fiestaturbo.com

[Rhinopower]

Tweak. Take the adaptor off and bolt it to the manifold so we can see what's happening from the other side

[Tweek]

Manifold side lines up 100% perfect but I can get a pic if you want lol

[Rhinopower]

Then the whole of the cvh part must be offset :-/

[jonyb4]

Maybe the adaptor is for a blacktop? But you can always get it milled back

All exhaust ports are the same on zetecs

Don't mean to be rude but if you have a look on blacktop zetecs they are circular on the exhaust ports silvertop ones are a weird shape.

yup..

[Rhinopower]

Il rephrase. They all occupy the same width, the exhaust manifold gaskets are the same. The only reason the silvertop has the funny indents is because of the egr system.

[Smo]

Like I said on Facebook, prior to seeing another photo on here, I think there's a risk of cracking if the mounting position of the CVH manifold was any further to the driver's side. And also, now I've seen the photo of the whole plate on here, that CVH manifold mounting hole on the most driver's side is very close to the Zetec flange bolt hole. I can't see how the adapter plate could be made any differently without potential weakness issues!

And if that manifold FRSJON is offering is £100, I'd take that in an instant and find a suitable turbo!

[Excursion]

Another vote for the manifold Jon is selling, if it's in budget.

[FRSJON]

Like I said on Facebook, prior to seeing another photo on here, I think there's a risk of cracking if the mounting position of the CVH manifold was any further to the driver's side. And also, now I've seen the photo of the whole plate on here, that CVH manifold mounting hole on the most driver's side is very close to the Zetec flange bolt hole. I can't see how the adapter plate could be made any differently without potential weakness issues!

And if that manifold FRSJON is offering is £100, I'd take that in an instant and find a suitable turbo!

£7 on ebay buys a t3 flange

[Rhinopower]

Was discussing this with nomad earlier. Problem with a frs manifold would be that the exhaust housing would be facing the wrong way. Don't know how much scope there would be fit spin that side of the turbo round

[Tweek]

The problem with that is I'd have to spend out on another turbo and exhaust downpipe. Skint now after buying the clutch

[Rhinopower]

Why not just buy another adaptor plate from Friday engineering? Mike has been making them for years no issue

[Tweek]

I did price that up originally but they're £98?

[FRSJON]

Was discussing this with nomad earlier. Problem with a frs manifold would be that the exhaust housing would be facing the wrong way. Don't know how much scope there would be fit spin that side of the turbo round

the cheapest way to cure this is a cossie exhaust housing and down pipe . not major money but more expense

[Tweek]

Very small update for this weekend. Got a few missing pieces for the engine, attacked the adapter plate with a dremel grinder and painted some of the engine bay...



Rear of the adapter plate now stretches to previously blocked edge of the ports:



And finally, added some colour to the engine bay. I've only done the lower half so far, depending on how the hammerite looks after I may do the top but then I may spray it body colour. Note, once it dries it'll be close to Java Blue, the colour the car will be painted.

[andymac]

If those marks on the plate are anything more than light surface scratches I'd suggest you use a smear of spa exhaust sealant when reassembling. Have use this two or three times now on reluctant seals with great success. Though it's sold as a gasket replacement (and allegedly suitable for turbo applications - lol), I'd use a decent quality gasket with fire rings and a smear of that sealer either side.

The heat of the exhaust cures it after five minutes of idle running, so is a relatively "quick fix".

[Tweek]

Cheers Andy, I'll bookmark it just incase. The marks on there though have almost no indentation at all though, just scuffing so fingers crossed should be fine.

[jonyb4]

thats looking better

[Excursion]

http://www.ebay.co.uk/itm/td04l-turbo-w ... 1e7600946e looks good.

[Tweek]

Keeping an eye on that now, will palm it off to someone else to sort out

Cheers

[Tweek]

A couple of photos from this weekend's work:

[FRSJON]

looking good

[Tweek]

Cheers dude. I've just come to realise I've done something very stupidly wrong. Cam pulleys are on the wrong way round, no wonder they were rubbing the middle cover! *double face palm*

[jonyb4]

not that bad, colour's come out nice

[Tweek]

Well, this weekend just gone has been a bit disastrous. I got supplied the wrong parts from Ford twice, then found some oil on the inlet valves, then realise I need a different turbo and exhaust setup

Anyway, before all of that, some positive news! In the last update I sprayed some colour into the engine bay, well, the weekend before this one just gone I lacquered it, with the help of a small radiator to keep the panels at a sensible temperature out in the snow. I left the heater on it for a few hours until it got dark then covered it all up. I uncovered it all the following weekend to a beautiful result!





Very chuffed with that! Onto my 2nd bit of good news, the set of alloys that I had planned to buy at some stage turned up on ebay at a bargain price. They need a refurb but even with the cost of that it's still a huge saving on buying them new:



Right then, back to the weekend's work. I filled the engine with oil and turned it over a few times, out of boredom I thought I'd watch the valves move up and down and discovered oil droplets on them:



As some of you will know, I went into panic mode Friday night wondering how and what it was doing there! I still don't have a definitive answer but I think the majority of it may have been the cleaning oils that were used when I had the head work done, at least I hope so. I cleaned/dried the valves as much as I could, then turned the engine over by hand many, many times, I couldn't see any new droplets formed in there, fingers crossed!

