Moondust K-Reg MK3 2.3 Duratec-HE Turbo. SOLD on 26/06/2011

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Moondust K-Reg MK3 2.3 Duratec-HE Turbo. SOLD on 26/06/2011

Postby jimmyesh on Mon Mar 24, 2008 9:59 pm

d!!INDEX

Pg 1.

1. Tired 1992 Moondust Silver XR2i CVH rescued from Ebay for £155.
2. Stripped down and resprayed.
3. FRST interior, bonnet, opening quarters, spolier & raven trim fitted.
4. Half-arsed attempt to save the old CVH.

Pg 2.

1. Focus RS clocks purchased.
2. Finally decide what engine I'm using.
3. MTX 75 gearbox & mount arrives.
4. Cosworth bearings & forged rods arrive.

Pg 3.

1. Pistons.
2. Cosworth Inlet.
3. MK6 ST PAS pump.
4. Engine Mount.
5. Fidanza Flywheel / Spec clutch.

Pg 4.

1. Fiesta MK 3.5 power steering components.
2. Turbo arrives.
3. Engine stripdown.
4. Pro Alloy rad.

Pg 5.

1. Burton / Cosworth gaskets.
2. Block rebored.
3. ARP Fasteners.
4. Mk 3.5 front hubs.
5. Engine build-up.
6. Modified fuel rail.

Pg 6.

1. Engine build (continued).
2. Cam cover, fuel rail and sump painted.
3. Mk 3.5 Power steering fitted.
4. Fiesta MK5 hydraulic clutch pedal box modified and fitted.

Pg 7.

1. Hybrid Mondeo / mk3 Fiesta PAS pipe
2. Sump oil returns.
3. EGR blanking.

Pg 8.

1. Exhaust manifold fitted.
2. Focus RS Gearbox.
3. Duratec/Zetec MTX 75 bellhousing differences.
4. Quiafe ATB Diff fitted.
5. Flywheel & clutch fitted.
6. Modified gearbox mount.

Pg 9.

1. Mondeo/Focus driveshaft extension.
2. Engine dummy-fitted.
3. Eng/gearbox mounts fitted.

Pg 10.

1. Engine bay resprayed.
2. Mondeo MK3 MTX 75 gear linkage fitted.

Pg 11.

1. Battery fitted into boot.
2. Turbo coolant pipes.
3. Crank sensor fitted.
4. RS2000 rear brakes arrive.
5. Engine & Gearbox fited.

Pg 12.

1. Turbo oil feed/drain fitted.

Pg 13.

1. Cosworth front discs / RS2000 rear discs fitted.
2. Pro Alloy rad fitted.
3. Oil returns fitted.
4. O/S driveshaft fitted.

Pg 14.

1. Custom Inlet plenum built and fitted.
2. RS 2000 servo & master cylinder fitted.
3. Focus 1.6 throttle cable fitted.
4. Exhaust fabricated and fitted.

Pg 15.

1. Focus RS Clocks fitted.
2. Siemens 630cc injectors arrive.
3. Sytec fuel pressure regulator arrives.
4. Goodridge 200-series -6 fuel hose arrives.

Pg 16.

1. Goodridge 200-series fuel connectors arrive.
2. RS 2000 Alloys fitted.

Pg 17.

1. Injectors, fuel pressure regulator & fuel hoses fitted.
2. Sytec "bullet" fuel filter ordered.
3. Bumper modified for FMIC and fitted.
4. Tailgate dented by an unknown and complete c*nt!
5. Boost pipes.
6. Aux drive belt.
7. Injector plugs.
8. Hybrid Focus/Fiesta hydraulic clutch pipe assembled.

Pg 18/19.

1. Had a wobble and nearly sold the car :aaah: .
2. Decided to keep it and gave myself a good talking-to! :devil:

Pg 20.

1. New lower arms & front tyres fitted.
2. Hard boost pipes fabricated, painted & fitted.
3. Sytec "bullet" fuel filter fitted.
4. Bumper splitter & small numberplate fitted.
5. Gearbox cradle modified and re-fitted to clear Mondeo MK3 Gearbox mount.

Pg 21.

1. Mondeo Gearshift Mech heatshield fitted.
2. Fiesta MK5 ZS PAS cooler fitted.
3. Megasquirt V3 ECU arrives.

Pg22.

1. Decided against the Megasquirt.
2. Focus RS wiring loom modified & rebuilt to suit my car.
3. Focus RS ECU/KEY arrive.

Pg 23.

