fiestaturbo.com

[SimonT]

Asad your a king in my book

[Asad]

Lol - Cheers Si!


Little update.

As you all know, I planned on using the ST170 manifold. When it arrived, I had a chance to see how the ports lined up..... the answer was not that good! :-




You can see the edges. The port on the manifold is oval and the throttle body is circular.

If I put the throttle body on backwards, it lines up perfectly :-




But the problem with this is that the butterfly is at the back, meaning poor at anything other than WOT.


So I decided that I might go a different way. My idea was to get a injector sandwich plate and weld tubes onto that to mount the throttle bodies.

I got this of Sunil :-




Thanks to Sunil as he let me have them free of charge!

So with both manifolds, I sat down wth my mate Eliot, and started thinking about the best route forward...

One option was to open up the pastic ST170 port to match the Throttle opening. This was possible as there was some meat on the plastic.

The other option was to weld onto the sandwich plate, so I gave my TB to Eliot to see what he had lying around. Eliot had a piece of 2" tube sitting around, and he widened the end a little. With this, the Throttle body could fit on the end. The other end actually fit in the ST170 manifold!

Now all we need to do is squash the end a little to make it oval, and hey presto! Smoother flow!

So I'm waiting for Eliot to machine the pipes to have an interference fit on the TBs and squashed to Oval on the manifold end. Minimal grinding of the ST170 manifold will be required.

This also means, as I can use top fed injectors.... I can use these







They are Ford Nippon Denson Injectors. Need to confirm the part number, but you cant go wrong with £40 for a set of new injectors!

Should have the TBs on Friday, so more updates and pics then!


Asad

[Asad]

As promised, here is an update.

I got the bits back today. My mate Eliot made up 4 reducers:-




Here you can see the flared end. This end goes on the TB :-



This end has been made oval to smooth the flow into the ST170 manifold:-




Here you can see the other reducers and 1 TB sitting in place:-




Then I got on with spacing out the TBs to match the ports. I got a long stud and nuts, and basically used the nuts to hold the TBs to the correct spacing :-




Using the nuts as they are, I am able to make adjustments to the positioning of the TBs :-




Here are the TBs spaced out how I want them:-




As you can see below, I need to do something to get the linkages to meet in the middle. I may either make "ears" or tack weld something on. Any suggestions appreciated! :-




And 1 more of the TBs :-




Things to do :-

I need to JB weld up Injectors holes ect.
Get linkages to meet
Secure on reducers - JB Weld possibly or weld
Fit new injectors
Make an adaptor for Cossie Fuel Regulator
And probably 10 more things that I cant think of!

I was going to fit my Mk4 dash this weekend, but it looks more blueish than grey to me. Doenst match the rest of my interior so I have left it.

Hoping to get all this done by Trax.....cutting it close!


Asad

[Zetecfiesta]

fcuking sweet, ive been reading this post and you are putting so much effort in its amazing!!

[Asad]

Lol @ effort!


Its hasnt been difficult actually!


just want em on there to see how it goes!


Asad

[FezzR]

recon you should get some good results with that

[OrionZetec]

Top work bud
Im now addicted to this thread!
Keep up the good work

[McNugget]

Hi man,

great work there!
The guy from http://forums.turbosport.co.uk/bbs/showthread.php?t=83594&page=5&pp=20 updoaded a sound file how the engine sounds with your configuration! Very cool. I'll trie to build one, too

What do you do with the second pack of injectors? NoS, or Water/Ethanol injection? Or just filling the holes with something?

Do you think the RS2000 injection nozzles flange would fit the Zetec-E, too?

Greets, Timo

[Asad]

Hi,

I wont be using a second bank of injectors, as I dont think fueling will be my restrictive. I will just plug the holes, and possibly use 1 hole to mount an Idle Temp Sensor.

As for your RS2k injectors, I think they are side fed injectors, so they wont be compatible with the ST170 manidfold. The injectors that I will be using are top fed.

The ST170 injectors, I suspect, probably flow more than the RS2k ones. I have a set of 330cc injectors that I will be using.

Here is a pic of a little more work done, courtesy of Eliot :-




The linkage has been extended with careful welding.

They will definitely not be ready for Trax Probably wont have them with me either as Eliot has them.

But they will be there in spirit!



Asad

[McNugget]

Sorry for my English, its possibly not the best within a topic on engines
I was not thinking about the RS2k injectors itself. I was thinking about the counterpart to the ST170 manifold you used, used in the RS2k engine... (I hope that makes sense...)

