fiestaturbo.com

[Ruishy1]

no bother, il let you know asap

[jayrs]

cool

[adrian83caveill]

hi mate try cr turbo engineering i've rang them a couple of times and are always helpful and they do a hybrid t2

[jayrs]

will ring round a fair few when i have money for turbo, but i checked there web site, they seem a bit pricey compaired

[jayrs]

right then slight update and nothing major.

i will be having a turbo coming next week to test out thanks to a memeber on here (you know who you are, cheers fella) so i went out there today against the bitter cold etc and decided that im not going to pull my engine out, ill use a xr2 engine i have sat there for the donky work.
so me and my dad lifted the engine out to the open (as it was outside) and then he had to go, so i stripped the gearbox off, inlt and exhaust manifolds etc and then lifted/carried/dragged the engine into the garage, round the RS (with like 3 foot gap:lol:) into the workshop and bunged it up on the engine crain and took the sump off, fitted up the turbo etc to the engine and fitted up a spare sump i had, maked out where i wanted the return pipe etc.

i will use this sump as a basis for what i want to do and use it on the xr2 engine for checking eveything goes how i want before i remove my sump off my RS.
the plan is, get it all sorted on the donor sump, pull mine off, drill it, fit the fitting silver solder it in, clean it up and refit it within a hour or 2.

im not going to have a rubber drain pipe, im looking into what braided oil pipe i can use with the size fittings i want to use, i want a big ID bore but i dont want massive great fittings like that fits onto a oil cooler as theres not the room, but ive got to nip into the hydralics place and have a word with tony and see whats about and go from there.
all being well, she will see the road in next couple weeks

prob just fcuking jinxed it now


anyways, i knows people like to see pics so i took a few random shot today just to post up






your note i plan to put the return hol between the bolt hols and between where the oil pick up pipe braket is and the conrod/big end comes round, even though the pipe will stick out the inner part of the sump no more than 1mm

[stembo21]

looks good mate need to get some done on mine lol

[jayrs]

nightmare this time of year aint it, too cold

[Brammer]

nightmare this time of year aint it, too cold

Looking good Jay, it's going to get colder as the artic wind is sweeping down the country as it's freezing winds here

[jayrs]

tell me about it mate, i was inside and fcuking freezing.

may have heating in there within next couple months, may have a job on with a mate i work with removing some old AC units, so gunna see if i can have one and plumb it in there.
wont be hard as i do AC and frige for work and the workshop has 3 phase power anyway so all good.

and for those that dont know, AC can be switched to pump out heat as well as cooler air, so best of both worlds with one of them.
fingers crossed the job comes up and i can get one, gunna need it for when i start on the xr2 other wise that can bloody well wait till it warms up.
too me long enough to get cracking today and its only going to get colder
if it wasnt for the fact i have the rs sat there taxed, mot'ed and insured and it has been since ford fair, well taken off road week after i would prob leave the rs till spring, but the machines etc need to get put in there now and the rs needs moving and i want to drive the fcuking thing again

plug the council have finaly done the work (ish) neede to the garage they offered me so ill be taking that on next week when i get paid as they want a month up front, so the sooner rs is on road the better, that way i wont be paying for a garage i wont be using

[HCS PIMP]

jay if u plumb the ac in the right way would be a good way of cooking cars after being sprayed lol double advantage and would remove humidity.

you'll get it sorted think iv decided imn gonna do automotive engineering at leeds so which shoudl be awesome

im gonna post some pics of the fez engine later so grab a butchers!!!

[jayrs]

will do

[jayrs]

right small update,

first off, i may be buying a turbo of rob (rob pace) it arrived friday, so as soon as my oiol return is done ill be bunging it on for testing.

anyway, the oil return..

im not going the same route as everyone else with pipe welded in sump and pipe welded to oil return flang and joined with rubber pipe, im going for 1/2" BSP fittings with 1/2" ID, and will more than likly use PTFE smooth bored pipe with the stainless steel braid, but seeing as the pipe will end up between inch and half to 2 inchs long i might get a rubber one with stianless braid.

went to hydralics place yesterday morning and all he had in was 1, 1/2" BSP fitting for the PTFE pipe and a few fittings for the 3/8", so came away with a lenth of 3/8" PTFE pipe, 1 3/8" 90 degree fitting and 1 1/2" stright fitting, which was all usless to a degree but was enough to messure what i needed to, and he didnt charge me for any bits, just took my name, address and number, so all good, so will return all that in the week and get the bits i do need to do the job.

