fiestaturbo.com

[Twiddle]

Looking good i have always like the mk2, but they are getting a bit thin on the ground now.

I am doing a T2 zetec turbo in my mk3.5 soon, and the water pump issue is now then only real problem by the look of it. My car is also already running a 2.0 zetec on mondy management with a few little mods (filter 4 branch manifold powerchip) but its just not good enough after drivin my ERST for 12 years (no in garage for full resto) so i need to turbo the fez, but like you dont want to spend too much as its only really a run about car and track day toy while escort is sorted.
As your is a mk2 what rad and intercooler will you use? and its worth looking at focus rs pistons and rods it picked up a set of new pistons inc rings for£100 and rods inc ARP bolts for only £80

[black2]

Been doing some research but struggling a little, wonder if anyone can help.

Basically I want a three way adapter (male,male & female) to screw into the back of the block where the oil pressure switch is currently located. I want to screw the adpter in the existing hole, screw the oil feed to the turbo on the new male fixing and then screw the oil pressure switch in the female. Sounds very simply and ive seen pictures of it done this way. Below is a diagram I quickly knocked up to show what im going on about :



Trouble is I cant find anything like this anywhere all I keep seeing is an adapter with one take off or a three way but two females and one male. Surly you can get such a thing?

If anyone knows please help me out as I need this to supply the oil to the turbo.

Gareth.

[Smo]

Replied to your other post about this, but I'll post it in here too...

Don't you just need a standard FRST oil feed adapter?

[jayrs]

same was what i was going to say simon

[black2]

Thats 100% what i need. I did'nt even think to look on my FRST to see how thats configerated feel silly noe, lol.

Any how thats great, where can I order it from?

Thanks again,

Gareth.

[allinking]

You cant get them from Ford any more that's for sure lol but lots of people seem to have them as when I was trying to sell mine loads of people replied and offered to sell theirs for less than mine

[jayrs]

i think i have one spare mate, will have to check the workshop though, cant check till prob saturday morning

[black2]

i think i have one spare mate, will have to check the workshop though, cant check till prob saturday morning

Jay mate your a legend.

Gareth.

[jayrs]

i think i have one spare mate, will have to check the workshop though, cant check till prob saturday morning

Jay mate your a legend.

Gareth.

you dont even know the price yet




1 MILLION DOLLERS!

[black2]

There goes the budget ZT lol.

Gareth.

[jayrs]

indeed

[black2]

Heres some pics from what I was talking about last week. Its not pictured but I have dummy fitted a suitable bottom hose and the good news is there is enough room to fit it all in with out needing to alter the water pump outlet.

Things left on the list to get the engine its self ready are :

1. Oil feed adapter
2. Decom plate & head gasket
3. Zetec inlet sandwhich plate (that the fuel rail sits in)
4. Drill block for oil breathing

Item three - I already have one but its being used on the car atm and I dont wont to be taking that all to peices only to put it back together again for driving everyday. I have a spare inlet manifold and fuel rail etc, but i need the sandwhich plate so I can mock up the inlet side of things. The main reason is due to using a cvh fuel rail & injectors I *think* im going to have to move the iscv to rear of the manifold, I had a quick look today and offered up the new fuel rail best I could to the car and it looks tight with the iscv but wont know for sure untill I can mock up a complete inlet scenerio hence needing that plate. If anyone has one let me know please.







Gareth.

[jayrs]

you can knock something off that list, i found the adaptor today mate

[black2]

Jay thats awsome bud , how much?

Gareth.

[jayrs]

pm'ed ya mate

[black2]

Pm'd you back buddy.

[my-first-rst]

loving the car mate such a sleeper ! where did you get the adapter plate for the turbo to head from ? and are you using a copper or stainless de-comp spacer ?

steve

[black2]

HI all,

Not much of an update really. Few more things have arrived including the oil feed adapter from Jay, who by the way is a total legned, cant thnak yoiu enough for that mate. Also got my sandwhich plate for the inlet manifold. Had a very quick mock up of the inlet side the other day with the fuel rail arrangements of which im going to have to relocate the iscv which hopefully wont be too bad.

