fiestaturbo.com

Project_XR2i_Trackcar :Welcome back Jim

Doesn't seem like a few days ago we were sipping coffee in Bastion. Have you spent your op bonus yet?

Hi Chris, cheers mate. Yeah spent some of it - see this thread to see where it went!

Was good meeting up in Afghan - I'll bet that it's the first time there's ever been a FT.Com gathering (well, 2 of us anyway) in Afghanistan!

Today's visit to G & L Autospares yielded the following (For just £30!! ):

Fiesta MK3.5 Si steering column.

Fiesta MK3.5 Si Power steeing Rack and track rods.

Fiesta MK3.5 Si Power steering pipework

Fiesta MK5 Zetec S Power steering L/P pipework with cooler.

Mondeo MK3 2.0 Duratec Power Steering H/P pipework (will be taken to hose specialist and a hybrid pipe made with the pump-end of this one and the rack-end of the Fez Si hose)

Mondeo MK3 2.0 Duratec Fuel Rail Inlet pipe.

Mondeo MK3 2.0 Duratec Alternator/Starter Motor wiring.

Mondeo mk3 2.0 Duratec bolts for engine/bellhousing, alternator, starter motor, P/steeing pump.

Mondeo mk3 2.0 Duratec Vehicle Speed Sensor.



Although these bits were dirt-cheap, removing the steering rack from a ground-mounted Fiesta Si that still had the engine fitted was "sporting" to say the least! Needless to say I was there for a fair old while today and left in a knackered state!

jimmyesh :
Was good meeting up in Afghan - I'll bet that it's the first time there's ever been a FT.Com gathering (well, 2 of us anyway) in Afghanistan!

and dare i say it the one and only

bloody bargain there matey, rack alone would have cost more than that on an exchange

some bargins there mate i just cheat i got a xr2i i slowly been pinching the bits of in my back garden

looking good thought u nearly got all the bits you need yet?

White2i : u nearly got all the bits you need yet?

Yeah not far off - got enough to get everything "thrown in the hole" so to speak. Gonna crack on with making everything fit / weld engine/trans mounting points etc once I collect the car and engine. That'll buy me some time to save a bit for fuel system components, Omex 710 or 600, Samco hoses, exhaust system and Quaife ATB diff.


If anyone wants an XR2i CVH EFi Engine (runs quietly but could do with a freshen-up), XR2i 'Box complete with driveshafts and linkage etc, full XR2i CHV loom & ECU, all mounts and a Scorpion Exhaust tail with standard centre-section. Just give me a shout - I'm putting it all on ebay soon anyway

LOL, good effort man, it's all about the moment when you roll onto your back with a cut up hand, aching arm, dripping sweat everywhere with that baxtered part finally out!

Looking forward to the progress on this!

if you need a hand mate you will have to shout and also if you need somethings making then shout i am a metal fabricator so can get bits knocked up at work lol on the quiet

sounds like you need to get car and engine asap then so you can get cracking

Feersum_Enjin :LOL, good effort man, it's all about the moment when you roll onto your back with a cut up hand, aching arm, dripping sweat everywhere with that baxtered part finally out!

Looking forward to the progress on this!

Cheers Feersum I've been in the state you mentioned there on a few occasions My scrap-yard visits this week have served as build-up training in preparation for some serious spannering to begin!

White2i :if you need a hand mate you will have to shout and also if you need somethings making then shout i am a metal fabricator so can get bits knocked up at work lol on the quiet

sounds like you need to get car and engine asap then so you can get cracking

Cheers Marc, I'll be in touch should I be needing a hand mate Yeah need to get cracking but family comes first - I've hardly seen my wife and kids the last few months so when my leave starts properly I'll be spending as much time as I can with them. Once they've done my head in I'll turn my attention to the car!

yea thats understandable mate, so will be a week or so before you get round to it then lol

Does Mondeo mk3 2.0 Duratec Vehicle Speed Sensor fits in old gearboxes?
Can you post pic of it?
Thanks!

disc :Does Mondeo mk3 2.0 Duratec Vehicle Speed Sensor fits in old gearboxes?
Can you post pic of it?
Thanks!

Here you go - even got my hands dirty for you!



The white blanking-plate on the left is what my late-MK3 Mondeo MTX75 'box was fitted with (they must use some other means of speed measurement, wheel speed etc...) On the right you can see I have fitted the early-MK3 Mondeo Vehicle Speed Sensor (VSS) in its place - This sensor is the same one that 5-speed MTX 'boxed Focus models (2-litre & RS) used too.

When you say "old gearboxes", which type do you mean? The small-engined Focus (1.4,1.6, maybe 1. came with the B5(BC-type) gearbox as shared by Pumas, Fiestas MK2-MK6 and therefore the Focus and late Fiesta should have some form of VSS fitted into the 'box too. If you mean older variants of the MTX75, the XR3i 130, MK5 & 6 RS2000, Mondeo MK1,2, Cougar, Probe were all fitted with this 'box over the years.

Hope that helps mate

Got a nice surprise in the post today.... A Turbo! Garrett GT28R Ball-Bearing to be precise, should be just what my car needs for a nice bit of poke but (hopefully) next to no lag - 2.3 Litres & 9:1 Comp should see to that!





Wasn't brand-new but has hardly been used either, as the seller was upgrading to something that would give him 400+BHP. There is no play in the shaft and everything looks spot-on so hopefully it'll produce the goods.

Here's a pic of my manifold that I've ordered from Pumaspeed (still waiting for it...), not cheap but is a good quality cast item that is also pretty compact. Although it doesn't have equal-length header it should still more than suffice for my power needs (people have extracted silly power on RST's using the standard manifold which is of a similar design to this )



Also took a bimble to Colchester Machine Mart today and purchased the obligatory £38 engine stand.

looking good mate what power you expecting from that set up then mate 300+?

