fiestaturbo.com

[jonyb4]

ive heard you can make your own TB gasket by the hammering card technique

but ofcorse a real one will be better

[black2]

update

Good day on he car today - engine is now out and striped of most the parts I need.

Inlet manifold.

Ive typed a reply out once & this s**t laptop crashed so cant be arsed to type it all again, heres some pics.







Random.







Gareth

[dangerousdave]

should be running by dinner tomorrow then

[jayrs]

ive had that before where you lose it all not good.

cars coming on nice mate

[jonyb4]

ive had that before where you lose it all not good.

lol and me, pressing back by mistake

i was wondering the other day, mainly due to daves thread, why people dont use the standard cast inlet for turbo conversions

but i see you are, how come? like daves using the rover one, and going through the massive alterations it takes, so i figured it was somehting big to stop you using the cast one

looking good man, the car high enough for you?

[dangerousdave]

i couldn be arsed to mess around getting mine to work properly the inj were a mess and leaked everso slightly as the zetec is ment to sit straight and the cvh rail is slanted so idealy you want a rover or blcktop rail, then id have to change the tb and iscv as i couldnt find a valve like garath has i didnt bother as the pipe would interfere with tb and inj etc and my mate had this rover inlet so i thought why not also it wont soak up heat from the head so cooler charge temps and i always wanted an end fed one it looks cool hehe

[black2]

The standard efi manifold can be used just needs some modifications, ie drill and tap for frst act sensor, use remote iscv, make up fuel rail to run top feed injectors & make adapter to allow fitment of frst tb so there is quite a lot of faffing around to do.

A small lunchtime update - the inlet is now finished bar knocking up a plate to blank off the original iscv location. Sump is also finished with the oil return now fitted.

After lunch i will make the plate mentioned above then start fitting my flywheel, clutch, gear box, sump and inlet to the zt engine - then its ready to go in.

More later,

Gareth.

[jonyb4]

and i always wanted an end fed one it looks cool hehe

haha aye the inlet hose wont covert he much decorated cam cover then lol

aye that is alot of faffing, but surely its easier than finding the rover inlet, cutting it up and making flanges or plates to get it to bolt to the head eh?

[black2]

Well today has been quite slow and frustrating, plus ive had a headache for most of it!

THis afternoon I ahve changed the injectors for my beige ones, made the plate to blank the iscv then start swopping bits round, flywheel and clutch are all bolted up etc etc. Im going back later to bolt the gear box on.

Any way heres some pics from today :









Gareth.

[jonyb4]

looking good mate

is that a T2 its gonna be running? a good choice for around 7-8psi and would spool nice and quick but you already know that lol

the exhaust adapter really does push the exhaust out a bit, i hope it fits mate

xD not long now

[black2]

Hi all, progress has been slow over the past few days what with bro writing off his frst and me having man flu!

Any how, I have removed all the zetec wiring loom and replaced with cvh turbo stuff, I have also wired in the frst loom and inj & fuel pump relays. The dash is back in bar the stero surround and heater surround. The zt is now in the bay all thats needed now is to plumb up all the water pipes fit the charge cooler and plumb that up then fit some FRS spark plugs and it should fingers crossed touch wood fire up. Gear box linkage needs connecting and drives shafts put back in etc.

The end is in sight. Pics tomorrow.

Gareth.

[jonyb4]

and me having man flu!

aye anoying aint it, got some too

the end is in sight,a nd i bet your syked for it

[black2]

Update.

As said yesterday the lump is all in, today I have done a through systems check to make sure all is ok. At first I had no fuel pump prime with the key and though here we go again as this is the same problem i had wen i fitted the old zetec in there but after loads of time ans frustration in transoired that I had left a hefty earth wire off the battery Put that one and the fuel pump primes A ok. THen wired up the coil to check for spark - which I have so the means all the wiring Ive done is fine. Then just checked all the dash lights etc are ok and working. The on;y problem of the day was the reverse light switch in the gear box some how snapped off in the box and typical i only noticed this after i had fitted the lump back in the car. It took ages and ages to get the broken bit out but got there in the end. Other than this all ive done is start mocking up the bay with the hude chargecooler etc, as seen in the pics its huge and is a vert tight squeeze in the bay but i think its going to work. Just need to move that rad down towards the drivers side so I have some space to fit the chafrgecooler pre rad on the left hand kind of behind the passengers headlight. #

Any how enough woffle heres some pics:










Gareth.

