fiestaturbo.com

[jayrs]

indeed lol
still there could of been something else, over kill as it may seem, you done the right thing.

[crazycage]

sorry to see your having a few issues with it but it looks like your not going to to be put off good luck with it ,its a awsome car.

[RS rob]

it can only be a good thing your doing things properly
you'll be alot more happy with the compression where you want it now when its all done

[FRSJON]

well im glad nothing major has been found wrong with the engine info on the 'old' pistons though please (bore size,pin size)

[jimmyesh]

well im glad nothing major has been found wrong with the engine info on the 'old' pistons though please (bore size,pin size)

Yeah the old pistons are 88mm (0.020" or 0.5mm oversize - standard Duratec 2.0/2.3 are both 87.5) Supertech items which give 8:1 on a 2.0 and 9:1 on a 2.3 (due to the different strokes of the two engines which share the same bore size).

I don't know any other info off-hand mate but here's the link to the shop sale of these pistons brand-new from the major supplier in the states;

http://www.massivespeedsystem.com/super ... 68274.aspx

I've also listed them on Ebay to recoup a few pennies on what I spent on the CP items - here's the link.

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... 3D1&_rdc=1

[muz]

Can't you press the oil return into the front of the block rather than the sump?

[jimmyesh]

Right, I've splashed the cash this month!

I decided my car deserves a new turbo - a brand new Garrett GT28R Just the same as it had already but obviously nice and new

http://www.turbobygarrett.com/turbobyga ... 6541_1.htm

I ordered it today so should have it early next week.

Plus my shiny new CP Pistons of 88mm / 8.5:1 comp arrived today





I've also splashed out on a rather nice turbo blanket, some new steel Garrett water lines (to replace my shonky home-made efforts!), some more heat matting (for underside of bonnet).

The original oil return into the sump is blocked off and some nifty mods are taking place - basically a piece of aluminium 35mm tube is to be welded into the back of the sump at the highest possible point (the duratec sump is very shallow as the crank sits higher than on say, a Zetec - up in a girdle in the block). This alloy tube has a -8 AN fitting mounted on top so that the oil drain can go directly down to it. My mate, Zig is doing that for me this week.

I've got another month or so left in the UK before my delightful 7-month stint in the 'stan so I think I'll easily have all this reassembled and be driving my car soon! (fingers crossed )

[Excursion]

They joys of a deep skirt block

Sounds good, it should be a cracker when done

[jayrs]

[jimmyesh]

Always nice to find this box waiting for you when you get home...



...especially when you open it and there's a brand-spanking new Garrett GT28R ball-bearing turbo inside



With new billet alloy compressor inlet fitted.



I've also ordered a Stack wideband Lambda kit and a couple of Spal pull-fans to replace my single, weedy push fan of unknown origin. I'm using "pull" as opposed to "push" fans as, unlike a normal FRST, I have plenty of room behind the rad due to only having my inlet manifold at the front.

Talking of inlet manifolds, I've decided to test my homemade effort for boost leaks by fitting a bicycle inner-tube over the throttle-body and sealing all vacuum take-offs off, then sealing it to my stainless work bench!

Lo and behold, I got it to 20 PSI and found a small leak in one of the welds on the O/S edge - I'll be handing it to Ziggy the welder tomorrow for some remedial attention I'd rather find things like this out now than wait until the car's on the road and losing boost/power and having to rip things back out!

Tomorrow, I'm getting busy gapping the CP piston ring end gaps to the correct specification and seeing how my sump is coming along with Zig.

Not long until this beastie is on the road - I mean it this time, honest!

[hb69]

Looking good Jimmy

[jayrs]

very nice
good job you checked the inlet mate, you go over it with bubble spray or felt it?
if you wanna be real anal about it you could seal it and put it under water

[FRSJON]

great work jimmy !

[jimmyesh]

CheeRS guys, nice to have some good feedback on the forum

Jay, yeah I used a paint brush and liberaly coated the thing in my daughter's Early Learning Centre bubble mix! Seemed to do the trick nicely

[jayrs]

propper job then

dont think ya daughter will be happy when she goes to blow bubbles and fins the bottle empty

[jimmyesh]

:lol: propper job then

dont think ya daughter will be happy when she goes to blow bubbles and fins the bottle empty

Fair one mate but I think a ride in the Silver Rocket will make up for it!

[jayrs]

a ride in it as well as to the shop to buy more

[jimmyesh]

a ride in it as well as to the shop to buy more

After my recent spending spree I haven't got any money to get any more! Time for me to get out to the 'stan and start saving...

[Excursion]

Not long now mate

[jayrs]

no, you have spent a fair bit.
was that turbo a exchange? or a brand new one with no exchange needed

[HCS PIMP]

nice work mate

[jimmyesh]

Cheers again guys, Jay; yeah the turbo is a brand-new unit, not recon and was bought with no exchange (cost me £665 from Horsham Developments).

