2 box thats going in is allready out and ready & waiting to be fitted, just needs painting before it goes in.

Update tomorrow night.

Gareth.

[black2]

Well the car is now repaired and back on the road.

It turned out that the gear box it self is fine - just the drive shaft broke. The CV joint nearest the gear box has totally sheered off and destroyed the steel casing, split the rubber boot and flung grease everywhere. So all in it was a very simple fix, simply popped the broken drive shaft out of the gear box, collect the oil spill whack a new shaft in fill gear box up with oil and its running sweet again.

Ive out an xr2 shaft in that side now, so hopefully that one will be stronger as they are a larger diameter than the 1100cc items. If and when the driver side one goes i will replave that with an xr2 item as well.

So there we have it back on the road, really tempted to book a track day at castle combe in the coming weeks, its £170 for the entire day & that sounds like great fun to me.

Gareth.

[jayrs]

nice one mate, nice easy fix

[black2]

Hi chaps,

Small update - bought some escort gti wheels and done away with the pots. This was basically due to the fact that unfortuantly the xr2 wheels are in bad condition and as such were leeking air around the rims due to the peeling laucquer etc, plus all four tyres were shot so got these instead, was cheaper to buy these with four good tyres rather than refurb the pots and get new tyres.

Plus points are I think they suit it really well, no rubbing & better handling.

Heres a pic,



Gareth.

[jayrs]

deffo suit it mate.
looks good mate

[black2]

Cheers Jay,

A few more pics after a clean & treated plastics.







Gareth.

[Sphinx]

SO cool!

[jayrs]

[black2]

Ok chaps, been pondering about it for ages and seeng as I have most parts ive decided to start building phase two of the project B reg.

Heres a couple photos to give you a clue..............










































& one big give away



Yep ive got another 2.0l zetec to turbo. The loom above is out of my scrap xr2i i have had lying around and from reading the guide on here its easy to convert xr2i loom to ofac FRST. Im going to use a decomp plate (like heemans zetec turbo) with two head gaskets to drop the ratio down, im only planning on running very low boost around 7 psi.

More updates when things progress.

Gareth.

[jayrs]

nice touch mate, didnt think it would be long before you would want to turbo that bad boy

[black2]

Yep the only main bits i need really is the OFAC ECU & map sensor.

All the other big things i have. Not sure when it will be finished and im not interested in big power just want a low boost zetec turbo to build. Im getting itchy fingers again now so cant wait to start building up the engine.

Things i still need to look at are fitting the xr2i/frst fuel rail on the zetec inlet, which i will start looking at soon as i have a spare zetec inlet to dumy fit the fuel rail on which means i can keep using the car as it is at the moment.

Gareth.

[jayrs]

it will all come together in no time mate.

[black2]

Update.

Today i spent a little bit of time dummy fitting the rst manifold to an old 1600 zetec i have lying around so i see what needs doing to fit it to the head. I know the 2.0l head will have bigger ports but the 1600 gives me a good idea of where things need to go.

As you can see from the photos below there is good and bad news. Firstly it is my understanding from offering up the manifold that 3 of the bottom 4 zetec bolt holes can be used which is excellent news, that means i only have to drill and tap the four along the top. I would however like to hear from people if this is how they have done it, ie keeping the bottom three but re-doing the top four?

Now the bad news is that as seen below I cant run a T2 turbo which was my intention because a) I all ready have a spare T2 so no cost involved & b) the t2 set up would take up less space in the cramped mk2 engine bay. Now i have no choice though because as you can see the turbo sits to close to the water pump outlet meaning i would never be able to get the associated pipe work on. I looked at my FRST to see how close it is on the cvh - it is close but not this close. So the only option now is to go T3







Later on today or tomorrow i want to start looking at the zetec inlet with cvh fuel rail so more updates then.

Gareth.

[jayrs]

alright mate.
have you thought about getting the pipe outlet pipe modded to come off at a angle??
worth looking into mate rather than go T3


bit like this i mean

http://cgi.ebay.co.uk/Water-pump-ford-m ... 286.c0.m14

of it you use a mainifold adaptor plate to bolt to the head then the cvh exhaust manifold to the adaptor, it would space the the turbo etc away from the water pump a little more, ok 5mm or 1/4 inch what ever the palte thickness is, but it might be enough to get a elbow pipe on the pump and the one on the turbo..

[black2]

Jay thats a very very good idea and one i did'nt think of. The housing is aluminum though so i would have to get some one else to weld it? But still cheaper than buying a T3. Good plan.

Whilst your here, they way ive described the manifold fitment and with those pics : is that how other people have done it? i imagine it is because the ports line up good and proper like that.

Cheers,

Gareth.

[jayrs]

not just a bald head and a damn good looking face am i
yeah your have to get a alloy welder to do it, but in the long term its going to be the better idea i reckon, and someone might wled a new bit on for a drink mate, making it a nice cheap job, but it might be worth thinking about getting a new pump, last thing you want to do is weld up a old one and find that goes wrong 1000 miles down the line.

as for the manifold, i dunno how everyone else doe it mate, tbh ive see the plates used and ive seen new flanges welded to the mainifold, so couldnt say to be honest mate, but if the 3 bottom ones allow it to be fully lines up then go with it mate, but a plate might be a better idea to drilling and tapping the head, but i know this has been done in the past too, how well it works out im unsure mate.

sorry for late reply, my pc decided the hard drive had to die and im now using my old slow as $hit bag of crap, 10 mins so far to tap this message out, jesus!

