fiestaturbo.com

[jonboisescort]

great work mate

going to be a cracking car once done

[Excursion]

Nice one Si, I get my engine back from a week on Saturday

[SiST]

Right I suppose I better give a brief update on where I am upto now

Firstly I have come to terms that the build will not be a three weeks build and after bumming lifts off friends and walking everywhere I started to look for a temporary car to drive in until the ST is done. My mate Chris stepped in at this point and has lent me an Aquarious Blue MK6 fiesta with a couple of mods on it to borrow for a few months - thanks alot mate - really appreciated!! It's been lowered since this picture:



ST wise there hasn't been that much progress unfortunately. Firstly I have sold the Dash2. The only reason for this is because of the price of the adaptor to connect it to the Omex 600. After discussing with Jon@Shawspeed I have decided to buy a new one from him with all the sensors etc as it is actually cheaper to do it this way. Jon has also agreed to fit the Dash2 to my dials with a carbon fibre background. Once I am sure I have everything for the engine then I will get this from him:

This is not a pic of mine - just a display pic to show how it will be fitted


Engine wise it just needs a few bits doing to finish it so I will hopefully have some pics of that finished in the next couple of weeks. I have asked the builder to look into fitting the alternator at the front of the engine where the PAS pump was originally - this way it will be easier to work on if needed and also means that the exhaust manifold and turbo heat cant damage it so am just waiting to see if this is possible. I have had a new oil return added to a spare sump as the original design caught the ranger block.

I have ordered everything needed now for the loom so that the original loom can have the Omex loom spliced into it. Jon@Shawspeed has kindly helped me with this also and given me diagrams of whats needed. I was hoping to have the loom modified before the engine is put back into the car but have found out that if I want the Omex unit held in the car behind the glove box that the Omex loom needs to be spliced into the loom in the car as the Omex connector will not fit through the hole in the bulk head and needs the wire feeding through from the interior

Whilst waiting for the engine to be finished I have taken advantage of the time to have a few things sorted out. Firstly I have managed to get some solid billet outershafts sourced instead of using some OEM quality shafts I was going to use:



The solid billet shafts are on the left and some OEM quality hollow shafts are on the right hand side - hopefully these should be more reliable with the extra power.

I have also finished my 'bumble-bee' mount for the new gearbox - what an utter pain in the arse fitting the big bush is as it is a one piece design - luckily my bud Dave was upto the challenge today



Other than that I have spent a small fortune on little bits that I forgot to get previously.

9 weeks till ford fair with no engine, the gearbox isn't finished (my fault) and there are loads of small bits that will need doing

[Excursion]

I have exactly the same thing to look forward to with my torque link

[SiST]

Cheap enough to do

Not really an update as just waiting for my engine at the moment but my spare gearbox turned up with the new gear ratios. That evening it was stripped and the gears are on there way to the engine builder to be added to the box.





Also heres a cheeky pic of the porting on my new head - cant wait!!

[SiST]

31/07/11

I went and picked up my engine and gearbox up from the south. I know it looks like everything has just been thrown in but it is all secure:



Got it all home and back on the stand and spent today working on fitting the bits missing - still lots to do before fitting it but its slowly getting there:











Tomorrows jobs include taking the water housing to be drilled and tapped and work out how to have two coolant sensors and the turbo feed on the water housing, waiting desperately for gaskets to finish the turbo setup off and finish the pulley off so i can order a auxilery belt.

Also MTX75 is back home with the diesel gears and the quaife - is back apart at the moment as the diff is tight when fully tightened so some work will be needed there.



Oh and finally one of my six paddle clutch

[SiST]

02/08/11

This afternoon we have done some more inspection on the gearbox thinking there must be some underlining reason why it doesn't fit right. All it took was a half turn unlock on the bolts and the diff moves fine so I was sure that the diff needed some more work doing to it to fit it properly. That coupled with the MK3 2.3 duratec turbo that was on Performance ford cover had a mk3 mondeo casing and he shimmed both the casing and the bearings at the top of both gears, I was adament either 1mm needed taking off the quaife below the top bearing or a gasket needed fitting to allow the bearings on the quaife to move.

