fiestaturbo.com

[FRSJON]

jimmy the pressure limiting part your on about is the male /male fitting that goes into the turbo and your oil feed fits on,these come in a variety of bore sizes cant think of any better test that anyones else hasnt said bar changing the turbo

[jimmyesh]

Been busy again today Got the car up on the ramps this afternoon and did a few jobs...

Firstly I connected the VSS (vehicle speed sensor) plug to the gearbox, then I lowered the ramps, started her up in 3rd gear (remember - driveshafts still not fitted at this stage ) and looked at the dash. Lo and behold the speedo works perfectly too!

Here's a short vid just so you can see for yourselves;



A couple of brews later I had both the new, shortened driveshafts fitted

Nearside;



Offside;



Here is my neat little Volvo PAS tank that I sourced from the scrappy;



Here's the fitting I made for it to connect to the inlet of the PAS pump (remember the pump-mounted Fez MK6 ST reservoir was too big for my bonnet to shut! )



One last pic of my silver rocket before I put it under the covers for a week or two... Looks as if you could just get in and drive her away!



On the ranges all this week shooting some big-ass machine guns , then parachuting the following week so I'm going to be itching to get more done on this after being kept away for so long

[jayrs]

nice one mate, almost there, i bet you wish you could just go for a spin

what ya shooting on the range then?

[jonyb4]

haha awsome mate, fudgekin slow down 50 is a bit much for in a barn!!!

what brakes you running mate 280's? think i remember some rear discs too?

have fun with the guns and paradropping

[mriley1980]

Just read this from start to finish, your my hero
if my fiesta looks half as good as this when its finished i'll be a very happy man

[jimmyesh]

I'm starting to get annoyed with the smoke problem now! Not got to spend much time on the car due to work commitments but had a play with it this week.

I'm still tring to work out whether the burning oil is due to the turbo or engine

I've got the following symptoms;

1. Engine starts from cold and runs with no smoke whatsoever for about 30 secs to 1 minute, then blue/grey smoke is emitted constantly and is more pronounced if you rev the engine.

2. I have considered the possibility that I may have broken a piston ring during my engine-build (unlikely but it could have happened ) but the likelyhood of all four pistons having damaged rings is pretty unlikely. Today I removed one spark-coil connector at a time to try to eliminate any suspect cylinders but the smoke remained...

3. Due to my engine having a Garrett GT28 Ball-Bearing turbo, I've found some info that states that GT-Series ball-bearing turbos need oil-restrictors (just the banjo-bolt part) fitting to limit the amount of oil that gets into the turbo otherwise they can pass oil into the exhaust...
Here's the restricted banjo-bolt compared to the original..



4. The next stage for me is to do a compression-test.

5. I know it's a bad idea in a lot of ways but the thought of blanking the turbo oil-supply just for a couple of minutes whilst running the engine at low speed/idle (just to see if the smoke stops) and having the wastegate stuck open in order that the turbo doesn't have to be under any load. This would be a definite way of showing whether it's the turbo or engine


Other developments are;

I just fitted this to the back of the removable panel that drops down from the top inside the glovebox. It is a Dakota SGi-5 Digital signal interface. As the Focus RS uses 18" rims and my car uses 15" rims, (taking the tyres sizes into account as well) the FRS does 804 wheel revs/mile and my car does 920 revs/mile. This means that my speedo will be reading 114 MPH when I'm really doing 100 MPH. This little black box lets you punch in a calibration factor (0.871 in my case) and just interrupts the signal from the gearbox to the ECU. Hopefully I'll be verifying this with GPS in the not-too distant future!

The good thing is that it's always accessible but is not taking up any space in the glovebox. It's all wired up now too and works fine.







I now have a set of Koni rear adjustable dampers and some Spax adjustable front dampers with some Spax -35mm springs (staying away from coilovers for now, as I want the car to be a comfy daily-driver not a bone-shaker! )

Need to fit those and also drop the fuel tank again to fit my MK5 Fez fuel sender, remove the standard crappy fuel diaphragm and suppressor.

