fiestaturbo.com

[Excursion]

A year has gone so fast! The weather really wasn't kind to us that weekend was it

Will look forward to seeing your car in action mate

[heeman10]

It was the best day of the entire year....in the morning! Was a nasty drive back too, I was still giddy as a young camel though I'll be around and about a bit in summer so I'll drop in to take you out in your "old car" if you're in. I'll help you wire in your ST170 4 wheel electronic ABS too, by passing the insulation tape

[heeman10]

Small update:

My braided hoses came through from Fusion today, with the metric ends for the Fiesta connections and correct imperial ends for the American Wilwood calipers:


I'm installing oil pressure and temperature gauges, and am taking the pressure feed off the turbo oil feed. You can see in this pic where I needed a T-piece to allow me to run the pressure sender in-line with the oil feed:


And this little baby will allow me to do that:


The silver male/male fitting screws into the block as normal, then this little anodised fitting screws onto the end of that. The pressure sender screws into the 1/8NPT female thread at the side, and the oil feed screws onto the end of the T-adaptor

I go home on Saturday for about five days of work on the car, and hope I will be able to get it up and running and out on the road for some gentle miles of fault finding and generally checking all is well

[heeman10]

Update:

Well I came home on Friday night for my 4-5 day session on the car between assignments and exams at uni My bedroom was FULL of things...chromed stuff, polished stuff, radiator, intercooler, ECU, engine bay loom, boost hose...ALL sorts, it was like christmas!!

Work began yesterday morning, and the first discovery was that my radiator and intercooler, after the lonnnnnnng wait, don't fit Rather than waiting a few more months for Radtec to resolve the problem, I'm sending the radiator to Lee at Fusion Fabrication to carrying out the alterations required to allow them both to fit. That means I can't mount the intercooler yet either, so I will not be going to FITP now. These things happen, so I'm not angry at that, but if I'd had the cooler and radiator several months ago when I should've done, I could've found this out in February and had them modified already and they'd be on the car now. Ho hum!

Plugged in all the engine loom, HUGE thanks to Scort for checking it over, giving me an ERST AMAL valve and Zetec CPS, he is my saviour Thanks also for the tech support calls, you saved yet another ECU from heeman humiliation! So at around 10pm last night, I came to fire up the ignition to check the fuel pump was working, and after several adjustments and checks here and there, still had no life from it. The pump was new about three months ago, so I assumed it to be fine. Having blown our last fuse in the multimeter, I had no meter to check all current outs, but used an indicator bulb today, and I have power at the pump connector, meaning the pump is not working. That's gay, but it's good to know the feed is getting there, and so I can now wire in everything on the dash (plazma dials, three new gauges plus ACT gauge then boot release, central locking etc) and get the majority of the interior back in.

Gearbox cradle is now modified for the Deflex gearbox mounts, which are now bolted on, so the gearbox and engine are back up in the car again, solid as a rock. Ran out of things to do today, so spent about four minutes putting my Rawli lights on, and they look lovely

So tomorrow I need to get some big fat M12 bolts to mount my new brakes, then bleed them and quite probably find my master cylinder is no longer good enough And the fuel tank and pump need to come out again to see what's going on with it, and a replacement sorted if need be.

My dad's been having problems with the Caterham since he tried using a faster-cranking geared starter motor. The company (Racemettle, for those wondering who to steer clear of) ended up sending three motors as they were all rubbish, and the car hasn't started since. My dad sent off the ECU to be profressionally checked, and has checked every single wire on the car (sound familar Mr. andyhardy? ) and found that the block temp sensor was a little inconsistent, so replaced it. In the meantime, the ECU was found to be spot on. He bought a set of Platinum NGK plugs for it, still no joy. Tried to old starter today and it fired up no problem! Misfire was gone, fuel was fine. So all that time and money (160 quid for ECU check) and it was these muppets giving him yet another crap starter motor! So after our frustrating day today, both having niggles with our Zetecs, I think we might be going out for a blast in the Caterham ahh 400bhp/tonne

Pics will be up around Thursday, don't have my PC with me up here.

P.S. I forgot...oil pressure sender is now plumbed in, inlet manifold is all re-assembled and back on the engine, and I've got dimensions for the custom bits I need from Fusion to plumb in the cooling. I've done lots more, just can't remember

[Captain Tightpants]

Glad to see its coming on mate.

Looking forward to seeing some photographs too.

Keep up the good work mate.

Steve

[heeman10]

Update



MY CAR IS GAY.

[MAD_Adamski]

aint that the truth like the owner

[Ghost]

Update



MY CAR IS GAY.

care to elaborate?!

[Captain Tightpants]

What up mate?

Steve

[RS_Rawli]

its all that bloody leopard skin around it,

[Excursion]

wha gwan?

[RS_Rawli]

just been on the phone to him, his car isnt actually gay

just had a bad day on the camp

[Rhinopower]

chrome bits good?

[heeman10]

Ok, well a proper update now. I'll try to keep it short.