White2i :looking good mate what power you expecting from that set up then mate 300+?

Around 300 BHP will be fine, a 2.3 producing 300 BHP is the same as a 1.6 producing 200 BHP or so, as far as how much stress the engine is under goes. So hopefully it'll be strong and reliable and have an abundance of torque due to the relatively large displacement

Amazing project! Cant wait to see it all come together.

with the capacity, turbo and compression ratio, i cant wait to see the torque curve

well done for doing something different mate, the world needs more people like you to break the mould

the parts are coming thick and fast mate.... ... just need the time to fit it all together....

Nice spec! Those extra 300cc's should spool the turbo up nicely! I take it the standard exahust housing won't be restricting at high revs?

Feersum_Enjin :Nice spec! Those extra 300cc's should spool the turbo up nicely! I take it the standard exahust housing won't be restricting at high revs?

I hope not mate - I'll just have to try it as it is then iron out any problems as/when they arise

Just been on the Earls Hoses website to sort out some steel -6AN Male fittings to be welded to each end of my fuel-rail. As standard it just has a single push-fit fuel feed and no return line, I want to keep the standard fuel tank set up and lines so am converting it to run a return line, along with a nice Sytec fuel pressure regulator with -6 fittings and aeroquip hoses.

you dont hang about with you project do you jim

Nice safe manifold there Loving the efficient compressor outlet too!

That engine will need bugggger all boost to make 300bhp, as you undoubtedly know already. Tis the way forward

heeman10 :Nice safe manifold there Loving the efficient compressor outlet too!

That engine will need bugggger all boost to make 300bhp, as you undoubtedly know already. Tis the way forward

Hi James haven't heard from you for a while mate, hope all is well

Yeah the compressor outlet and other gubbins is for a Nissan 200sx so I'll probably be binning it (definitely after your piss-taking! ).

You're right mate - "no substitute for cubes" and all that, especially when an alloy 2.3 4-pot weighs the same or less than a 1.6CVH!

nice project i must say!

good to meet you as well, hope the exhaust is what you were looking for

This'll be a brilliant project. Keeping my eyes peeled on this one seeing how much of a success the MANJ was!

rob pace :nice project i must say!

good to meet you as well, hope the exhaust is what you were looking for

The exhaust is perfect cheers Rob, should sound lovely with my beast of an engine howling through it! That FRST of yours is a stunning car too

Didn't get back to Colchester until 8:30pm after going to Sittingbourne to pick the engine up from my mate's house

We have progress!!

Ancillaries all stripped from the engine and it's now mounted on the stand ready for stripdown and re-bore.






The other day I moved all my car parts for this project into a secure locker at work - This allowed me to sleep better at night as previously, they were all stashed in my rickety shed begging to be stolen!



When I get some more "quiet time" at work I'll strip the engine down and get the block off to Cober Engineering in Colchester.

Obviously yesterday's update wasn't interesting enough for you all!

Well here's what was achieved this morning... May be of interest for anyone who wishes to see the innards of the rather strange engine that is the Ford/Mazda Duratec 2.3

Pro Alloy full-width Rad & GRS Intercooler collected from DHL depot.



Engine Stripdown - Duratec has a cover over the timing chain which needs removing first.



See, cam chain NOT cam belt, bit different to the Zetec eh?



Cams need removing to enable head removal.



Cam Bearing-Caps all labelled using good old Army Issue Mine-Tape



Oil Pump chain and pump need removing prior to block machining.



Ready for Head removal.



Head Removed





Here's the crank setup - note the balance-shaft mechanism that is specific to the 2.3 (due to its longer stroke) - Driven at 2 x Crank speed by a gear on the Crank (see pics) can be removed though and I may just do that as it's a heavy old thing! Just need to research a few yank forums and see how harsh the engine is without it...







The crank on the Duratec is carried high in the block in a cradle which incorporates all the main caps.



Crank with cradle removed.



Bare Block at last!



Off to Cober Precision Engineering, collecting it middle of next week all freshly bored to 88mm for me to rebuild bloody light too, you can easily carry it with one hand!

looking good mate, and thats one weird crank set up , when you reckon engine will be back together ready for fitting?

jayrs :looking good mate, and thats one weird crank set up , when you reckon engine will be back together ready for fitting?

Engine should be assembled within the next week (dependant on my Cosworth gaskets arriving from Burton Power - they had to order them in. Also still waiting on my ARP main and head studs from the states, should hopefully be here this week...).

As for it all being fitted "in the hole" I'll stick my neck out and say "by January" but that's barring any serious setbacks and/or wife losing the plot with me!!

lolo, fair enough mate, is that a time limit like something i put on my rs of er, 6 months

Coming along well mate, looks like you've got your work cut out between now and January then!

LeePFRST :Coming along well mate, looks like you've got your work cut out between now and January then!

Lol I love a bit of graft!

engine looks in really good condition mate.... ... all coming along quickly too...nice one...

looking good mate, some good progress there, you will have engine back together no problems then if rest of bits turn up, i cant wait to see this all done and finished

fan-bloody-tastic is all i can say

Well done Jim on another stunning project, you sure your not a VM lol.
Just to get things straight in my head, is the bolt patten for the duratec (proper) different to the zetec/I4 etc as there seems to be alot of differant opinion on different websites, basically will a mtx75 gearbox (my only option due to needing 4x4) bolt on?

What boost you planning on running with a 9:1 compression ratio, surely running this high you have limited it to not alot huh? But there again I suppose you need to keep the power sensible to keep control of the torque steer.

How come your going Omex management?