[dangerousdave]

what about trying to weld lugs onto the top 4 holes mate??

[black2]

Small update today. After chatting with another member on here he is indeed correct when he says all of the holes have to be tapped. I offered up the cvh exhaust gasket today and you cant use three of the bottom four as i originally thought as the gasket would cover to much of the ports on the head. So i have to tap all eight.

Not done much else really apart from look at fitting the cvh fuel rail on the zetec inlet of which it dos'nt look theres any straight forward way of doing it so im still pondering on the inlet side of things.

Im tempted now to buy the inlet manifold adapter to allow fitment of the cvh inlet. THeres plenty of room to the bulkhead to faciltate this so it is an option. Do i remember reading though if you fit the cvh inlet to the zetec that you have space the top half from the bottom half in order for the throttle body to come over the top of the zetec cam cover??

Gareth.

[jayrs]

can you not use the rs1800 inlet and make the cvh fuel rail fit then?

[black2]

After some more investigations I think i will stick with the rs1800 inlet.

Im going to make two little "supports" from aluminium and then get my freind to tig weld them on the cvh fuel rail. This way it will bolt down the existing zetec inlet. I will get some pics and details of what I mean.

Gareth.

[jayrs]

sounds good mate

[black2]

Update 19.08.09

Small update had my 2.0 engine now for about a week, stripped all the unnecessary items off and proceeded to remove the cams, tappets and then the cylinder head ready for cleaning and fitment of the new head gasket and decomplate.

Inlet manifold & fuel rail will be ready for dummy fitment soon. After a lot of thought and conversations with people in the know I have decided not to drill and tap the head, ive heard not many good things about it so instead im using a manifold adapter plate which will be arriving shortly. Im only using a T2 so there should be no issues with clearence to the rad (fingers crossed).

Tonight I have throughly de-greased the block ready for painting/extra work. Ignore the water pump & sump as these are being removed.

PICS:











Gareth.

[knuckles]

loving the burgendy with the kit on

reminds me of my 1.1 mk3 my 1st fiesta. Wondered what a nice burgendy example would look like
Havent checked this post for ages ... you have made good progress. Makes me want a mk2 to play around with.

[black2]

Yeah the car has come on quite a way since I bought it, lol.

Just enjoying it with the 2.0l in at the moment but excited about building the ZT and dropping that in, as ive said from the start this is going to be no big power engine, just a bit of fun for me to build up certainly not spending much on it.

I think you should get a mk2, they are great fun and so light, much lighter than the mk3. I still have my FRST but its not been on the road for best part of two years now just tucked away in the Garage.

Gareth.

[jayrs]

agreed, mk2's are so much fun, go karts!

hoes it going with the water pump plans mate? decided what ya gunna do yer?

[black2]

Well Jay - Im hoping that because (in the above pictures) the turbo was in the wrong place that by fitting the 8-9mm adapter plate coupled with the fact the turbo will be brought further to the right as we look at those above pics that it will clear the outlet for the pump, thats the plan any way - if not, the end will be cut off and re-welded at the appropiate angle.

Just waitng for the adapter to turn up then I can dummy fit the turbo, down pipe, the air filter pipe and the bottom hose off the w/p to really see whats what.

Gareth.

[jayrs]

ah i see, fingers crossed it all comes together mate

[black2]

update 22/08/09

Small update. Today spent a few hours on the engine, removed crankshaft pully, cam belt and old water pump. Done a ittle more cleaning fitted the appropriate fiesta water pump. Then painted the block in a nice Blue and preped the cam cover ready for paint.

Still waiting on the adapter.... should be here soon.

PICS:







Gareth.

[black2]

update 24.08.09

Got a week off work this week, not really to spend on the engine mostly the House but today managed to squeeze in a few hours on the ZT.

My manifold adapter plate arrived today, I am very pleased with it, does the job fine and all the ports line up perfect the biggest plus point is that it does away with the need to drill the head. The only issue I have with it though is that its a little thicker than I was hoping for. It measures 10mm which I know is not a lot in most walks of life but in a mk2 Fiesta engine bay thats quite a lot - I wont know what effect this has on clearance issues untill the engine is bolted into the car. I have dummy fitted the head back on the block and bolted up the turbo to check for clearance to the water pump outlet. I have no photos today but - its tighter than I was ideally hoping for again Im not sure if its doable at the moment, not untill I fit the air filter pipe to the turbo and offer up a bottom hose, of which I dont have a spare one, still if it does'nt fit then I will get the outlet for the pump re-jigged to give the desired clearance.

Other than the above I painted the cam cover In Radiant Red which looks pretty smart.

As said no pics im afraid. But if I find time tomorrow I will hopefully dummy fit the airfilter pipe, exhaust down pipe and have alook at the oil feed for the turbo and get some pictures of the setup aswell. Would'nt mind fitting the crank shaft oil seal as well but will have to see what time is avaliable.

Gareth.

[jayrs]

10mm in a m2 bay, i hear you mate still i reckon your be alright with that though