fiestaturbo.com

[FRST5090]

looking good, are you going to put the sump baffle back on or do without as you are using arp main studs and they dont work with the standard baffle????

[Excursion]

looking good, are you going to put the sump baffle back on or do without as you are using arp main studs and they dont work with the standard baffle????

I milled my baffle slightly to give them clearance.

[xrsi]

looking good, are you going to put the sump baffle back on or do without as you are using arp main studs and they dont work with the standard baffle????

I milled my baffle slightly to give them clearance.

thats the first i heard about that... looks like the grinder will be making an apperance to give it room to fit!

[MattPym]

Good work mate

[xrsi]

well not best pleased this evening!

First of all i will now have to wait 5 working days for a replacement part to get shipped from america, yes i managed to brake a piston ring!

Its my own fault really, i was getting annoyed with the compressor and did it up and then realised the ring wasnt all the way in after turning it a bit more so snapped a bit off the end....

Well here is the offending item!



Took a 10 min phonecall to the USA and $4 to get a new rng posted out to me, prob would have ben as cheap to buy a set off ebay america thinking about it

However apart from the slight setback i have managed to get 3 of the 4 pistons and rods in fine tho so that atleast is some comfort.

There is however a slight worry i have with the machine work... that is the engine is very very very stiff to turn over, im having trouble turning it over with an 18mm socket on the end of my small breaker bar. is that normal before the engine has turned over and started to run?

Anyways here is a quick couple of pics of the 3 pistons in the block complete with ARP fastners and the H section eagle rods.





The setback just means i can get the rest of the shed painted along with all the other engine parts that need a quick lick of paint before fitting. oh and finish off the gate that i have half made!

[FRST5090]

believe it or not i had the same problem with mine i broke the top ring!! had to wait 3 weeks for my new one, mine was quite tight to turn over and the was some ring dragging which looks liked scores but i was assured by Ian from Area Six that it was normal.

[Matt_fez]

Looking good so far mate, you do know they would have made the pistons with any cr you wanted if you had asked? I got mine from the same place and they ordered from JE to my own top secret spec Just took an extra couple of weeks to have them made.

All be worth it in the end mate, my car still puts a smile on my face on a daily basis.

[xrsi]

believe it or not i had the same problem with mine i broke the top ring!! had to wait 3 weeks for my new one, mine was quite tight to turn over and the was some ring dragging which looks liked scores but i was assured by Ian from Area Six that it was normal.

thats alright then!

Matt - git, na im more than happy with the pistons actually, 9:1 is fine as long as it is setup and mapped properly and will be great off bost and fuel economy will be slightly improved as well, just means it a 2ltr not a 2.1 as i origionally wanted. Cant have everything tho can we!

[FlashXR2i]

James mate, you made some great progress, piston ring is on his way and you'll be back on track

Like the high-compression setup, much better option for road use.

[Excursion]

Did you gap the rings mate?
Sometimes you have to file bearings for a perfect fit.
Sometimes even the machine shop sends back a block slightly out of true.

For reliability you need to measure, measure, measure. Dummy build first to check clearances.

Plastigague and a dial caliper are your friend

[xrsi]

Did you gap the rings mate?
Sometimes you have to file bearings for a perfect fit.
Sometimes even the machine shop sends back a block slightly out of true.

For reliability you need to measure, measure, measure. Dummy build first to check clearances.

Plastigague and a dial caliper are your friend

pistons are comming back out as i didnt check all the gaps! off to get a ring grinder today as i think they may be a little under gapped causing the stiffness.

Will see if everything is fine in a little while after i have got the bits.....

[Ollybee]

Solder it back together?

[xrsi]

Solder it back together?

i had considered welding it to the piston!

[Excursion]

pistons are comming back out as i didnt check all the gaps! off to get a ring grinder today as i think they may be a little under gapped causing the stiffness.

Will see if everything is fine in a little while after i have got the bits.....

Good stuff. It's more likely to be the bearings giving clearance issues though.

[xrsi]

pistons are comming back out as i didnt check all the gaps! off to get a ring grinder today as i think they may be a little under gapped causing the stiffness.

Will see if everything is fine in a little while after i have got the bits.....

Good stuff. It's more likely to be the bearings giving clearance issues though.

they shouldnt be as the bearings were as new when i took them out so have reused them and they are in the exact same place as removed so they should be sweet as. Yes it pikey i know but to change them for the sake of it seems pointless really. The engine hasdone no work so they should last longer than the rest of the engine spec.