Modified gearbox cradle with Deflex mounts:


Oil pressure sender and turbo oil feed on back of the block:


Fast and the Furious style photo of all the stuff in my bedroom waiting for me:


Radiator/intercooler problem. Radiator pipe sticking out sideways blocked the intercooler pipe:


The pipe (top left) needed rotating round to face backwards, the bottom right pipe needed shortening, and I needed tabs on the top of the radiator to secure it to the car:


Drove all the way to Fusion Fabrication in the Metro, as I needed it all sorting ASAP. Lee set aside his entire afternoon (and early evening) sorting out all my problems, dedicating all his time to solving one problem, then saying "NEEEXT!" and I'd bring in the next offending item. The outcome....modified rad (sadly he welded the tabs on the wrong side, an oversight on my part partly ), modified exhaust (to give alternator better clearance), custom actuator bracket (pics further down) and new intercooler mounting brackets.

Lovely weather for the drive down:


Radiator modified:


My actuator couldn't be mounted ANYWHERE with the compressor housing pointing down, and my new custom bracket allows it (A) to be mounted and (B) to clear the radiator healthily. The actuator had to be positioned as close as possible to the boost hose, and it is absolutely perfect:

Front view:


Rear view:


Lovely piece of work, and solved a number of problems

Also, this was sitting in his workshop:






My turbo assembly compared to ERST setup:


Test fit with new radiator:


Intercooler is not mounted yet, that is supported in position.

Heater vent block-off plate to stop my ACT and boost gauges overheating in cold weather with fans on hot:


And my new dash layout. Plazma dials, Autometer gauges and ACT gauge:


Brakes aren't finished yet, but close:






An idea of how the engine bay will be:


Fusion Fabricated Metro:


And the awesome sunset that greeted me when I arrived home:



This is a very brief update, there were a large number of problems I faced in this five day blast, and working on the car alone, doing the kind of work I was doing, was extremely draining physically and motivationally. I think I'll miss my live map at MSD thanks to the wasted time with the radiator and intercooler being made so slowly, but I should have it running by/before June anyway. Exams are next up.

Any questions, ask away

[Excursion]

Good stuff Jim - nearly there!

What was the reason for mounting the radiator back to front then?

[Ruishy1]

coming along nicely there mate

[Classkeeper]

Looks great. Cant wait to see the finished result!

[PaulFRST]

Hi mate, cars coming along great

where can i get those plasma dials, they look wicked

[Max M4X WW]

Everythings looking spot on

[Mint_FRST]

What are these things...?


And where did you get them

[Max M4X WW]

Looks like the rear panels to me!

[FezzR]

scuttle / bulk head pannels

[heeman10]

Excursion - I'm not mounting it back-to-front you tart

MintFRST - Yep, bulkhead panels. I'm not 100% happy with having so much chrome stuff, but I want everything clean, and smooth/shiny surfaces make that easier! I think I'll get used to it, and it's better than it was.

Another update...my Forge recirculating dump valve:


Was a bit of a rushed update above, so if anyone does have questions I'd be happy to answer them

[Excursion]

Excursion - I'm not mounting it back-to-front you tart

slut.

Maybe back to front was the wrong term, end to end perhaps? The piece you just had modified should have been like that, it goes to the water pump - that's why you've got the header tank inlet on the wrong side now (that small tube). Did you have some clearance issues or something with the new turbo arrangement?

[heeman10]

wtf I thought the small nubbin pipe was for turbo water or something Ah well, it'll work as it is It WILL work

[xrsi]

spoke to radtech today mate!

will be with me wed/thurs!

doesnt lok like i'll have any probs with fitting at all from those pics!

they said that they were waiting to hear if there were any fitting issues with yours befor they finished mine off completely as it wasnt from their own design!

oh and also yeah you rad is swapped round... what you have on the right should actually be on the left as you look at the front of the car! it would have needed modifiying anyways as the angle the bottom hose would have entered was backwards from where it should have been!

but yeah the small hose connection is for turbo cooling water to be put back into the rad!

[heeman10]

All is well. I don't have a water-cooled turbo anyhoo, and the radiator needed to be RIGHT over to the left hand side, so it's all still fine. Glad you're getting yours in good time at least!

[xrsi]

wont hold my breath over it but will be nice when it does come!

where did you get all the chrome bits from? wouldnt mind getting a few bits done myself!

[heeman10]

Chroming and polishing was done through Rhinopower. Sadly some bits got damaged in the post, resulting in cracked chrome. I'm not totally sure I like it all chromed, but time will tell. Just need it running and driving first

[sleeky]

Coming along really well mate, gonna be an awesome car

Lee.

[andyhardy]

Great stuff - it's really taking shape now mate!

I'm watching this post with a keen eye

Cheers,

Andy

[Superal]

im gonna be following this closely as i am hopefully going to embark on a 1.8 zetec turbo project in future

[wilson123]

Cant wait to see the end product of this, its become somewhat of an emotional rollercoaster for me, like a favourite dvd that i just watch over and over again

Shaping up to be awesome end product though, any ideas how much wonga you spent on it so far J?

[MAD_Adamski]

All im gonna say id those leopard skin pants are coming off to often man you need to get a g/f and get out more

[Rhinopower]

Glad you like the chrome, what bits got cracked?? If you want i'l give the place a call on monday and see if he'l redo it FOC for you??

Want more BLIIIINGGG and shiny link that?? PM ME PEOPLE!