i will need in 1/2" BSP fitting with 1/2" ID, 1x 45 degree fitting, 1x 90 degree fitting and approx 2 inch of pipe, which will need cutting down


anyhow, today, i sorted the fittings for the sump and turbo flange, well i say i did, it was my dad that done it, im on call this weekend and got a call out this morning so met him over at the guys house whos lathe were using and he was basicly done when i got there

they did both start out with a thread both sides, but as you can see turned to fit what we want.
the one with the short small end is for the turbo flange, this fitting has a 3/8" hole in it not a 1/2", this was choosen for the flange so it can have a good wall thickness at the small end and be fitted into the flange withoug having to drill a bloody great hole in the flange, if im not clear, the pictures next time will explain it.
the other is the sump one, the smooth side will have basicly most of that end cut off, it was turned to such side and shape to stick out a given distance, but the end was left on so when ive had the pipe made up, if it needs to stick out the sump a tiny bit more then the metal is there for it, again pictures next time will explain better.
both fittings will be brazed in.
the fittings have been turned in this way to remove the hex from it and reduce the diameter to stop it getting in the way with bolts , trust me ive thought about it as i dont plan on doing it twice

the pipe with the fitting one is NOT what im using, its there to show just how small the oil retun pipe is going to end up
i know some will say its a lot of hassle, why bother i should of done this or that etc, but this is how i want it, i dont want the hassle of, is the rubber pipe going to split? always on my mind, and deffo dont want all my oil pushed everyewhere after the time and money ive spent on it, so this way, the return is better, strong, less likly to leak etc

enough of me typing, few pics to explain it a bit better

[jimmyesh]

Top work mate - can't beat a good oil return!

[jayrs]

after what ive done so far mate it would just be wrong to slap a half hearted return on

[rob pace]

ill put a picture on here later jay mate, that return looks a lot higher up than mine mate

[jayrs]

ok mate cool

[FRSJON]

t3 would of been soo much easier..

[jayrs]

yeah maybe, but then i would of had problems with my rad and intercooler mate.
remember, i modded the pipe on my intercooler to make it fit nice and snug, to bung a T3 on there now could put this out, and maybe to a point it couldnt be used due to the mods i done to it mate.

plus i couldnt get a T3 to test fit anyway

[niracka]

So what turbo are you going for jay???? Just read the whole last page and it doesn't say. Unless I'v missed it lol.

Sounds like you'v given the return pipe alot of thaught. Like you said its always best to be sure. I just fitted new suspension to my foci and now I have to take the front to bits again because top mount has gone as I didn't bother doing it properly with new ones

Keep updates coming mate.

Ollie

[jayrs]

sticking with a T2 mate.

yeah its funny you say about shocks, when i put the rs back together, well from a complete bare shell, i had fitted the front shocks etc then rememeber about the bearings at the top so took it all down again and fitted new ones .

we all do things then thing of something after

[jayrs]

well update time,

over the weekend i preped the car ready for sump to come off and got the fittings.
the place i was getting the fittings from let me down and didnt get them over to the island in time, even though he had 3 days notice so i went else where.

anyone thinking of doing a return the same as this (cant see it ) i would strongly advise to sort out the fittings first based on the space you have, i was limited to what fittings i could use with the give thread size as well as the ID (inside diameter) i wanted and due to the space i was looking at PTFE pipe fittings, but as i say i got let down so went else where, and they only had the fittings your see in the pictures and only had 90 degree ones great start to a saturday morning, cos without these fittings i couldnt do nothing.

anyway £5 later saw me 2 90 dree fittings, well i say 2 90 degree, the guy offered to heat one up and bend it into a 45 for me, nice one, saved me doing it


anyhow as i say saturday was preping only as i had to leave early and go get a new washing machine, but on sunday the work was done, its not complete yet but its near enough.

the fitting was brazed into the turbo flange, the pipe fittings were modded to do as i wanted (no pics yet) and it was rough fitted up to the donor engine to see where was going where and your note that the fitting in the sump needed to be lowered which it was, so also sunday the sump was dropped.
due to the thinness of the sump wall, a 3mm thick bit of steel was brazed onto the sump, well the hole was drilled on the piller drill first, as was the sump then it was all ground up, then it was brazed in place along with the fitting, and this plate was added for strenth.

those that dont know, braze does not rust or corrode as the braze is brass, basicly you use a gas welding torch, heat the stuff up to cherry red or there abouts and feed the brazing rod in and the rod melts and flows round what ever is hot enough and when cooled forms a very strong joint, it can cope with lots of heat, and i mean lots and pressure.
the brazing done on the sump and fitting will not fail when the fitting are tightened, incase anyone is wondering why it was brazed and not welded.
welding it would of of had to of been done by gas welding or tig, but welding would of not been needed for the reasons above


back to it, the sump was done, degreesed and fully cleaned out and refitted and thats where it was left sunday, it was cold in the work shop, an by this time it was dark and i had 15 mins to get back to watch my daughter in a thing over the school, lucky when i got there half hour later they were just starting so wife didnt bust my balls

pics so far, there not complete as i didnt have time to get any before i left

preped for turbo





the sump can be a b1tch to get on and off with this bit in the way and can cause the seal to come out, and you dont know as you cant see, but i wasnt going to get into that crap



ah, more room



not a bad buy for £17.50 s/h, was got for doing the arches on the xr2, should of got one years ago




trial fitted on donor engine




ah almost forgot, seeing as the old oil return pipe was now scrap seeing as i hacked the flange off i took the other end off, squashed the end over and brazed it up to block off the oil return




thats it for pic's, will update again at weekend when it should all be done and running again, then its tracking to be sorted and hopfully no more problems and im away