After getting ready to take it to the machinists, we put it back in for a final check to see if the quaife body was catching the casing (highly unlikely and it wasn't) Whilst tightening a couple of the bolts, it was moving freely and with all bolts tightened now it is working correctly. We have put it down to some dirt that was in the bearings and also we dont think it was sat right originally in the casing but at least we definately know that the quaifes fit without any other work - happy days!! Now that is sorted it should be bullet proof I should have taken a pic of the comparison between the uprated bearings and the standard ones on the Open diff that come with the MTX75 as they have a plastic casing instead of my uprated ones which are metal and will last a lot longer (let's hope hey)

My engine spacer and top gearbox bracket have arrived from the Kyle (ultrav87) and will be bolted to both the shell and the box tomorrow so the engine can now be fitted as soon as I have finished the niggly little jobs in the next couple of days. Thanks alot Kyle!!

A couple of pics of the engine spacer:





Hoping to move the car tomorrow to the garage but it is dependant on if the current job in there is finished in time.

Si

[SiST]

03/08/11

Right not really done that much today tbh - still waiting on parts I have ordered earlier this week before fitting the rest of the turbo parts and taking it off the engine stand.

One thing that has been done is my water housing has been drilled and tapped for the water line and the Omex sensor.



After some time cleaning and spraying it a more subtle black:



I have also dropped my pulley off with him and have given him my design and thoughts - will be picking that up friday and I hope it works soI can measure and order the aux belt on friday (the last real job for me to get done).

I also spent some time on an MTX75 conversion for a customer. Crown wheel and uprating bearings are currently sat with the quaife waiting to be pressed on so I can fit it in the box



Finally i have paid my bill with Shawspeed so a brand new Dash2 is on order (sold the 2nd hand one) and all the sensors and loom to fit the Omex.

Hopefully some more of the parts I have ordered will be here tomorrow and if all goes to plan the ST (yes I still have one of them!) will be sat in the garage with the engine

[SiST]

05/08/11

Yesterday we moved my ST into the garage with the engine so I can get the engine bay and interior ready for the engine.



Today I picked up my pulley back from the engineer who had created a spacer and pressed it into the pulley so it fits to the block and lines up correctly:





Fitted:



I then got a dummy belt quite close to the size needed to test I had made no obvious mistakes with my design:



I have measured and ordered the belt I need now so should have that fitted tomorrow.

The turbo gasket still hasn't turned up which is really annoying me now as every bolt/stud and nut has been sourced today so as soon as the gasket arrives I can just bolt it all up and start connecting it to the gearbox ready for fitting.

Si

[SiST]

06/08/11

New belt is on and engine is off the stand now but i dont seem to have any bolts for the rear crank seal so thats stopping me fitting the clutch and 'box and the turbo gasket still isn't here. Will just ask a mate to get me one from ford fair tomorrow I think - sick of waiting.

On a slightly different note, I had these randomly dropped off at my house this morning - could be quite nice fitted

[SiST]

08/08/11

Been busy at it today and done quite a lot. The car is ready for the engine to be lifted into it as the heat shielding has been fitted, the subframe has been modified for the MTX75 mount, the new duratec MTX75 lever and likeage is in now as well.

I found a local supplier for the gaskets as have given up hope with GT3 Turbo so the engine has had the turbo and downpipe fitted and the flywheel, clutch and gearbox fitted. Just need to add the turbo water lines and then its ready to be fitted. Hopefully Jon from Shawspeed will be down one night this week dropping my Omex and Race Tech stuff off so I can plug in all the sensors and start the wiring for him to finish.

[SiST]

09/08/11

Engine fitting day!!

Before


After






Been a bit of a wierd day - most of it was spent doing the two minute job of plumbing in the turbo pipes which is a Bic™ and a half of a job to do and didn't finish till about 4pm. Luckily Kyles bracket was correct and the fitting wasn't as painful as it could have been.