Also got a few oil & coolant-leaks to contend with. The oil leaks are from the sump, the cam-chain cover and the oil-filter housing. I will be removing all these and re-sealing them with the correct Loctite 5900 that I should have used first time! These will be a Bic™ to remove as the engine-mount will need to come off, all the pulleys and numerous hoses just to get to the cam-chain cover!

Also could do with re-torquing my ARP Head-studs as apparently that's standard practice with these

Ah well, I'm sure it will be done soon...

[SEG1]

about the restrictor on the gt28 have you fitted one ?

as this happened to a mate of mine. lots of smoke

[jimmyesh]

about the restrictor on the gt28 have you fitted one ?

as this happened to a mate of mine. lots of smoke

Yeah fitted it yesterday mate, still smoking

[HCS PIMP]

have you checked to see the oil return is flowing properly could be over pressuring and leaking past the seals and entering the exhaust housing

[jayrs]

i still reckon its the turbo mate.
the smokes white / grey isnt it

[SEG1]

about the restrictor on the gt28 have you fitted one ?

as this happened to a mate of mine. lots of smoke

Yeah fitted it yesterday mate, still smoking

i dont think its the engine,must be the turbo .
Where did you buy it from?

[jimmyesh]

about the restrictor on the gt28 have you fitted one ?

as this happened to a mate of mine. lots of smoke

Yeah fitted it yesterday mate, still smoking

i dont think its the engine,must be the turbo .
Where did you buy it from?

Ebay!

[Ruishy1]

i know this is a bit daft, but how bout using piping to connect another engines turbo to your inlet and see if it still smokes ?
or connect your turbo to someone else engine and see if that one smokes

[jimmyesh]

I did get a quote of over £800 for an exchange turbo from Turbotechnics For that money I've found that you can buy a complete new Garrett GT28R outright anyway... Just need a spare £800 first!

[Ruishy1]

ouch, not try a lesser cheap turbo just to get it mobile and all the niggles sorted ?

[jimmyesh]

ouch, not try a lesser cheap turbo just to get it mobile and all the niggles sorted ?

Might have to mate - A good friend at work collects his new Focus RS on Saturday, which he's letting me take for a spin Driving that beast is going to make me want mine done even more!

[Excursion]

I love the thought that's gone in to this, good luck with the Turbo

[jimmyesh]

I feel as if the best thing I could do now is drop the engine, strip it down and give it a good once-over After some checks I did today it's looking like it may be the engine that's at fault It may be the headgasket but I'm not getting any "mayo" in the oil/dipstick but it does seem to get hot very quickly and bubbles up in the header tank (I do still have some coolant leaks though so that doesn't help). Also, it's running very rich on the Siemens 630CC injectors and standard Focus RS Map (no surprise really) so I'll probably fit some standard Focus RS injectors for the time being, as it's using the map for them and if I want silly power at a later date I can re-fit the Siemens - I think the standard Focus RS injectors can handle up to 300BHP or so anyway The spark plugs were all black (from the richness) but also seeemed oily on the threads which leads me to thinking of either headgasket or piston ring problems

I know it sounds a bit drastic but I'm more than happy that this car is even running (and well too! ), given the mish-mash of parts and new ideas trialled here. To be honest, up until now a lot of what I've done has been experimental and really I can just take it as a dummy-fitment of the parts, before removing the powertrain and giving everything a good spruce-up to make it all look perfect and fit immaculately under-bonnet.

Other developments are;

As you know, the MK1 Focus RS came with a boost gauge built into the instrument-cluster, unfortunately this meant that they didn't fit a temperature gauge! Personally I like to know how hot my engine is at any given moment so have just bought this, a Stack capillary water temp gauge (nice and accurate but not as £££ expensive as their "stepper-motor" types).



I also bought a Nomad A-pilllar twin-gauge pod, as I'm going fit a nice Stack wideband lambda gauge.