1. Engine - bay wiring with Focus RS loom completed.
2. Dash removed and all wiring spliced to the Focus RS loom.
3. OBD II connector & Focus PATS wired in.
4. Focus RS clocks wired up and all working.

Pg 24.

1. New Cosworth uprated Walbro fuel pump fitted.
2. THE ENGINE RUNS! :o + VIDEOS OF IT RUNNING :Q

Pg 25.

1. New custom driveshafts fitted.
2. Video of the Focus RS Speedometer working with the car running :)
3. Nomad twin A-pillar gauge pod purchased.
4. Stack coolant temp gauge purchased.
5. Koni rear + Spax adjustable front shocks fitted, along with Spax -35 springs.
6. Garrett oil restrictor purchased (in a vain effort to stop my engine smoking! :oooh: )
7. Turbo in-line oil filter purchased.

Pg 26.

1. Car still smoking like a Bic™ - oil is being burned, many possibilities; Turbo :-? Piston rings :-? Headgasket :-? Bore damage :-?
2. Got a few oil leaks and coolant leaks - not happy! :(
3. Nothing else for it! - Engine taken out and stripped down.


Pg 27.

1. Brand-new Garrett GT28R ball bearing turbo (+new water lines, turbo blanket etc).
2. New 8.5:1 CP forged pistons.
3. Engine rebuild.
4. Plenty of heat-proofing near the exhaust.
5. Stack wideband lambda gauge ordered and boss welded into downpipe.
6. Inlet plenum pressure tested, leak found and fixed.
7. Turbo oil return revised and sump modified.
8. Oil leak cause found - timing cover repaired.

Pg 31.

1. Car passes MOT, gets taxed and insured.
2. Driven on public roads (for the first time since 2007) on 06 March 2011.
3. Completes over 300 miles of normal road-driving, 35 MPG, happy times! :)
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Jan 2008 EBAY HELL!!! Here's where it all began at the start of 2008 :aaah: One very abused and forlorn 1992 K-reg XR2i 1.6 CVH, but I had plans! :D ......

It's still at the seller's house in these pics, waiting for me to load it up and take it away :)

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Check out the bonnet!! :o :x

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...and the mirrors, top clobber! :lol:

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Harnesses all in place for the twisties on the way round to Maccy-D's! :bonkers:

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Check the sticker on the rear bumper - pure comedy for adults! :P

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Right, now things begin to improve with the addition af an FRST bonnet, pop-outs, rear spoiler and some MK3.5 electric mirrors. (Full FRST recaro interior, Clocks, Steering Wheel, green stripes set & FRST decal saved for the car's return from BodyTone - see the end of this post)

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Feb 2008 Off to BodyTone in Wokingham where untold horrors were found and subsequently rectified :)

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It transpired that both doors had previously been bent by thieving scrotes before being re-straightened at some point in this car's chequered past :rolleyes: , luckily I had a MK3.5 Si handy for spares so I supplied the bodyshop with two good doors and subsequently fitted all the "MK3" bits from my old doors into them when I collected the car. A new front panel & x-member were fitted, all bodykit was removed, any grot removed and repaired - the car is now rust-free and straight :)

I was also lucky enough to find a full "raven plastic" dash and plastic trim waiting for me in the donor Si so that's all in the Silver beastie now and compliments the Recaros nicely :)

The Si also kindly donated its heated front screen as mine was cracked, that saved me a few bob :D

March 2008 Here we have the (nowhere near!) finished article, Collected from the bodyshop, doors reassembled, windows all fitted, decals all stuck where they should be etc.

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The bonnet hinges are the old, bent ones so the bonnet isn't sitting quite straight, new hinges will be fitted as soon as possible.

I know the wheels are pants!!- :rolleyes: They're just there for it to roll on for now as I have a set of 15" RS2000 diamond-cut alloys with 195-45-15 tyres ready to go on the car that are currently waiting for refurb at Lepsons so should compliment the car nicely.

For those that know of my previous eploits with "the manj", this car will carry on from where I left off with that one (I still regret selling it! :cry:) Don't worry, it will be sitting a bit lower once the new rims are on it, will also have discs on all corners, coilovers, and (once I return from 6 months in Afghanistan and have a healthy bank account), a nice Black-Top zetec-Turbo, either MTX75 5-speed or Getrag mt285 6-speed, Quaife ATB, Standalone management etc.