I then finally put the rest of the engine together including a nice swanky clutch that I must thank Rich Tiller for sorting out for me!



And then after bolting on the CTS box, the engine was in:



Rear engine mount holes lined up perfectly as do the front engine mount holes, albeit no threads yet. The bracket I had welded in for the top 2 bolts on the front mount is also a perfect fit. Infact, it was like bolting the engine to a Zetec shell!

Onto the turbo problems, at first glance the radiator was going to be a bit of a mission, but I was already expecting that, here's the actuator's position:



And then after looking down I could see the exhaust wasn't going to fit so I fetched it out the loft and had a go. I was right



So, after speaking with Ryan and Smo, I'm now looking at going down the Focus RS route. Currently trying to negotiate a price for a setup including a GT28 turbo

A mixed up weekend, a few steps forward but a couple back. Engine in and all the masking tape removed:

[- Danny Boy -]

Glad the valve stem seal problem seems to be sorted. When you said about it the other day I almost cried for you.. lol.

[jonyb4]

Bloody lovely!

those wheels.. yes yes YES!
be nice to see a change from your 5 spokes

[FRSJON]

lacquer looks great really like those wheels and wouldnt mine a set myself... did you try bolting the down pipe on? mines very close to the front cross member but not touching it..same set up as yours?

[Tweek]

Mine's got the crappy adapter plate on though, unless yours has too? I couldn't get it to fit over the stud, didn't want to force it and risk damaging the exhaust

[FRSJON]

Mine's got the crappy adapter plate on though, unless yours has too? I couldn't get it to fit over the stud, didn't want to force it and risk damaging the exhaust

as i scrolled to the top of the page i saw the adapter plate pic no i dont have one never going to fit then

[FRSJON]

if the gt28 works out too pricey you also have to option of a cossie exhaust housing and make a down pipe? im sure you could easy do that for £100

[Excursion]

Wow that turbo is very far forward. I don't think I've seen one that far out; it wasn't always a Zetec shell, was it? Does your rearmost engine mount bracket (near the header tank) have two holes or just one? Some of the 1.1/1.3 engines are sat further forward and the hole is around an inch further towards the headlights than on a Zetec shell.

It's been a while so I can't remember anything more than that but my photo may help you. My radiator was in the standard position and I used a Saab exhaust housing. I could have got a 10mm adapter plate on but it would have been close.

[Tweek]

It's a late 1.3 Frascati shell. The rear mount area has 2 holes in it, the zetec mount slotted straight into the rear hole after lining up the side bolts. Even with that in, the holes in the chassis leg are a perfect match for the zetec front mount, there's just no nuts/threads in them. It is an odd one, I was expecting it to be tight but not that far out

[Excursion]

It's a late 1.3 Frascati shell. The rear mount area has 2 holes in it, the zetec mount slotted straight into the rear hole after lining up the side bolts. Even with that in, the holes in the chassis leg are a perfect match for the zetec front mount, there's just no nuts/threads in them. It is an odd one, I was expecting it to be tight but not that far out

Sounds like the shell is OK then. The only other thing I can suggest is to hook the rubber radiator locating on the forward side of the crossmember lip - if that makes sense. It means the radiator is pointing out towards the front of the car along the lower edge. We used to do that a lot and I seem to remember having to move the PAS cooler a bit too, and also griding a little off of the actuator bracket to get more clearance.

I hate to say it, but if you haven't got a welder, I'd just 'massage' the crossmember and downpipe with a mallet!

[jonyb4]

ha clever choice of words

id simple "nook" the crossmember myself, ive seen it done simply to make room for a fan...

[russ-RST]

lovin the progress on this engine bay has come up well for wht I assume was a rattle can job? will be watching this very closely as I'm very much considering ditching the CVH in for a full zetec , iv found the frascatti shel seems to have all the holes where needed everywhere Just might not have the thread in them which is bloody handy also not meaning to be rude but changing all your manifould down pipe and turbo just for 5-10mm of persuasion on the front panel seems a bit of a mess about to me, look at te vauxhall boys when it comes to getting xe's and lets in there shells plenty of them have to massage the chassis leg/engine bay for clearence iv got to admit tho mark that picture u have posts further up^^ you have alot I clearence there! iv just fitte a t3 to my CVH just now as iv got no where near that amount of space lol and iv mounts the rad exactly the same way you mentioned, over the lip on the cross member at the bottom and its helped endlessly, still not much room down there mind you looking forward to more progress

ps. how comes you went for the adapter plate rather than re drilling the head? or just weld a zetec flange on the CVH manifould? just ditching that adapter plate would solve your hassles with the Down pipe and more clearence

just to add I'm not picking at anyone's ideas etc. nor am I trying to cause an argument just asking as I am very Interested in doin this to my frascatti

russ