Well I meen this one:
http://cgi.ebay.de/ws/eBayISAPI.dll?ViewItem&item=7996320789&rd=1&sspagename=STRK%3AMEWA%3AIT&rd=1

I think now it should make sense what I'm trying to explain

Greets, Timo

[Asad]

I see what you mean!

That "injector Sandwich plate" (as i call it) cannot be used with the ST170 manifold. I was going to use it a different way, but I decided to use the ST170 manifold.

If you want to use the Sandwich plate, you will need to fabricate a manifold for the bike throttle bodies.

If you want to use the ST170 manifold, you may need to ensure you have good flow between the bike Throttle bodies and the manifold.


HTH


Asad

[McNugget]

Ah, ok I think we're comin' closer
I want to use the RS2k Sandwich plate, cut some of these metal around the holes away so that I can fit the TBs directly to the Sandwich plate. Without the ST170 manifold. I want to try this because the ST170 manyfold is very expensive (about 190 EUR).

So the question is: Will the RS2k injector sandwich plate fit to my Zetec-E 1.8l zylinder head? In othere words, is there a chance to use the RS2k Sandwich plate with my Zetec-E without changing a lott of things to the RS2k sandwich plate?

Greets,
Timo

[Asad]

The sandwich plate in my pictures is from a 1.8 zetec. I *believe* they are all the same. So yes it should fit to your Zetec head.

Too be honest though, you want to make sure the flow is smooth. The other issue you might have to contend with is that your runners will be short. You ideally want approximately 8 inches from throttle to valves.

If you have to use the sandwich plate, its best to make a custom manifold to bolt to it.

I take it you want to use 8 injectors?


Asad

[McNugget]

The sandwich plate in my pictures is from a 1.8 zetec. I *believe* they are all the same. So yes it should fit to your Zetec head.

That sounds good.

Too be honest though, you want to make sure the flow is smooth. The other issue you might have to contend with is that your runners will be short. You ideally want approximately 8 inches from throttle to valves.

I hope I have enough space behind my engine for all this

I take it you want to use 8 injectors?

That is one of my ideas for the future. The second rail of injectors is an offer to everyone who wants to play around with ethanol/water injection or NOS. But thats much too far away from now to think about

But connecting a GSX-R 1000 TB with a standard Zetec as cheap a possible is an interesting project!

So thats what I think about:
Zetec 1.8l 16v 128hp --> RS2000 Sandwich plate --> adapter manifold --> GSX-R 1000 TB --> four mini aircleaners from K&N, connected to the MegaSquirt v2.2 with extra firmware. Maybe some performace cams but not planned yet. I hope to get some extra hp from this configuration. I think about 175hp or so.

Greets,
Timo

[disc]

Look what I purchased today from USA:




Innovate Wideband Lambda controller and Bosch sensor - 200$

Also my second "home made" PCB/Megasquirt:





ZetecTurbo comming next year...

[Asad]

I should be getting my LC-1 too soon. £130


Good price for what it is.


Asad

[FezzR]

ok so im dodgy but does anyone know if the block on the multi plug is a dongle or the like?
ii have loads of the sensors software is easy to copy and i dont like paying £130

[OrionZetec]

Whats Wide Band Lambda control then? is it needed? Wont my std Lambda work anymore then?

[FezzR]

Whats Wide Band Lambda control then? is it needed? Wont my std Lambda work anymore then?

wide band lambda sensors detect oxygen in the exhaust, determining the state of combustion.
wideband is used for mapping as it is far more accurate and useable data source

[disc]

Wideband lambda is more accurate than narrowband. You can use WB as precise AFR meter.
NB output is 0-1V, switch point (lean/rich) is ~0,5V - if you see 0,3V output from sensor ECU know that AFR is lean, bit how much?
WB output is 0-5V, switch point is ~ 2,45V if you see 1,6V output from sensor, ECU know that AFR is 15:1!

With custom ECU you can have AFR Target table (like Megasquirt). WB tells actual AFR and ECU can make adjustments to to reach AFR table targets.

That's the idea! Tune your engine at home!

My english is terrible and can't explain everything in my head.

[Asad]

ok so im dodgy but does anyone know if the block on the multi plug is a dongle or the like?
ii have loads of the sensors software is easy to copy and i dont like paying £130

Its the Wideband controller. The LC-1 has the controller built into the cable.