For now she will have to be a "sheep in wolf's clothing" until my return from "the Stan" then it'll be worthy of the RS badge that it currently has no right to wear!! :lol: :bonkers:

Kinda gives you a warm fuzzy feeling rescuing a poor, neglected Fez that was destined for the scrappy and reincarnating it as it should be don't you think? :)
Last edited by jimmyesh on Sun Jun 26, 2011 10:25 am, edited 139 times in total.
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Re: My new project - (starting from ebay hell!)

Postby FRSJON on Mon Mar 24, 2008 10:30 pm

nice one mate...cant wait to see it progress in to a fine example like manj... :Q :Q :Q
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Re: My new project - (starting from ebay hell!)

Postby j7aoc on Mon Mar 24, 2008 10:37 pm

Look's loads better. Keep the picture's comeing
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Re: My new project - (starting from ebay hell!)

Postby heeman10 on Mon Mar 24, 2008 11:10 pm

Great write-up :lol: What a transformation! :o You really did start with a prize winner there Jimmy boy! :lol: Let's fast forward a few months and crack on :)
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Re: My new project - (starting from ebay hell!)

Postby Mikee_RS on Tue Mar 25, 2008 1:06 am

fooking hell!! was abit chive-tastic wasnt it!!

i dont have any doubts that you will transform this into another minter :D
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Re: My new project - (starting from ebay hell!)

Postby Tweek on Tue Mar 25, 2008 1:07 am

Muchly improved, top bombing :D
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Re: My new project - (starting from ebay hell!)

Postby Turboboy67 on Tue Mar 25, 2008 1:14 am

I think we all know how this is going to end up :Q :Q

Good work so far fella :D

:aviator:
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Re: My new project - (starting from ebay hell!)

Postby Brammer on Tue Mar 25, 2008 2:26 am

Carbonboy67 wrote:I think we all know how this is going to end up :Q :Q

Good work so far fella :D

:aviator:


I agree with Shaun, this is going to be something special :devil:
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Re: My new project - (starting from ebay hell!)

Postby Ollybee on Tue Mar 25, 2008 9:47 am

That was a shockers to begin with. :o
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Tue Mar 25, 2008 10:18 am

CheeRS for the kind words there everyone - It's great to be back on the scene :) Part of me wishes that I could just get everything done now and have it ready for the summer shows but I need my op tour of Afghan to pay for everything in the first place :( I'll revive this thread in about 6 or 7 months when things should start happening - I just hope my new boss is as free and easy with me using all the workshop's facilities as my old one was with the Manj :lol:
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Re: My new project - (starting from ebay hell!)

Postby jonosi on Tue Mar 25, 2008 11:29 am

shall be keeping an eye on this one
looks so much better than the abused car it was when you got it

engine plans etc.. sound wicked :devil:
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Re: My new project - (starting from ebay hell!)

Postby jayrs on Tue Mar 25, 2008 2:52 pm

another one saved fron ch@vs
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Re: My new project - (starting from ebay hell!)

Postby moondustka on Tue Mar 25, 2008 3:47 pm

Glad to see another one back in the hands of someone who knows what they're doing! :)
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Re: My new project - (starting from ebay hell!)

Postby Excursion on Tue Mar 25, 2008 3:51 pm

Great transformation mate. That petrol cap really lets it down now though. Get a black one :idea:
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Tue Mar 25, 2008 4:03 pm

Excursion wrote:Great transformation mate. That petrol cap really lets it down now though. Get a black one :idea:


Crikey, give me a chance! :lol: :P
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Re: My new project - (starting from ebay hell!)

Postby Chris 2i on Tue Mar 25, 2008 4:27 pm

what a transformation, glad to see a sh itbox turned around and made better than ever :D
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Re: My new project - (starting from ebay hell!)

Postby allinking on Tue Mar 25, 2008 8:09 pm

Looks good if it's anything like Manj this will be one hell of a car
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Tue Mar 25, 2008 8:13 pm

Cheers again for the kind words everyone :wink:

Got her running today (after finding a serviciable EDIS module - All the scrappies round here don't exactly have an abundance of early '90's Fords! :rolleyes: ) runs well enough but I reckon it needs a set of valve stem seals before it goes for MOT (smokes slightly on idle but not when revved). Had a little hoon around the Sgt's mess car park and enjoyed all 93 or so BHP! (optimistic estimate) :lol:
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Re: My new project - (starting from ebay hell!)

Postby Excursion on Tue Mar 25, 2008 8:18 pm

jimmyesh wrote:
Excursion wrote:Great transformation mate. That petrol cap really lets it down now though. Get a black one :idea:


Crikey, give me a chance! :lol: :P


:lol: Ha! Fair point! It's great so far anyway :D
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Re: My new project - (starting from ebay hell!)