Other than this the car its self is going for its mot tomorrow @ 8.00 in the morning. Fingers crossed.

Gareth.

[jayrs]

your welcome mate.

when you say re-locate the ISCV, you got a remote plate to bolt it too? like what the escorts use?

[black2]

Just a follow up on the mot side of things.

It went in Wednesay morning and.........................failed but only on two very minor things being : Passenger trackrod end worn out and the other thing was drivers side outer CV boot had split.

So when I got home from work on Wednesady went stright down and repaired it, rather then fit a new CV boot to the 1100cc drive shaft I simply removed the whole lot and fitted in my xr2 shaft. thought it was a good oppertuinity to do so. Then took it back the following morning and it now has a full ticket. The mot'er commented on how good the car is underneath, no rott anywhere

Happy days.

Gareth.

[jayrs]

i belive its time for more pics mate

[black2]

Been doing some more work, research this evening.

I have struck a few problems though, one of which being that the remote iscv on my scrap 2i is the early webber variant and as such is moulded to the air box, so I cant use that, I need the later Hitachi designed valve.

The second problem im having is with the TPS on the zetec TB. Ive read that when using FRST management (which I am) you have to use the FRST TPS. I did intend on fitting the FRST TB to the zetec manifold but this invloves a 5mm spacer to prevent the throttle linkage fouling the manifold its self and I have no alluminium to make one. Plus all the other issues of using ther original zetec manifold such as fueling (need to use top feed injectors) but when doing so takes up the space where the original iscv sits etc etc etc......

So Im now thinking of buying the adapter plates from Ferriday engineering to allow fitment of the entire rs turbo inlet manifold, this gets over all the issues with fuel rail, TPS's & idle valves etc. The only two problems I see with this method is

a) its costly (£200) &

b) The ports dont line up 100% between the cvh manifold and the zetec sandwhich plate.

Its serious thinking time as im not sure what to do.

Gareth.

[jayrs]

well thats not a problem mate.

i have some alloy about er, 7mm thick i think but no time to make one up for you right now as such, although over the next few weeks i will be getting one of the lathes up and running in the work shop so could trupan (if thats how its spelt) the bore of the spacer out, hmm, its do-able though with what i'll have running shortly, hmmm

anyway, as for the ISCV, use the later type remote one, which basicly uses the FRST ISCV on a remote housing as shown below, and is whats fitted to escorts, and i think i might even still have the one pictured below somewhere in the shed






if you had a plate to put on the manifold with pipe take offs, or even put take offs in the holes that are already there you could pipe it up to the remote ISCV.
bit of work and messing about, but over all, wont cost hardly anything just time
well, there would be my wages which will bankrupt you

[black2]

Jay that sounds cool.

Basically I have two options.

1. Stick with the zetec manifold, space out and tap the manifold to fit the cvh throttle body. Block of the existing zetec iscv location. Make a take off on the rear of the manifold to allow for plumbing of the remote xr2i iscv. Sort out a suitable fuel rail.

2. Go the expensive route and get the two adapters from Ferriday engineering to allow fitment of the cvh manifold.

Pro's and cons of both are :

Option 1. Pros - Its far cheaper & retains the zetec manifolds. Cons - A lot of messing with spacing the cvh TB, fiddling with fuel rails and blanking off the original iscv location.

Option 2. Pros - Simply easy fitment, no messing with fuel rails, Throttle positions sensors or iscv's. Cons - Its bloody expensive @ £200

What would you do mate? Would you be able to knock up a spacer to allow firment of the cvh TB on the zetec inlet? How much would you want for that? Also If you have a spare remote iscv I'll take that off your hands also, just let me know how much £.

If I carry on like this, this engine is going to be co-built using all your spare parts and your skills lol, It'll be like your own zetec turbo.

Gareth.

