fiestaturbo.com

[FRSJON]

nice...so more fabrication for injectors....you like a challenge...

[jimmyesh]

nice...so more fabrication for injectors....you like a challenge...

No, not at all Jon - That much effort is not required here! The Duratec Injectors go dirctly into the head, with the injector rail also bolting directly to the head, hence the reason that the Duratec inlet plenum is such a simple affair.

This will be illustrated in the new updates.


My mate, Mick who does the TIG welding has been promoted and posted but on this aft's leaving piss-up he said he's gonna teach me to TIG weld before he goes. I'm mega-happy with that as I can already MIG quite well but have never tried TIG which is a must for all-round project car fabrication - Hopefully I'll pick it up

[HCS PIMP]

beaut then learn spot welding and then cnc machining lol

ill have these skills sorted by the end of my engineering degree then i can start my tunning firm lol

migs are the best i love welding i need to with my mini

so whats the crack with it being a civilised road car (very unlikely) lol gonna be superb

[Ruishy1]

beaut then learn spot welding and then cnc machining lol

ill have these skills sorted by the end of my engineering degree then i can start my tunning firm lol

migs are the best i love welding i need to with my mini

so whats the crack with it being a civilised road car (very unlikely) lol gonna be superb

Have you ever actualy put any though into anything before you post ?
For a start, just because you can spot weld and CNC machine,doesnt mean you know the first thing about tuning cars, i can do those, and a hell of alot more, but i cant open a car tuning firm that would be any good.

Secondly, mig is for retards, its the easiest weld to do, TIG is the weapon of choice for skilled people, and lastly, it is a civiised car, if it wasnt, he would up the power considerably, and strip the nuts out it.

So please start to think before you post

[jayrs]

Ha cheers for the "advice" chaps but I intend on staying married for a few years thanks!

Here's what landed on the doorstep today, I've been waiting for that manifold so that I can get the inlet fabricated - mega happy that it's turned up



The discs and pads are just standard Escort Cosworth 280mm items to go with the Esc Cos calipers that arrived the other day. I'm not into fancy drilled/grooved stuff as my car is a primarily road-going civilised beast!

lol, it was just a thought, but getting some his and her overalls might not be as bads as you think, the missis may want to help one day cant see it but stranger things and all that.

inlets gunna bea goodun mate

as for disc's, agreed, drill and grooved are not needed, although i have them but they came with the calipers.
out of interest how much were the disc mate as i'll be looking into getting a new set of disc later this year

[jimmyesh]

lol, it was just a thought, but getting some his and her overalls might not be as bads as you think, the missis may want to help one day cant see it but stranger things and all that.

inlets gunna bea goodun mate

as for disc's, agreed, drill and grooved are not needed, although i have them but they came with the calipers.
out of interest how much were the disc mate as i'll be looking into getting a new set of disc later this year

Discs & Pads were £74 delivered, I know there are cheaper ones out there but I wanted something from a reputable brand but at the same time not paying silly money just because they have a few holes drilled in them!

Me & Mick worked hard on the inlet today (in Army time! ), it's coming on a treat and is looking great I still have to sort all the vacuum connections, tap a hole for the ACT sensor, fit an ISCV somewhere, fit an outlet for the servo pipe and also weld on a bracket for the throttle cable - so not too much left to do then!

I'll take my camera in tomorrow, promise

[jayrs]

buy cheap buy twice, i rate mintex myself mate, although ive never tried there disc's but the pads yeah, spot on so thats a good price imo.
as for paying more for drilled disc, yeah there a rip really, standard solid disc for my rear disc conversion were about £30-£40 cheaper, so i got them, made a jig and drilled them my self

[jimmyesh]

Here's how the new plenum's shaping up - not bad for one we knocked up at work!





Still a lot more to do with it yet but it's getting there

[HCS PIMP]

not bad with a bit of grinding, polishing and sanding would be beautiful lol

gonna be nice

[Ratspeed]

inlet looks stunning mate! proper top job!

[Ruishy1]

whats the radius like on the ports mate ?
have you done all the necessary calculations

[jimmyesh]

whats the radius like on the ports mate ?
have you done all the necessary calculations

Right, that's it I'm throwing it in the bin!

I was quoted £500+ from several well known tuners/fabricators to make me a custom plenum and that was INCLUDING me supplying the DCOE inlet manifold (another £80). My self-built effort only cost me £100 all-in

I only resorted to making this because space is so tight at the front of the bay, too small even for the standard plastic one. As this car is using forced induction and I'm not after crazy power figures, I'm sure this will be more than up to the job.

The 4 inlet manifold runners are 45mm diameter each so no restriction there - I've radiused them round inside where they meet the plenum to aid gas speed and flow - I was going to use proper velocity stacks from the US but I can't justify the cost.