Here is the temp gauge illuminated;



I'm still waiting for my Spax PSX adjustable front shocks to arrive in the post (should be here by Wednesday) but have received my -35mm Spax MK3 Fez RST lowering springs (part no 11036). I bought these as the car had some G-max things on the rear and some pikey cut-down springs on the front!



The Koni adjustable rear shocks are now fitted (I adjusted them before hand as you have to dismantle them to do it).





The rear sits around the same height as before which is good



Also, I dropped the tank, fitted the MK5 fez fuel sender (inverted) and removed the crappy diaphragm thingy. Fuel gauge works 100% now

Time is getting tight to get the car done now as I'm on a 6-month tour again as of September, time with my family is precious and work is hectic so I'll do what I can in the meantime!

[jonyb4]

trying my hardest not to be condesending here mate, but some times a headgasket failure isnt always complete

few mounths ago the 1800 in my mk4 had a gasket problem from hard revving one night, but it still ran fine, loads of power, no oil cantaminated (lucky as it just had a service including expensive castrol magnitex oil) but the only symptons were high pressur eint he coolant and white smoke in the exhaust

after getting the head off i found only part of the gasket had failed, where the water galley and bore was

just a thought

[jonyb4]

oh nice update too

[moondustka]

I think the standard Focus RS injectors can handle up to 300BHP or so anyway

Yup

Those siemens injectors are waaaay too big. My brother has got a set and had them fitted to his FRS engine and took them out. They're just not needed unless going for silly power.

A long shot, but you could find that your smoke is the rings as those injectors, as you know will make it run mega rich, especially on the FRS map. The excess fuel could have caused bore wash possibly.

Shame, cos it's an awesome car

[SEG1]

if you need to get rid of the 630cc injectors ill be interested.pm mate

[jimmyesh]

if you need to get rid of the 630cc injectors ill be interested.pm mate

PM'd

My new Spax front shocks arrived today, along with a turbo pre-filter







Now just need to get my hands on a set of standard MK1 Focus RS injectors - anyone happen to know the rating (in lb or cc), or the part numbers for them?

I know the white Bosch injectors on the Blacktop 2.0 Zetec are around 200cc, the ST170 ones are 315cc, not sure if the 170 shared the same ones as the RS? I know people keep the same injectors on the FRS up to 300+ BHP so I would have thought they were closer to 400cc?

[HCS PIMP]

from my research around 400 - 440 cc injectors hope that helps been on 6 sites to find this

[jimmyesh]

from my research around 400 - 440 cc injectors hope that helps been on 6 sites to find this

Cheers mate - yeah the standard MK1 Focus RS Items were Bosch 440cc, makes sense really when people have been getting over 300bhp on the standard FRS injectors.

[SEG1]

jim where did you get the turbo filter from and do you know what thread it is?

[HCS PIMP]

looks m12 / 15

[muz]

I love the fact it looks standard! Veeeeeery cool car Jimmy.

[jimmyesh]

I love the fact it looks standard! Veeeeeery cool car Jimmy.

Cheers Muz, much appreciated Just wish it was driveable now - it looked so nice sat out in the sunshine today

jim where did you get the turbo filter from and do you know what thread it is?

Kinaguwa Turbo on Ebay mate - he is a seller from Japan but I've bought quite a bit from him and it's been with be within a week every time, cheap postage too (P.S your injectors will be with you tomorrow )

[jimmyesh]

Had a spare hour or two today so fitted the spax PSX front shocks with -35 Spax Fiesta RST springs.

Old pikey "modified with an angle grinder" springs (previous owner's work not mine!)







This looks a bit better...





Still got a perfect stance (in my opinion ) - Lower than I thought it would be on Spax -35 Springs

[jayrs]

looks good mate

[FRSJON]

looks great jimmy,hope to see this at a show soon!

[RS rob]

looking awesome,
those stack gauges look awesome,
they are on my list currently haha

[jonyb4]

the height is perfect! spot on mate, btw that disc looks huge or is i just me

[jimmyesh]

the height is perfect! spot on mate, btw that disc looks huge or is i just me

Ha, must be just you mate! They're only 280mm - all I could fit behind my RS2000 rims