[stembo21]

looking good mate hope you get it sorted soon

[jayrs]

cheers dude

[jimmyesh]

Top work Jay

[jayrs]

cheers fella.

here, if you come across a good in car fuel pressure gauge, pref white face to match the rest, let me know mate

not a really expensive one though

[niracka]

Looking like its coming on well again jay.

Make sure you get a sound clip or video of your car up when its finnished. Would be nice to see it running as I missed you at ford fair.

Ollie

[jayrs]

Looking like its coming on well again jay.

Make sure you get a sound clip or video of your car up when its finnished. Would be nice to see it running as I missed you at ford fair.

Ollie

will do mate

ok had the day off today, by the time i had got motivated, a hot sausage roll and had a cup of tea or 2 and a fag at my parents place i headed off a mole down the road to the work shop
didnt spend too much time down there as it was fcuking freezing, and there was a fair bit of fcuking about with the turbo and the return.
the turbo i was sent by rob didnt have the exhaust elbow on so had to take that off one of my scrap ones before i could fit anything up on the engine then came the, hmm, ahhh, hhmmm, yeah that will work, when it came to trial fitting the return pipe, and to say space is tight is a biiiig understatment!

anyway, the return pipe was fitted, pipe shortened to do what i wanted etc etc, but its not fitted up there to stay, the turbo will be coming off to have the actuator fitted, water pipes fitted and anyone thats removed and refitted a T2 will know the oil feed pipe can be a bit of a mare as you just cant get a socket on it nicly, well, that depends on how the turbo was set when built
anyhow, the pictures are not the best, i was bitter cold and the thought of a hot cup of tea stopped me taking more time to get better pics, so hopfully your see what ive done from these, but once finished i will put better pics up, which will be at weekend as i plan to have it all finished and running, fingers crossed the turbos a good one and i wont have any problems.


oh, and i would advise anyone against doing a return like this unless you like doing things the hard way, like me


your see i have not put the stainless over braid on the pipe, and tbh im not going to, due to not being able to get the pipe crimped as i first wanted ive got to use other crimps, and although theres going to be very little to no pressure in the pipe, i think the over braid will stop it having a nice seal with the crimps im going to use (as seen in pics) so i will be heat wrapping the down pipe to stop the hose from getting too hot, but i would like to add, this is proper hydraulic hose made for oil's and a bit of heat, so it will be fine









the pictures dont show it but its bloody close (turbo end) to the alternaotr bracket, but i can get a bit of paper between them so its all good, but the big pipe fitting that will screw onto the turbo return can only just come off the turbo it so close

[FRSJON]

so is the car back on the road yet???....

[jayrs]

at the week end mate, come get cold helping if ya want

[HCS PIMP]

why did ford just do that in the first place when designing the engine and not make it outta stainles pipe lol

good progress jay im looking forward to seeing it running mine made 125 bhp yesturday on the rolling road so i would be far behind ya on the road

[jayrs]

cheers mate.
ford should of of made a new return for it tbh , but it would of ment more work, the sumps would of needed changing and stuff like that.

and for being far behind me, well, i guess not when i pull over and wait

[HCS PIMP]

ull see

[rob pace]

cheers mate.
ford should of of made a new return for it tbh , but it would of ment more work, the sumps would of needed changing and stuff like that.

and for being far behind me, well, i guess not when i pull over and wait

it wont get in the way of the downpipe will it?

also what is the inernal diameter of the pipe? i used a 19mm internal diameter samco hose.

also make sure its rubber pipe for oil jay!

[HCS PIMP]

said hes using the pipe ud use for high pressure hydralic fluid i.e oil

[jayrs]

cheers mate.
ford should of of made a new return for it tbh , but it would of ment more work, the sumps would of needed changing and stuff like that.

and for being far behind me, well, i guess not when i pull over and wait

it wont get in the way of the downpipe will it?

also what is the inernal diameter of the pipe? i used a 19mm internal diameter samco hose.

also make sure its rubber pipe for oil jay!

alright mate, no wont get in the way of the down pipe, i had it all rigged up on a old cvh engine before finally doing all the bits and bobs

internal diameter of the pipe is 1/2 inch, more than big enough for oil return.

the pipe used is as pimp says, its hydraulic hose so will be fine.

come the summer, i may well look into having this all out again and i'll redo it with the stainless over braided PTFE pipe, but were see