fiestaturbo.com

[Tweek]

Right, been over a month since I last updated this. Lost all motivation with this turbo but it's now been rebuilt by Turbo Dynamics and I've started getting back to work on it.

Turbo itself wasn't in too bad condition but they did find a large crack in the exhaust housing, probably from accident damage of the donor car:



Crack fixed:



Fresh turbo returned:





Recreated the oil return using a proper Focus RS pipe:



I also wasn't too happy with twin 8" fans so I upgraded one to 10". Was a pain to fit, too large. Had to modify the bonnet catch support. Bodge I know but it fits lol:



Jess cleaned up the intercooler for me:



Number plate back on:



And finally. The paint on the cam cover got destroyed with all the fiddling. I managed to find some obsolete Hammerite Dark Blue aerosol and repainted it the same as it was on the 5dr



More to come soon hopefully.

[jonyb4]

thats not a bodge...

good progress!

[Dave5300]

mmmm nothing like a fresh turbo looks great mate! shel be ready for ford fair so!

[knuckles]

Left hand headlamp is wonky needs lifting up next to indicator. Needs locating properly

everything else 10/10

[jonyb4]

Left hand headlamp is wonky needs lifting up next to indicator. Needs locating properly

everything else 10/10

on that level of picky ness, the n/s lamp is too far back indicator side

[jayrs]

Looking good Wayne, shame I won't be at ford fair to see it

[Ratspeed]

How long till the 1st burnout vid?

[Tweek]

So, it would appear my massive overfueling is caused by the lower/small injector seals. For some reason they're not sealing and fuel's just pumping straight into the engine

These are all brand new seals from Ford too but it seems the Subaru/Nissan injectors push down on them too much distorting them. Nuisance!

[dontpannic]

Getting there though, at least it's 'only' injector seals and nothing more serious!

[Tweek]

Well, it's good and bad. Good because I know what it is but bad because after doing some further research there seems to be a few bad reports of jap injectors not sealing in the Zetec rail.

[Tweek]

I've been flat out on this all weekend. Apart from getting covered in all sorts of crap I developed a nice tan too

First up was the brake pedal. The pedal's been sitting too low for some time now and after some researching I solved it. I put a few washers on top of the shaft behind the pedal, then the big white spacer ring before cutting off a chunk of the white tube thing since it was now too long. The result:


I pulled my finger out and purchased a wideband setup!


I didn't realise they're sensitive to voltage drops. Took a while head scratching to realise my battery was only putting out 11.58V and thus kept error-coding "supply voltage too low."

Because of this, I had to put it on life-support :


Calibration bits:


After shaving off a tiny piece of battery tray, an air filter went in:


Horn back in it's original location along with the boost control solenoid:


Breather system starting to take shape now. I dislike the blue hose a lot, shall replace with black when funds allow:


Also acquired some new items of sir Bark Mennett. It took me a long time mulling it over to decide to get them, hard to see in the pic so you'll have to guess



Finally ended the weekend by removing things instead...



Not far to go now

[andymac]

Finally ended the weekend by removing things instead...

Know that feeling all too well

Excellent going, I'm surprised the LC1 is so sensitive to volts drop, I'd have expected it to live on a 5v feed internally so would be okay down to 8-9v. Just got to sort the jap injectors now and you'll be laughing; you'll be wishing you'd had the spare inlet off me with the injectors soon...

[Tweek]

Cheers Mr Mac. I actually had a FRST inlet manifold with beiges at one point too. This seemed a better idea at the time

[Tygress]

Awesome Stuff Boyf... Things Are Looking Up With Your Car, It's About Time Too...
Here's A Cute Photo Of K80's Luverly Orange Sister Giving Her Life... For You! ^-^

[Max M4X WW]

Looking good, I did my breather this morning after a 9hr flight and no sleep. Tyre fitting tomorrow

Still hoping for Ford Fair?

[Tweek]

Dedication right there Max lol. I don't know yet, we'll see how this next week goes

[FRSJON]

good effort

[hb69]

I know what you had off Bark, seeing as I don't have them lol

[jonyb4]

So close!

[:: blade ::]

looking good matey cant wait for you to take me for a spin

[Smo]

I know what you had off Bark, seeing as I don't have them lol

Haha!

[Dave5300]

nearly there!