[Excursion]

they shouldnt be as the bearings were as new when i took them out so have reused them and they are in the exact same place as removed so they should be sweet as. Yes it pikey i know but to change them for the sake of it seems pointless really. The engine hasdone no work so they should last longer than the rest of the engine spec.

This happens when bearing caps are tightened unevenly, for example when tightening the bolts/studs to bring a cap into position rather than aligning it beforehand (This is especially true of the main caps as they can be difficult to slot in to place).

Check for high spots on the the bearing surfaces which will show themselves as shiny patches. The shape of these patches will tell you the cause of the problem (excessive bearing crush, contamination behind the bearing, or mis-alignment).

I'm sure you'll figure it out.

[xrsi]

the crank was spinning freely when there were no pistons on it so the main cas are all going to be fine, it started to get very hard with the pistons added to it.

anyways off to get a ring grinder or a decent small fine toothed file!

[xrsi]

well yes im a numpty, i have checked the piston that one of the rings cracked on and there is NO piston gap to talk of really......

So they do all need a little bit taking off, prob explains why it is so bloody stiff to turn over!

[H41-NSF]

Hi mate good progress since i last looked. just to add you do know the cr ration on the series 3 zetec engine is added up with the super thin metal head gasket so if you go for a normal zetec gasket (much thicker) it will have the more desired cr ratio.

[xrsi]

Hi mate good progress since i last looked. just to add you do know the cr ration on the series 3 zetec engine is added up with the super thin metal head gasket so if you go for a normal zetec gasket (much thicker) it will have the more desired cr ratio.

yeah but the metal gasket is alot better and stronger so staying with the multi layer metal gasket

[xrsi]

well got home from work tonight to find a nice package from the US containing my JE single 2nd ring to replace the snapped item!

To say i am absolutly fcuking livid with JE is an understatement!

i was told it would be a total of $4.10, to get an ivoice saying my credit card has been debited $73.84 came as a bloody big shock! i questioned the total of $4.10 at the time and even said "wont you have a problem with shipping to the being that price for everything?" to be told no it wont be a problem!

No fcuking wander it wont be a fcuking problem! cos i got charged an additional $69.74!!!!!! tossers! bearing in mind the item is litterally a couple of grams in weight!!!!!

Where do i stand with the matter as if they had of told me that was the price i would have told them what they could use the piston ring for! could of got a full set off a website in america posted to me cheaper than that!

On a slightly better note, i have removed each of the 3 pistons that i installed and checked the gaps and there was no gaps in the rings, which is why there was a very large force required to turn the engine over! it defo saved my bottom end as it would have siezed solid if it hadnt of shown up...

But gapping piston rings with a small file is the most boring thing known to man!!!

[jayrs]

bloody hell thats a right rip, can your credied card company not step in here?

[garyhurn77]

as jay said if you paid via a credit card then you may be covered! saying that if you paid by any other method i dontthink there is alot that can be done! £73 for a piston ring is very foooking steep

[MattPym]

how big was the box to cost so much in shipping?

[Excursion]

What have you had it bored to mate?

What clearance are you going to run?

[xrsi]

i forget the exact number off hand but it was a couple of thou that it was bored by to give the correct clearance, it looks like the rings are generic rings for a number of pistons so they have to be gapped, i have gapped them to 0.4mm for th top ring and 0.45 for 2nd compression ring.

[Excursion]

cashback

[xrsi]

well its certainly getting there now....
Just spoke to the credit card disputes at Lloyds TSB and they are disptuting the postage charge on my behalf, have also i am able to use the item as i am not disputing the item charge as i am desperate for that part... so that has cheared me up a little... so hopefully supm may be on this eve as unfortunatly a 306 has called halt to play tomorrow eve as the backbox has snapped on mum's so i have to fix that....

Oh well cant have everything.

[MattPym]

well its certainly getting there now....
Just spoke to the credit card disputes at Lloyds TSB and they are disptuting the postage charge on my behalf, have also i am able to use the item as i am not disputing the item charge as i am desperate for that part... so that has cheared me up a little... so hopefully supm may be on this eve as unfortunatly a 306 has called halt to play tomorrow eve as the backbox has snapped on mum's so i have to fix that....

Oh well cant have everything.

Good to hear, Typical French cars

[xrsi]

well went to fit the sump and remembered that i needed to machine bits off the baffles so didnt want to do that this eve as i wouldnt have time to clean all the swarf off properly and this way i can paint it off the block so will leave it for a couple of nights....