Thats where the cost comes into it.

And yes it does help with tuning. Dont get me wrong, I have tuned my MS using narrow band and its not too difficult. The AFR calculated by the MS software is not jumpy. Wideband is a must for Turbo applications.

But with an Wideband you can be more accurate, as well as use Target AFR tables like disc said.


Asad

[McNugget]

I'm searching for other TBs on the net and found the one from the Kawasaki ZX 12 R from the year 2000. It looks like they could fit, too.

Does anyone have some information about this one?

Greets, Timo

ps. here is the link. It may helps
http://cgi.ebay.de/ws/eBayISAPI.dll?ViewItem&item=7995441008&rd=1&sspagename=STRK%3AMEWA%3AIT&rd=1

[Asad]

You have to make sure they can split into 4.

Although if you are making a custom manifold then it doesnt matter.

Other than that, i dont know much about them!



Asad

[chris-fiesta]

looking good m8 cant wait to see it finished!! keep up the good work!!

[OrionZetec]

Thanks for the info
Itching to do this to mine too. Cant wait to start messin with the throttle bodies and ecu
Shame you cant make trax m8 Never mind im sure itll be running soon

[Asad]

I will be at trax!

So you can see the MS running etc. Just wont have the throttle bodies on.



Asad

[McNugget]

Hi Asad,
I found out that the TB of the 1000 and the 750 are the same.

Can you tell me the dimensions of the GSX-R throttle body?
I want to calculate the dimensions of the whole construction (manifold and TBs) so that I can see if I have to modify the firewall (cut a hole into it, so that the TB can breathe).

Any updates?

Cheers,
Timo

EDIT: Fixed some spelling, because I don't think one can understand what I wrote

[McNugget]

See what I got here

My MegaSquirt v2.2 just arrived from USA. Pretty fast - about 6 days!



Do you remember the very small and nice stimulator?
This is my version of it - saves about 40$



And after some soldering...



About one hour later I was able to check the power supply. Everthing fine...



And now, another 3,5h later I'm ready to rock



Now I'm another stupid f*ckin guy with a MegaSquirt in his hands

Hey Asad, you have nearly same engine as I have. Could you give me your tuned property-file so that I have a point to start with? That would be great!

Thank you,
Timo

[Asad]

Ive got my TBs and also my ST170 exhaust manifold.

Pics in a bit. The TBs are looking crazy!

McNugget :-

Send me your email address and ill get the file across to you.

[chris-fiesta]

dude saw you agen on wednesday on tollington park road on the bend near the entrance to finsbury park i was in a blue 325i!! never get to hear the car inits full glory!!

[ant pittaway]

show us the pics!

[McNugget]

Hi,

I have very big problems with pulling the ECU plug. I cannot reach the screw. The cables are too short for pulling the ecu off the case so that I'm able to reach the head of the screw. I tried to unplug the ECU for about one hour. The result is that I damaged some of the cables slightly.
Well I think I have to remove the whole board. When I cannot unplug the ECU tomorrow I'll have to wait.

Damn it...

Is this some kind of safety device for children??
Is there a way extend the the cabled, without cutting them off?

Cheers,
Timo

[niracka]

hope it all goes well m8. I wudn't have a clue were to start lol

[McNugget]

Well, ok. I got a hint from my mate in the German fiesta-ka-tuning.de forum some minutes ago that I have to remove the water header tank. Then I can remove the screw from the top.

Have a nice weekend

[Asad]

Right, first Pics!


This is the ST170 exhaust I am hoping to fit. Hopefully without too much hassel!




Here are the TBs. Upside down. You can see the spacers that were made.



This is the bracket that was also made. The TBs are very sturdy now. Even though the jubilee clips are not tightened, or the reducers welded on, they wont move!




This is the end of the ST170 fuel rail modded to provide a take of for a fuel pressure regulator. Welding courtesy of my mate Eliot :-




This is with the Cossie Fuel Reg fitted (yes i know thats the vacuum feed! lol):-




Throttles open. You can see the better port matching:-




Close up of the ports:-



Compared to:-




And the view from above! :-




I have a couple of things that I need to do first.

Get my grey injectors on
Paint some of the exposed metal to prevent rust
Sort out accelerator cable
Get some pipes to take off vacuum from the bike injector ports
JB weld on the reducer pipes


Would have done most of it this weekend but I have a wedding to go to, hence I needed the car


Hopefully more later this week.


Asad