[Tweek]

Pretty much finalised the breather setup this evening. I'm missing the ECU cover plate thing, when I get one I'll bolt the breather separator to that. Amongst this, this is the cheapest part on the car so far



FRS Heatshield. Was really ropey to start with, polished up fairly well thanks to Jess and Dad scrubbing at it. I need a mint one really to set it off. Also a well engineered spacer for the water rail

[Razer]

looks good mate,
like the 2 fan setup, my own single erst fan doesn't do the job....
How do the connect to the rad ? with clips or just a massive bolt through the rad

[Tweek]

looks good mate,
like the 2 fan setup, my own single erst fan doesn't do the job....
How do the connect to the rad ? with clips or just a massive bolt through the rad

Hi mate. They do universal fitting kits which is basically weird zip ties that go through the fins with a locking washer the other side. combined with a spring and some foam pads.

[hb69]

What's the target finish date?

[Tweek]

April 2013 So who knows!

[Tweek]

Well, the injectors still won't seal. I've managed to get 3 to seal up fine but the first one refuses to, even after swapping the injectors around. I managed to get it to hold on for 2 fuel pump prime cycles but the third just burst and pissed out

What makes it really more awkward is it isn't the fuel rail either. I shoved a 1.6 Zetec injector in there for testing and the whole lot is holding pressure fine.

aarrrrrgghhhhhhhhhhh



After calming down, I've had one more throw of the dice. The lower O-rings on there at the moment are the Zetec ones, 7.52mm inner diameter, 3.5mm cross section, 14.8mm overall diameter. Ordering some 7x4x15 rings now. Should be more of a snug fit. Must add, in order to get the 3 injectors to seal I had to remove the pintle caps, it's the only way at the moment

[FRSJON]

s**t new mate but all will be worth it in the end.

[Excursion]

My gut feel is bad here and my advice is to look for some more suitable injectors or a matched fuel rail. If all four were leaking it'd fair enough, but they aren't which suggests something isn't quite right i.e. machining or alignment. I've read about and seen far too many projects and the associated hard work go up in flames because of fuel system issues, so it just doesn't seem worth it to me.

[Tweek]

Cheers Mark. Seeing the seal burst was pretty horrible and has cast a big shadow of doubt over using them! I do keep reading more and more threads across the internet where people are using these though so I really don't understand why they're not sealing up. I'll go down the scrapyard tomorrow and get a replacement mondeo fuel rail and see if that makes a difference. If no joy I'll probably end up getting a FRS inlet manifold. Making an end-fed injector fuel rail fit here looks a bit beyond me

[Excursion]

Cheers Mark. Seeing the seal burst was pretty horrible and has cast a big shadow of doubt over using them! I do keep reading more and more threads across the internet where people are using these though so I really don't understand why they're not sealing up. I'll go down the scrapyard tomorrow and get a replacement mondeo fuel rail and see if that makes a difference. If no joy I'll probably end up getting a FRS inlet manifold. Making an end-fed injector fuel rail fit here looks a bit beyond me

It is a shame the setup isn't working as like you say other people have used it successfully. Making an end feed rail will take a bit of time.

The FRS manifold is quite dear as you probably know, but a cheaper option would be to buy a standard Focus plastic inlet and fit the Mk1 Mondeo alloy throttle body, providing you could get a hose fixed securely. I saw http://www.ebay.co.uk/itm/Mk1-Focus-RS- ... 3383c90b63 - may be of use.

[Rhinopower]

Also needs the spacer plate to route the bypassed air for the iscv if you go that route.

[Excursion]

Also needs the spacer plate to route the bypassed air for the iscv if you go that route.

It will bolt on fine if you get the right version - some of the Mondeo bodies have the air bypass built in to the TB.

[Tweek]

Cheers guys, I'll look into it if I still can't solve it this week. Also looking at Rover inlets too but tbh I don't think it'd clear my servo.

This weekend I've got the exhaust back on and bolted up. It's still slightly angled at the rear but it's much straighter than it was before so it'll do


Everything under the car now bolted in place properly:


Strut brace sprayed up Java Blue. The old Hammerite can was faulty and refuses to spray half the can


Ran out of things to do now so fitted some chromey bits. They don't really stand out on the old rubbish paintwork though.





Hopefully it'll be running this week, fingers crossed, hope and pray lol.