[HCS PIMP]

rushi stop being mean was me first now you attackin the constructor of this duratec beastie
end of the day with forced induction wouldn't make a huge difference
probs only 15 ish bhp and thats at the flywheel
granted would get a better throttle response and the turbo would spool quicker
but then again times money and this is not a track female provider of 'horizontal refreshment'

[Ruishy1]

whats the radius like on the ports mate ?
have you done all the necessary calculations

Right, that's it I'm throwing it in the bin!

I was quoted £500+ from several well known tuners/fabricators to make me a custom plenum and that was INCLUDING me supplying the DCOE inlet manifold (another £80). My self-built effort only cost me £100 all-in

I only resorted to making this because space is so tight at the front of the bay, too small even for the standard plastic one. As this car is using forced induction and I'm not after crazy power figures, I'm sure this will be more than up to the job.

The 4 inlet manifold runners are 45mm diameter each so no restriction there - I've radiused them round inside where they meet the plenum to aid gas speed and flow - I was going to use proper velocity stacks from the US but I can't justify the cost.

Lol, dont be daft mate, its just some simple things that will need doing, but as a first go, it dont look too shabby
You need bellmouths inside the plenum, you need to calculate the volume of the plenum needed which IIRC is between 50-75% of displacement accoring to old Corky

Just remember that air is a fluid mate, and will move as such, and impedance to flow, tumble and swirl will seriously hinder what is otherwise a fantastic setup

and as for the other comment, i wont even dignify that with a thought out response

[FRSJON]

looks good jimmy... very similar to the jamsport one i had... so polish or paint??

[FRST SILVER]

shes coming along well fella..

[jimmyesh]

looks good jimmy... very similar to the jamsport one i had... so polish or paint??

This one is going to be polished to within an inch of its life!

shes coming along well fella..

Cheers mate

[jayrs]

looking good mate, i can see why you want to polish it, to show off your hard work, and good on ya too, but i cant help thinking a black would be better

[jimmyesh]

Yeah black looks good too - decisions, decisions

I'm going to taper the shape of the plenum down from the throttle end to the closed end which is how a lot of custom plenums I've seen are shaped but is mainly due to space constraints at the front of the car! I measured the capacity of the plenum and it's more than the CC of the eninge at present so losing some of it won't be a bad thing!

I'm also going to buy some alloy trumpets/velocity stacks as used on bike carbs & twin DCOE's etc and install them inside the plenum to ensure pleasant running and good gas flow - might as well do this properly!

I have some -4 and -6 JIC-to-barb fittings that I'm using for my vacuum/boost take-offs (3 vacuum and one larger one for the brake servo pipe), for this I'm using 3 -4 JIC male aluminium weld-on fittings from Earls and one -6 JIC.

I also need a weld-on aluminium 3/8 NPT female boss for the ACT sensor.

Over the next week or 2, things will take shape

[Ruishy1]

im glad your taking it a bit further mate, no point spending such painstaking hours and development into this monster, to be let down by something as daft as the plenum

how long are your intake runners ?
are you after high top end, or more low down grunt ?

All these little things will help develop the plenum into exactly what you require the engine for

[jayrs]

sounds like its gunna be a nice custom job mate

[jimmyesh]

Just got these on Ebay for a bragain - a set of CNC-Machined 45mm Velocity Stacks (NOT including those ancient carbs that they're stuck to in the pic! ) which I'll be fitting on the inside of the plenum, feeding into each inlet runner They're 57mm long, which is about all I can allow for with my inlet being tapered in shape.



I bought a FRST ISCV today as well which is more simple to fit due to the bypass having a simple pipe connection going past the throttle body instead of me having to do loads of intricate fabrication to allow the Duratec ISCV to be fitted

Also managed to buy a Focus throttle cable which fits my throttle body, once that arrives I can get the mount sorted for that on the plenum.

Will be phoning Earls tomorrow and ordering the weld-on fittings for all the vacuum take-offs and ACT sensor boss, bye for now

[LeePFRST]

Good progress mate, glad to see everything still coming along well! Keep it up!

[jayrs]

nice one mate

[HCS PIMP]

good work

[jimmyesh]

Some Aluminium bits from those nice chaps at Earls Performance Hoses arrived today - the weld-on fitting for the A.C.T Sensor, along with the -4 & -6 fittings that my vacuum/boost fittings are connecting to Also, the FRST ISCV turned up too

I cut the plenum along its length yesterday so that it tapers in from the throttle end, just waiting on the Ally velocity stacks + throttle cable so Mick and I can get this thing put together.