On a more positive note i managed to clean out alot of my tool chest so that is a bit better organised now tho!

[xrsi]

just bump it up to the top again with another quick updat of what i have done on the engine this eve.

Again i have good news and bad news......

first of all the good news and to see if you can spot the prob in the pictures as to what i have done this time as there are things missing ompaired to the pics in the last update....

Well good news is that all 4 pistons are in and the engine spins over freely so that is great news and with all correctly gapped rings.

Also i have managed to fit the oil pump, water pump, oil pressure switch and gauge T piece, and also the new front crank oil seal.

Have also managed to give the visable parts of the water pump, oil pump and the metal part of the timing belt cover the first coat of silver high heat paint to make them look alot better as against the painted block they looked very scabby although they were in great condition they still didnt look perfect!

so anyways here are some pics....







And the big clue as to what i have done is what is missing in this pic if you look closely!



The answer is the ARP rod bolts, i managed to miss read the table on the ARP bolts a couple of nights ago and have snapped two by over torqueing it. By time i realised i had over torqued it was too late and had already experianced none elastic deformation of the bolts shaft, they actually snapped undoing them not doing them up. But its a good job i did realise otherwise it would have been bye bye engine!

Anyways i have had some more sent by Gilly yesterday and recieved this morn. Now as i am running a black top and Eagle rods whch were only for the black top zetec you would think they used the STD 9mm black top ARP rod bolts, NO THE BLOODY DONT! they use the series 1 8mm bolts! so i am now bolt-less still and this is again holding up the bottom end being finished.

All i have left on bottom end is following:-

locate and fit ARP rod bolts
Machine baffles in sump
Refit upper + lower sump and oil pick up pipe
Fit oil pump crank seal
Press in 1/2" oil return pipe and seal (prob use sealant on inside of block and chemical metal on outside)
Fit water pump into housing wth new O ring

So really there is no more than a couple of hrs work left on the bottom end and them i can start to look at the head.

[H41-NSF]

ye i had that problam the BT zetec uses the 1.6l ST arp con rod bolts. good progress anyway mate.

Nice bike

[xrsi]

well the bolts are not std ARP boolts for eagle rods, they use a thread pitch of 1.5 instead!

so have had to order a set again from america, this time i have been told the postage costs is going to be likely around the $40 mark, they do a discount on the list price of the bolts and the international postage where i am getting the bolts from so all is well.... just gotta wait a week for the bolts to arrive!

On a more positive not the rest of the bottom end is assembled and the baffles in the sum have been modified with an angle grinder so the clear the ARP main studs.

So all that is left to do is to get a starter motor and modify the front lower part of the sump so i can retain a front mount starter as the turbo is going to be over the gear box so want back pass side of block as clear as poss for down pipe.

Have also got this off ebay, http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1&item=330228217290&ssPageName=STRK:MEWA:IT&ih=014
i know it wont improve acceleration or increase BHP like alot of people try to make out, but i couldnt find a std lower pulley anywhere and ford prices are very expensive for one so this was the cheapest option for time being.... can always paint it black so it doesnt look quite as shiny!

Oh and Nath - that boke is about 30 years old, its a very old Rally (i know its not spelt like that but i dont care ) it needs a bit of tidying, but loads of my family have learnt to ride a bike on it...

[xrsi]

Well after a disheartening couple of days after finding out that the bloody focus TDci bell housing on the MTX75 box that was needed to fit to a cvh uses a completely different lower bolt pattern to the petrol model MTX75 bellhousings so meant that not only could i not retain a front mount starter i needed to buy a new gearbox...

One has been found just gotta go and collect it so that will be stripped and the bellhousing cleaned and painted and then fitted to the rear half of the focus RS box to make a standard focus RS box again!

also the alloy crank aux belt pulley arrived yesterday so fitted that along with painting the rear mount for the alt and test fitted everything to the now nearly built up botom end! the head is only dummy built at the moment and all the parts need to be sourced for that part of the build yet but it certainly looks good all complete like it will do ready to fit.

the head and rocker cover needs a good clean and a lick of paint where wont be sealing a gasket to make it as clean as the bottom end as it looks manky against it!

[xrsi]

well i have got another quick update!

i really couldnt wait till morning to add this so here goes!

i have now in my possession have the management that i will be using for the zetec turbo, its the following......






Yes an omex 600!

i left my house at 8.45pm this eve and traveled to leicester to get it, 250 miles in just over 4.5 hrs, including a couple of stops, i have been at work all day and am shattered! but very very happy!