Postby heeman10 on Tue Mar 25, 2008 8:22 pm

Excursion wrote:
jimmyesh wrote:
Excursion wrote:Great transformation mate. That petrol cap really lets it down now though. Get a black one :idea:


Crikey, give me a chance! :lol: :P


:lol: Ha! Fair point! It's great so far anyway :D

It's too late for niceties now Mark, you have disrespected his creativity and taste already. No going back now :(
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Tue Mar 25, 2008 9:08 pm

heeman10 wrote:
Excursion wrote:

:lol: Ha! Fair point! It's great so far anyway :D

It's too late for niceties now Mark, you have disrespected his creativity and taste already. No going back now :(


:lol: I'll let it go just this once! :bonkers:
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Re: My new project - (starting from ebay hell!)

Postby Excursion on Wed Mar 26, 2008 11:28 am

jimmyesh wrote:Image


I missed that the first time round :lol: :lol: :lol: :lol:

Just showed my Dad what you'd done, his face went from a look of disgust, to relief, as I scrolled down through the images :lol: :lol:
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Re: My new project - (starting from ebay hell!)

Postby luca on Wed Mar 26, 2008 11:39 am

Top work Jimmy, looking like its going to be another awesome car :D
KEEP IT THOUGH ONCE FINISHED :wink:

Is that rear sticker in the right postion :lol: (joke its perfect) :Q
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Re: My new project - (starting from ebay hell!)

Postby filtra on Wed Mar 26, 2008 11:54 am

Impressive, for a completely chaved up mobile it doesn't look too rotten at all?! Good find! Can't wait til you get back from the 'stan so we can get some proper updates :Q
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Re: My new project - (starting from ebay hell!)

Postby xrsi on Wed Mar 26, 2008 2:08 pm

YOU BETTER NOT GET THE MTX IN BEFORE ME! :lol:


great transformation mate, real big improvement over how you got it.
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Wed Mar 26, 2008 8:30 pm

xrsi wrote:YOU BETTER NOT GET THE MTX IN BEFORE ME! :lol:


Ha, beat you already with the Getrag MT285 6-spd in my old car so I'll let you beat me to it with the MTX because I'm a nice guy and a busy squaddie! :lol: :bonkers:

Feersum_Enjin wrote:Impressive, for a completely chaved up mobile it doesn't look too rotten at all?! Good find! Can't wait til you get back from the 'stan so we can get some proper updates :Q



Yeah was lucky on the rust front mate, was good around the filler cap, sills, etc. Just when I removed the cracked windscreen I found some tin-worm behind the rubber so that's been dealt with, there was also a little bit on the rear arches behind the bodykit which has been replaced with fresh metal,

The car only cost me £155 originally but I've spent over 10-times that amount getting it where it is now! :o It was listed on ebay as "just needs a radiator and will be driveable"! :lol: :rolleyes:

So far I've fitted:

1. Rad & FRST Fan.
2. New EDIS module.
3. New battery.
4. New Exhaust Centre-Section.
5. New alternator belt.
6. Countless bulbs (had to replace a load of blue ones! :rolleyes: )
7. Front N/S wheel bearing.
8. 8 X new Valve Stem Seals.
9. New Rocker Cover Gasket.
10. New front panel & x-member.
11. Full FRST interior (inc clocks & steering wheel.)
12. Full FRST decals.
13. New Number Plates.
14. Orange square side repeaters.
15. New Ford Badges.
16. 2 X new doors (mk 3.5).
17. Full Raven Dash & Plastic trim.
18. New heated front screen.
19. Black Carpet & Parcel shelf.
20. FRST Bonnet.
21. FRST Rear spoiler.
22. New weather seals.
23. Frst Rear pop-out windows.
24. New HT Leads & Plugs.

Still to do for MOT on Friday:

1. Get a new steering rack on (the old one has a disgusting amount of play in it! :rolleyes: )
2. Get some Front Seatbelt Female ends fitted.

Hopefully it'll pass the MOT :aaah: - Was hacked off today fitting the exhaust system in the pissing rain with only a poxy scissor-jack and a couple of bricks holding the car up, especially as it'll all be removed again later on when I get a proper engine squared away! :lol:

My flight out to "The 'Stan" has been put back to May now as my new boss wants us to have time to move back to Colchester as a family and get settled, have pre-tour leave etc. Just need to find somewhere safe and undercover to stash the Fez while I'm away...
Last edited by jimmyesh on Fri Mar 28, 2008 9:50 pm, edited 1 time in total.
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Re: My new project - (starting from ebay hell!)