[jayrs]

looking good mate
reckon your have to rethink the air filter, dont look like you have much room

[Ruishy1]

loks good mate, will be a propper little weapon

[jonyb4]

i just got mine in and running and

At first I had no fuel pump prime with the key and though here we go again as this is the same problem i had wen i fitted the old zetec in there but after loads of time ans frustration in transoired that I had left a hefty earth wire off the battery

i had the exsact SAME problem

pain int he fanny lol


so glad its all in and getting there mate, ruishy isnt wrong

[black2]

Cheers guys.

Jay your right about the air filter its defo tight but im hoping my old piper cross one from the frst will fit as its quite small. Will dig it out and have a trial fit.

Progress will be slow from now on though because im back to work this week so will only have the evenings to work on her Mainly just small things to do now like fit the drive shafts, connect gear linkage, re-fit bottom ball joints and tidy up the engine bay. Im just hoping theres enough room for my chargecooler pre rad as i would like to use this, if this fails i will have to use a standard frst ic but their tiny and a bit crap really. SO fingers crossed i can shift the rad arrangement around a little.

Gareth.

[jayrs]

your be ok mate, im sure it will fit one way or another.
worst case you could cut the intake pipe down and have it facing up, and build a shield round it and plumb in a cold air feed

[black2]

Not really much of an update - I have tidy'd up all the wiring in the bay now and fixed the map sensor, co2 pot & edis unit to the car properly.

This evening after work i had a little play with plumbing up the charge cooler and after a lot of thinking im going to scrap the idea of using it - its just to tight in the bay and i feel like its all too much of a bodge to have it there so im going to take it out again.

The plan now is to use the standard frst set up so the rad and ic. I know its not ideal but it will at least allow me to get it running and for me to do my "shake down" millage to establish what issues I have and where, as their will inevitibly (spelling) be some niggles to sort out. If (fingers crossed) after a few hundred miles all is well and the car is settled into running the zt with no issues i will look at getting either a 4x4 cosworth ic and fit it low down in the front or a universal small front mount. I have seen both these set ups on the mk2 and they both look fine and not in your face.

More updates when time allows,

Gareth.

[jonyb4]

sounds good mate

so what does your little shakedown involve? how many miles you hoping to do before you know its getting trhere?

i got somethign similar to do tomorrow now my insurance starts

[black2]

HI all a few more updates.

I have been plodding along with the car gradually putting it back together. Drive shafts are back in, gear linkage bolted back up etc so basically the suspension and everything is all finished. I ve also ni on finished outting the dash and carpets back in, just have the stero surround left to fit.

On the plus side today I had it running, it fired straight up idled for about 3 seconds and conked out. I then re started it and it idled fine so thats the god news, now for the bad news though the turbo oil feed is leeking and because its so tight in there its a real pain to get at the two bolts which bolt it to the turbo. So the easist way (due the radiator not being plumbed in) is for me to unbolt the entire exhaust manifold and check the bolts are tight and that theres a gasket in there.

The other problem is I still need to fabricate a bottom water water which should'nt be to hard as I have the fiesta si hose which was on there before it just needs to be altered so it goes round turbo airfilter pipe. Other than these two problems the car would be reay to drive.

Who knows one day it may be finished

Gareth.

[jonyb4]

theres always problems when doing a conversion this big mate, im sure you will see them through, i had my share and theyre almost sorted

[black2]

Small bit of progress I suppose. The car is all finished bar the exhaust, (exhaust should be sorted by the end of the week) boost hoses and bottom rad hose, dash etc all finished.

This is where progres ends though - as im using the T2 turbo I have no space down by the water pump oultet and as such have had to order one of Roose motorsports hybrid hoses which is specifically designed for this application ie fiesta running a zetec and T2 turbo. But the problem is there is a maximum of two and a half week wait. So I wont be using it untill this arrives, no biggy really as I can just keep using my diesel run around.