Did make a start on fitting my front brakes this morning but my little girl has a puking bug so I had to leave work to get her from the childminders - I dunno, you pay £600+ a month for child care but as soon as your kid's sick YOU have to sack work to look after them!

[HCS PIMP]

yep thats life youd be better havin the children helping you with the car as soon as i have my own sprogs gonna train them to hold spanners and pass me parts by there 12 birthday they have rebuilt 20 engines and restored 3 cars

sounds alot but not with my plans

[jimmyesh]

Bit of an update readers!

Here's how the inlet plenum is taking shape - in the pic the inlet is upside-down as all the vacuum/boost take-offs, ACT sensor and ISCV will be mounted on the underside for a clean, un-cluttered look. The main reason though is clearance for closing the bonnet! As you can see the velocity stacks arrived but as the first pic shows, they were a bit too tall for my compact plenum A bit of a tickle in the metalsmith's workshop later and they're now a decent size.





On Monday, Mick the TIG welding guru is back so he's going to crack on with finishing the plenum

I fitted a Focus 1.6 throttle cable too which is just perfect - it goes through the original fiesta bulkhead grommet and has a ring-fitting on the end which is the exact size of the Duratec throttle mechanism arm fitting. Once the plenum's done I'll sort a cable bracket.

Escort Cosworth front brakes now installed, a nice well-proven budget brake upgrade and perfect for my car as it's staying on 15's (NOT the hideous TSW Stealths that it's wearing now! ).



Also removed these shabby bits of scrap metal from the back end...



...and replaced them with these




For now I've reverted back to a conventional single coil ignition setup as I just want to get this thing up and running for the least outlay and hassle for now - I'm keeping the individual coils stored in case I get adventurous at a later date



Also fitted the Pro-Alloy rad, firstly so I could check that the plenum will fit, but also so I could gauge the route my coolant hoses will take.



Here's a view of the turbo oil return to the sump and also the one from the oil catch tank.



As is normally the case with project cars, I rushed something when I was tired on a previous spannering session (that night when I fitted the engine) and as usual, it all needed ripping out and doing properly with a fresh mind and body! I'm referring to the rear "torque-link" mount that stops the whole powertrain from swinging fore and aft as you take up drive - I got both the main top-mounts spot on but when I fitted the torque link it wasn't 100% straight and also the engine was "canted" slighly (swung on its axis so that the front was higher than it should be and the rear was lower), meaning that driveshaft alignment wouldn't be acceptable. As the torqe link just bolts through welded on mounts on the lower cross member, I ground off my original ones and started again with the engine held in the position for perfect driveshaft alignment.

It's better just to crack on now and rectify any problems than just bodge it and suffer massive failures once it runs!

Here's the pics of how it sits now



Engine totally straight (not swung on its axis). The best bit is that now the actuator and turbo are totally clear of the brake linkage bar. Also it means that I have slightly more room height-wise for the plenum at the front



Those that have followed this thread will have seen how close the oil filter housing was to the front panel originally As you can see, with the revised rear mount there's plenty more room



After all that messing around I managed to get the O/S driveshaft fitted, looks straight to me







One last pic of the car before I collapsed in the bath at home



Bye for now

[jayrs]

loving it man, attention to detail is where its at mate, will pay off in the long run as you say mate

[j7aoc]

You need a bigger turbo



Ian Howell's

[jimmyesh]

[quote="j7aoc"]You need a bigger turbo



Ha, let me get it running with the one that's there already first mate!

That one doesn't count anyway because it's in a Focus not a MK3 Fez - there's acres of room to fit engines/turbos in a Focus

[j7aoc]

You need a bigger turbo



Ha, let me get it running with the one that's there already first mate!

That one doesn't count anyway because it's in a Focus not a MK3 Fez - there's acres of room to fit engines/turbos in a Focus

ok ok think he got the stroke down to make it a 2l so the compression was very low to run very high boost

[Ram]

havnt checked in on your thread for a while, its come so far! you must be proud mate

inlet is looking sweet too, gotta be polished finish with sum anodised bolts

[jimmyesh]

ok ok think he got the stroke down to make it a 2l so the compression was very low to run very high boost

Yeah sounds like that would work as both 2.0 & 2.3 Duratecs have the same bore size so I suppose a 2.0 crank & rods in a taller 2.3 block would achieve that

havnt checked in on your thread for a while, its come so far! you must be proud mate

inlet is looking sweet too, gotta be polished finish with sum anodised bolts

Cheers mate, polished is a given Dunno whether I'll go as far as anodized bolts though!

[M1K3Y_B]

Nice progress mate

You seem to have an endless supply of money

Sorry if i have missed it, but what wheels is she going to be sitting on once shes done?