Big thanks to my mate Chris for his help fitting it - much appreciated!

[SiST]

10/08/11

Right got a few bits done today:

OE loom is now loosely in ready for the chopping to commence.

The billet shafts are fitted and are a perfect fit - thank f**k for that one!!


Also couldn't help myself so I bolted the boost pipes and cooler onto it to see if it all fitted correctly with the engine spaced up 10mm unike when Ryan had it and spaced it 10mm lower:

[SiST]

11/08/11

I have had a bit of a lazy day today - i just can't bring myself to work on the ST directly today! That said I have dropped the battery plate and exhaust support bracket under the car which were both rusting and just generally minging to a local sandblasters and powdercoaters to be done black.

Also I have started work on the PAS setup and have found a place to fit the 13 row PAS cooler (why do it half heartedly?). I am fitting it where the aircon tank was and am going to run a feed from the drivers side foglight to ensure it gets enough air.

After offering it up to the area I want it to go, i decided that the strength of the cooler brackets were a little flimsy and could break under pressure so I got some 4mm steel cut to the same size of the cooler base, widened the size of the holes on the cooler to 8mm and drilled four 8mm holes in the steel. After a touch of paint, I gave it a trial fitting and it fits fine! I am hoping it wont be below the front bumper but I am going to fit a splitter so it should be about level.





Also Jon from Shawspeed came round to give me my race tech and Omex goodies and has told me how to start with the pre-work before he comes and chops the loom for me.





Tomorrow will probably involve designing a bracket to mount my 3 bar MAP sensor somewhere and start with installing the loom etc - no rest for the wicked

[SiST]

12/08/11

Done a fair bit more today - most not really worth mentioning but I have fitted the 3" exhaust

[SiST]

Right now thats the end of my summer holiday in my garage - and to think i could have gone to Spain for two weeks in the sun

Still loads to do so should have some more updates very soon

[Ratspeed]

Definately worth waiting for that update!

I love it when its engine fitting time

[Excursion]

Nice one, Si! What forum have you been updating on? I will have to check it out for more regular updates.

BTW, keep an eye on the Cosworth TB - IIRC the spindle wears in the alloy housing which leads to a boost leak and eventual failure. Ian has even had one go on the Dyno!

[SiST]

Hi Mark

This is my main topic on FiestaSTOC - there are a couple more pages than the one on here mind so its nice to update this one so I can see how if progressed over time lol - http://www.fiestastoc.com/forums/topic/ ... [ERRR]-fitted/

I haven't heard about that before but will definately keep an eye out - does Ian recommend a different make throttle - I only got it tbh because my friend had it and offered it me cheap and its practically brand new.

PS Where is your bloody engine? lol

[Excursion]

Hi Mark

This is my main topic on FiestaSTOC - there are a couple more pages than the one on here mind so its nice to update this one so I can see how if progressed over time lol - http://www.fiestastoc.com/forums/topic/ ... [ERRR]-fitted/

I haven't heard about that before but will definately keep an eye out - does Ian recommend a different make throttle - I only got it tbh because my friend had it and offered it me cheap and its practically brand new.

PS Where is your bloody engine? lol

Si,
Thanks I was going for the Cosworth TB but Ian advised against it - I've been advised to stick to an OEM type with sealed bearings, so I'm now going for a Mustang TB from the states. There are ported versions available if you like 70mm http://cgi.ebay.com/ebaymotors/BBK-1501 ... 5d2fe8220e but from what I've read about WRC engine development over the past two years, the new approach is to step down TB and boost pipe size in order to improve response. The new WRC cars run 2"(62mm) boost piping and a small TB, and recently Ford made a publicity stunt by remapping one of the old Focus (Mk2 RS shape) WRC cars without the restrictor - it made 600hp and out-dragged an F1 car, so there's definitely no restriction with such a small size!

Engine is on back burner until the shell is water tight. It's sat at Ian's ready built, I've got to buy the Dry Sump, management Turbo and inlet manifold now - not looking forward to the 4k bill just for that lot

Cheers,
Mark