The other issue to note is the fact the bonnet wont close with the satndard FRST TURBO cross over pipe so what ive decided to do is : Have a 62mm dia 90 degree elbow from the tb which reduces to 51mm - short length of 50mm ally tube into anothe silicone 90 degree bend and then run another length of aly tube to the intercooler. This will work fine, allow the bonnet to close and also means i wont have any heat soak from the cam cover, the down side is it was another added unexpected cost but I have got all the bits bar the first 90 bend from the tb off of egay, so those bits should be here soon. Today has been a rather expensive day setting me back in total arounf £160.

I really hope the car turns out to be good and reliable, I just have visions of driving it and blowing it up from the off Boost will now be set at 10psi and not going above this either as the car has to be relaible due to the fact I use it everyday.

More updates when my boost parts arrive.

Gareth.

[Ruishy1]

its amazing how even budget build can spiral out of control !
good to hear its close to completion, you must be dying to drive it !

[jayrs]

it will be fine mate im sure.
unexpected problems are to be expected with this sort of swap mate

[black2]

I am quite anxious to drive it now but more worried about the reliablity of it. Just hope everything is ok.

Gareth.

[jayrs]

thats the thing aint it with projects like this.
still, your maybe have a few problems from the start cropping up, but im sure after a couple-few months anything thats waiting to go wrong would of and it will be all sorted.

[jonyb4]

felt exsactly the same a week before mine was done, thinking if it works it will run s**t or what have you, but everything turned out fine and runs spot on, mind you, i thought you could only do a max of 8psi with the budget zetec turbo build??

specially with standard internals

[dangerousdave]

just thinking about it mate, but do you have a turbo rad for it?? them hoses have a side outlet for an rst rad ......

[black2]

Dave - yeah running frst rad. The standard xr2 rad has a side oulet as well though.

My ally boost pipes have turned up now just need some hoses to connect it all up.

Hows yours coming along Dave?

Gareth.

[dangerousdave]

lol, taxed and moted the focus so being on the dole cant aford to do anything at the min, got a short tem temp job starting monday tho so hopefully will be able to aford to get the tb plate welded on next week then ill fire it up, ow still need a proper turbo too lol


your making good progress tho buddy! its always something thats an unexpected cost tho ait there

[black2]

Jonyb4 - From what ive seen 1 bar is quite acheviable when using a decom plate. Heemans was running a bar or around that for quite some time iirc, ive also seen a few others running over a bar but due to the fact im using the standard ic i think 10 psi will be plenty and the fact the car weighs far less than a mk3 it should be fine for a while.

A tiny update is that two of my boost pipes turned up the other day so I have measured up the ally pipe i bought and cut it all to the correct shape etc, all i need to do now is get a take of welded into one of my ally pipes to feed the the iscv, i will take a pic of it soon, i think it actually looks ok plus the bonnet shuts fine

Other than this im still waiting for my hoses to turn up from roose and ive also bought a standard frst rad fan off of rs220bhp on here so im just waiting for that to arrive now as well. At least if the fan turns up soon I can whip the rad back out and make the slight cut to the front panel in order to fit the fan, then extend the two wires to power the fan, bung the rad back in then its just a case of plumbing in the bottom hose, fitting the the top boost hose connecting up the water cooling for the turbo, filling it up with water & anti freeze, filling the gear box up with oil and then connectecting the exhaust up and then fire up proper.

Its getting frustrating now its been off the road for what seems like ages, theres still quite a lot to do, ive just had to tax it and im still no where near being able to drive the bloody thing defo looks like castle coombe is out of the window for me on the 24th of this month

Gareth.

[cowie20]

hey mate, good work getting engine in, looks spot on. when i looked at pictures i wondered about water pump hose. looks very tight.
if you need silicone hose joiners for boost ive got 3 of them, 2" size. ill do them lots cheaper than ebay

[knuckles]

looking good fella
i admire you for persisting and adapting everything to work.
I certainly would of thrown in the towel a long time ago

keep it up

[black2]

lol its frustrating but i cant do much about it atm. I just hope im rewarded with a nice quick (ish) car and more importantly reliable fun car.

Gareth.