[jayrs]

thats not a bad price for brand new turbo mate, well compaired to what you can pay for exchange ones like the T2/T25/T28 etc

[jimmyesh]

Been relatively busy the last couple of days;

Firstly the redesigned turbo oil drain mod on the sump is done (small brass-coloured connector is the drain for the oil breather tank);



I welded a new lambda boss into the downpipe for the wideband UEGO sensor for the Stack wideband gauge/kit (that should hit my door-mat tomorrow )

The boost leak in the inlet manifold weld has been rectified by Ziggy and his Tig skills.

I've drilled & tapped one of the inlet manifold mounting holes in the head and fitted an M8 Time-Sert for my peace of mind as the Duratec has one very short hole due to the head design. The Time-Sert allows me to stop worrying about stripping the threads out of it!

The twin Spal cooling fans are now fitted to the rad.

So glad I took this apart now! - When I examined the timing-chain cover I found that I'd fitted a bolt that was slightly too long when locking the crank-pulley at TDC during the previous build Basically it had punched a hole right through into the timing-chain area, that'll explain my mystery oil leak then! Luckily this has now been rectified by my mate, Ziggy and his Tig welding skills (It's the small bolt right next to the crank-hole)





The turbo now has all its new water & oil lines connected, is fitted to the exhaust manifold and is wearing its new turbo blanket as-per my endless mission to control radiant heat in the bulkhead area.



I spent a while today setting the gaps on the rings to CP's specifications - those nitrided top-rings are a real Bic™ to file! Even worse when you go straight to filing the second rings which are cast iron, therefore easy to work with so you run the risk of taking too much off - I took my time and got them all bang-on.





Finally, tonight I fitted the rings to the pistons than fitted the pistons to my Eagle rods.





I'm going to start rebuilding the whole engine back up tomorrow - things are looking good at the moment

[Ratspeed]

good job on finding the oil leak, its always a Bic™ when you cant see anything wrong!!
Cant wait for the rebuild

[Ruishy1]

wow you have been busy, but top work as usual

[SiST]

I love it mate.

I am currently building a 2.3 duratec with a GT2871R for my fiesta ST and have been reading your progress for a while now. Its a shame you have had to rebuild the engine but will be good to see how the CP pistons are like as I have a set ready to put into my block.

Do you have any more pics of the sump with the new return pipe? I think I am going to do something similar.

Keep up the good work!!

[jayrs]

nice mate, bet ya over the moon you found the oil leak

[PumaNoob]

Hey Jim, after emailing you through Ebay yesterday, i realised id signed up to this forum a while back, just forgot about it. Anyhow, awesome project here mate, this has got to be a 1st in a mk 3 fezza! Glad you decided not to sell up, and see it through. Ill be keeping a close eye on this one, as you know, im planning something similar!!

[jimmyesh]

Pumanoob - that Duratec Turbo Puma will be a weapon. The 1.7 zetec-se is the same layout as the Duratec and also uses a similar engine mount so should be a bit more straightforward .

Another bit of activity today on the never-ending project that is my Fezzer!

I was about to leave the house and head on up to the workshop when a roll of graphite exhaust wrap landed on the door mat - I ordered it to cover my downpipe and replace the white heat wrap (that I'd proffed from work! ) - this matches my manifold now and doesn't get dirty as much.

Note the extra lambda boss for the Stack wideband UEGO sensor;





Got sidetracked into sorting some neater pipe-runs and doing some more heat-proofing;





Finally got round to fitting the pistons I took it slowly and liberally coated the pistons, rings and bores with copious amounts of oil. Luckily no rings were broken in the process or else I'd have to order more from the States and start re-gapping them!



I torqued the ARP big end bolts up to spec with some ARP moly lube and re-checked the ARP main bolts too.

The headgasket and head were fitted and the ARP head nuts torqued to spec with yep, more moly lube!

I started fitting the cams but had to leave to collect my little girl from the child minders.

Here's where I'm up to;



Hopefully I'll be putting the engine back in the car at some point next week - here's hoping work give me the time to do it!

[Ruishy1]

damn you move fast, mega jealous mate of not only your skill but also your facilities

[jimmyesh]

damn you move fast, mega jealous mate of not only your skill but also your facilities

Cheers mate

[Ruishy1]

at this pace the car will be finished in no time at all, and it WILL be one of the most unique FRST's out there

[jimmyesh]

at this pace the car will be finished in no time at all, and it WILL be one of the most unique FRST's out there

It's just an XR2i really!

[jayrs]

at this pace the car will be finished in no time at all, and it WILL be one of the most unique FRST's out there

It's just an XR2i really!

dont worry about that mate, many a good car started out as non FRST, were just not so anal about it like some, take passionford, jesus, they would tare you apart