[dangerousdave]

hi pal forgot your doing a budget zetec turbo too! well im collecting parts at the moment but its almost identical to you as i have new t25 i am using and all my cvh stuff!!

i am using the zetec inlet, i know you can use the 200sx inj in the zetec rail but there only 10.7 ohms so i am assuming they will overfuel with ofac management!? and i cant aford megasquirt at the min

also @ jayrs could you explain how the iscv would work from another mounting location? do i make a plate with a pipe fitting in to cover the side of the inlet? i will be making all the bits myself as im an engineer too buddy and ill go highjack my old works shopfloor!!


sorry for the slight highjack mate and its looking great so far cant wait to see how you sort the last stage of the engine out!!

[jayrs]

Jay that sounds cool.

Basically I have two options.

1. Stick with the zetec manifold, space out and tap the manifold to fit the cvh throttle body. Block of the existing zetec iscv location. Make a take off on the rear of the manifold to allow for plumbing of the remote xr2i iscv. Sort out a suitable fuel rail.

2. Go the expensive route and get the two adapters from Ferriday engineering to allow fitment of the cvh manifold.

Pro's and cons of both are :

Option 1. Pros - Its far cheaper & retains the zetec manifolds. Cons - A lot of messing with spacing the cvh TB, fiddling with fuel rails and blanking off the original iscv location.

Option 2. Pros - Simply easy fitment, no messing with fuel rails, Throttle positions sensors or iscv's. Cons - Its bloody expensive @ £200

What would you do mate? Would you be able to knock up a spacer to allow firment of the cvh TB on the zetec inlet? How much would you want for that? Also If you have a spare remote iscv I'll take that off your hands also, just let me know how much £.

If I carry on like this, this engine is going to be co-built using all your spare parts and your skills lol, It'll be like your own zetec turbo.

Gareth.

me being me, i wouldnt give someone £200 of the queens face just for a couple of adaptors, im not saying there bits aren't worth it, after all people gotta make a living, even if i do thing its over priced......, but the way i look at it is, if i was in your shoes, i have the machines, ok not wired up yet, i used to be/am a engineer, so i would make the bits up my self to do the job i want it to, yeah its a bit of messing about, but just look at what its taken so far to get a injection engine in a mk2...... look at these things as finishing touches, i would


you also got to remember mate, in a mk2 bay there isnt much room, and what space would you have by using the cvh inlet with these adaptors?

back onto the bits, first off, i wouldnt let a iscv go as i only got a couple spare i think, but you got a cvh inlet so you should have the iscv it self yeah, the remote bit, tbh, prob aint ever gunna use it so you know..
just bear in mind the zetec iscv wont fit it as that has 3 bolt holes and the cvh one has 4

as for the spacer plate, i'll have to have a look into whats needed to make the cvh TB fit on the zetec mainifold, and i cant look untill i got to the workshop as my zetec inlet is wrapped up tucked away in the corner waiting for the xr2 to be done but off the top of my head i think 1 maybe 2 bolt holes dont fully line up, or am i thinking of jons old janspeed inlet, i dunno, been a long day mate

and the fuel rail, with the iscv out the way fitting this should be ok, the plate to block off the old iscv location need not be thick alloy, couple mm thick bit of steel or a few mm of alloy will do it with a gasket/gasket sealer
this though would be a bit more involved to make if you wanted it machined the same shape as the iscv, although some time with a vice and a flat and rats tail file would see one come to life

also @ jayrs could you explain how the iscv would work from another mounting location? do i make a plate with a pipe fitting in to cover the side of the inlet? i will be making all the bits myself as im an engineer too buddy and ill go highjack my old works shopfloor!!

yeah basicly, knock up a blanking plate for whats there and take off from else where like black2 mate, or take off from the plate point, it shouldnt really matter tbh

the iscv allows "X" amount of air through while on idle, the valve is opened by the ecu to allow more in, so basicly allowing both these holes to merge into 1 pipe after the iscv then back into the inlet, is no different to having 2 holes in the inlet, 1 is always going to have a bit coming though, the other will only let a bit more in when the ecu tells it to, so as long as the air thats needed gets into the inlet / engine, then using a remote or fixed iscv shouldnt make a differance really

[black2]

Jay - I know what your saying. The CVH throttle body needs three of the four holes tapping out along with the spacer plate in the middle. Like you say its not a big job but unfortuantly I dont have the materilas or the machines to do it. Let me know if you can chap as that would be a massive massive help.