Postby Captain Tightpants on Thu Mar 27, 2008 9:57 pm

I like! :D

Thats where all my bits were going then! :lol:

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Re: My new project - (starting from ebay hell!)

Postby xrsi on Thu Mar 27, 2008 10:10 pm

jimmyesh wrote:
xrsi wrote:YOU BETTER NOT GET THE MTX IN BEFORE ME! :lol:


Ha, beat you already with the Getrag MT285 6-spd in my old car so I'll let you beat me to it with the MTX because I'm a nice guy and a busy squaddie! :lol: :bonkers:



That very kind of you good sir ;) :lol: At this rate i may actually have it and the zetec turbo in before ford fair and all up and running the speed i am building the zetec turbo up.
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Re: My new project - (starting from ebay hell!)

Postby rsonblackwheels on Thu Mar 27, 2008 11:13 pm

its bin brought back from the dead :o

gr8 progress

very cool :aviator:
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Re: My new project - (starting from ebay hell!)

Postby jimmyesh on Fri Mar 28, 2008 10:03 pm

I had to bin the MOT appointment today as there were things that I just new weren't right and it would just fail anyway :rolleyes:

Even though I changed the valve stem seals, the 1.6 CVH still seems to be smoking slightly.

I was only going to get it roadworthy with the '2i running gear for the house-move back to Colchester in a couple of weeks but I'll just pay someone to transport it there for me now instead (£££ :rolleyes: ).

I'll stick to planning what I've got in store for it later in the year, saving some pennies and just stash it somewhere safe (and dry! :oooh: ) for the next 7 months or so :wink:
Last edited by jimmyesh on Thu Oct 23, 2008 8:36 pm, edited 1 time in total.
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Re: My new project - 2.3 Duratec!!

Postby jimmyesh on Wed Apr 30, 2008 8:56 am

Right, I'm literally days away from deploying on tour now - the delay gave me time to find a suitable powerplant for the silver one :)

I was wracking my brain trying to decide what engine to go for (Focus RS - Been done before in a few MK5's, Focus ST 2.5 - Maybe a bit long as has an extra cylinder :-? , 2.0 Duratec HE Turbo - 2.0 Duratec (fiesta ST, Mondeo/focus) These engines are still a bit pricey in the UK due to all the classic Ford boys snapping them up and....

...Why bother with the 2.0 when Ford also kindly made a 2.3 All-Alloy Duratec for the U.S market Ford Focus which weighs less than a 2.0 Zetec (or a 1.8 for that matter)! :D Also, the duratec has the Inlet at the front of the engine bay (which I think is better :P ) in that it keeps the roasting-hot turbo away from the rad/intercooler without the need to dangle the turbo above the gearbox etc. I'll be keeping the individual coil-on-plug ignition setup too.

So that's what I've managed to buy for $500 (£250) - a low-mileage 2.3 Focus Duratec + $200 (£100) shipping to Barking in Essex - Just down the road from me! :Q What with the dollar being so weak at the moment, it's a great time to get stuff like this from the states and use a U.S shipping company :D

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Needless to say I'm getting proper rods/pistons/bolts etc and a few Cosworth goodies for it (Cosworth do loads of nice products for the Duratec). Also it will be turbocharged and should make 300+BHP with relative ease, nice and reliably hopefully as this engine is basically the Mazda 2.3 MPS engine but in N/A form (for now!... :devil: )

I'm replacing the manky alloy rocker cover with the Black one that features on many 2.0 Duratecs too and mine will be running on aftermarket management so the wiring will look a hell of a lot nicer than it does in the pic! :aaah:

Right, there won't be much in the way of progress in a "hands-on" kind of way for a few months but I will get to the internet suite whenever I can at camp Bastion and order some bits here and there to hit the ground running when I return :wink:
Last edited by jimmyesh on Tue Mar 23, 2010 1:55 pm, edited 7 times in total.
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Re: My new project - Got a 2.3 Duratec!

Postby FlashXR2i on Wed Apr 30, 2008 9:02 am

2,3 Duratec :Q

Nice one Jimmy :wink:
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Re: My new project - Got a 2.3 Duratec!

Postby Excursion on Wed Apr 30, 2008 9:25 am

Nice mate, take plenty of pics :D
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Re: My new project - Got a 2.3 Duratec!

Postby j7aoc on Wed Apr 30, 2008 9:39 am

Very nice
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Re: My new project - Got a 2.3 Duratec!

Postby allinking on Wed Apr 30, 2008 11:46 am

NICE :aviator: :Q
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