The iscv no worries about that im sure I can find one on flebay or a scrappy etc & I have worked out how I would plumb it in : I would take one feed from the Fiesta RS Turbo cross over pipe, then I would chop the original outlet off of the cvh manifold (the one the rubber pipe goes to on the FRST from the cross over pipe) and get my freind to weld this on the zetec inlet, job done I would just mount the valve in a suitable position in the bay etc.

Fuel rail wise on the zetec inlet, im pretty sure of how to go about that, black top fuel rail & blank off the old place for the iscv.....

Gareth.

[dangerousdave]

does the black top use top fed injectors then pal??

dave

[jayrs]

Jay - I know what your saying. The CVH throttle body needs three of the four holes tapping out along with the spacer plate in the middle. Like you say its not a big job but unfortuantly I dont have the materilas or the machines to do it. Let me know if you can chap as that would be a massive massive help.

The iscv no worries about that im sure I can find one on flebay or a scrappy etc & I have worked out how I would plumb it in : I would take one feed from the Fiesta RS Turbo cross over pipe, then I would chop the original outlet off of the cvh manifold (the one the rubber pipe goes to on the FRST from the cross over pipe) and get my freind to weld this on the zetec inlet, job done I would just mount the valve in a suitable position in the bay etc.

Fuel rail wise on the zetec inlet, im pretty sure of how to go about that, black top fuel rail & blank off the old place for the iscv.....

Gareth.

sounds likea plan to me mate.

as for the spacer plate, drilling and tapping isnt a problem, i have a shed load of taps and dies and a piller drill thats working in the workshop.
im sure i can help, but i got a $hit load of college work i have to get done for tuesday and im on call over the weekend so i dont think ill get a chance to do anything this weekend, but i'll play it by ear, if i get a spare half hour once things are done i see what i can do, but it will prob have to wait till in the week

[black2]

Jay,

Been doing some looking about and I have come across on flebay some sheet alluminium 250mm x 250mm x 6mm thick. Its cheap and ideal for the job.

Im an Architechtural Technician by trade and as such use CAD all day everyday. Im thinking of buying the ally drawing up my own spacer plate and getting one made up by a local engineering firm?

If i give them the material and the drawing that should keep costs down?

Does this sound like a plan?

Gareth.

[dangerousdave]

hi pal im a cnc turner by trade normaly and if you supply the mat it will keep the cost down slightly as with supplying the drawing if you supply in the cad foemat on disk then yes it will be cheeper as if done by cnc it will be a case of making a program from the disk but as jay knows its prob only an hours labour on a manual machine hence i would pay him or a local engineer to do it with a fag packet sketch

if you dont get it ask again tomorrow as i have been for a beer or 6 now....

[jayrs]

before buying it i would price up what a firm will do it for, if its a cash in hand saturday job whitcxh is gunna be cheap go for it mate.

as for doing cad drawings that might com in usfull for me at some point, and with you dangerousdave being a cnc lathe programmer/operator, that could also be of advangtage to me maybe at some point

dangerousdave, i never got into the cad thing, and never operated cnc machines, i was stuck on the manual stuff

[dangerousdave]

mate if you wanna have a play with a system so you can get a feel for it download ( legitimatly of course i dont condone illigal activitys!! ) bobcat 17 its the easyest cad programme ever pal you plot points and it works out if you dont like the sharp edges of something high light the edges and tell it what rad you want etc its very very simple

as for helpin with anything just ask

@black2 im going to get on a manual lathe next week to make the plate for my tb mount if i can get it to work pal ill try and do 2 if you want one?!

[jayrs]

hmm, when i get a chance i will have a look mate.
only bit of it i ever done was a few days training in a old job doing 2D cad on a water knife, but i got laid off before i got on the machine.
now that was a great bit of kit, could of had one of these plates cut out in about 3 mins, prob less being alloy, would of only needed the thread hole drilled and tapped

[black2]

Ok guys, im far too drunk to understand much at the mo - wil try and mske sense in the morning, lol .