fiestaturbo.com

[jimmyesh]

Well done Jim on another stunning project, you sure your not a VM lol.
Just to get things straight in my head, is the bolt patten for the duratec (proper) different to the zetec/I4 etc as there seems to be alot of differant opinion on different websites, basically will a mtx75 gearbox (my only option due to needing 4x4) bolt on?

What boost you planning on running with a 9:1 compression ratio, surely running this high you have limited it to not alot huh? But there again I suppose you need to keep the power sensible to keep control of the torque steer.

How come your going Omex management?

Hi and welcome to FT.com Paul! You can use any MTX75 'Box so long as you have the bellhousing from a Duratec (1.8 or 2.0) Mondeo MK3 (2001>) or one of the MK2 Focus that came with the Duratec once it replaced the Black-Top Zetec. Basically the bolt pattern on the end of this engine is a Mazda one (as this is where these engines originate) therefore it breaks the Ford tradition of using the same bolt-pattern for decades (as does the Volvo-Lumped Focus ST).

The gearbox itself will be pretty much identical right from a MK5 Escort XR3i 130 up to a late Mondeo, It's only the bellhousing that has changed to adapt it to the Duratec and therefore you can just unbolt your Escort bellhousing and bolt up the Mondeo one

That's also why the Duratec is so good for RWD customers as it is used in the MAZDA MX5 which has 6 speed transmission in RWD layout, might have to consider that for a project one day!

Oh, gaskets arrived today Just waiting on ARP Head & Main studs now



As for the compression ratio - quite a number of cars are running over 9.0:1 now (see Nick's [one of the editors] S2 Escort Turbo in Performance Ford Mag) as modern management and strong engine components, combined with not going too spastic on Turbo size creates a powerful, responsive and torquey engine that isn't lazy off-boost like some low-comp ones can be.

[paulgrs2]

oooooooooo i see, thats ok so long as the mondy mk3 bellhousing bolts to the mtx75 box casing (I presume there the same bolt patten). If this is the case I can feel a post herrick 2009 engine build myself coming on lol as the duratec has got to be a better option, power to weight, than this 4 man lift I4 lump I currently run.

[jimmyesh]

oooooooooo i see, thats ok so long as the mondy mk3 bellhousing bolts to the mtx75 box casing (I presume there the same bolt patten). If this is the case I can feel a post herrick 2009 engine build myself coming on lol as the duratec has got to be a better option, power to weight, than this 4 man lift I4 lump I currently run.

Yeah definitely mate - the old I-4 RS2000 lump is a solid, dependable old beast but you'll save a hell of a lot of weight by swapping to a Duratec - They also make silly levels of N/A power easily 2.0 Variants make 200BHP without breaking into a sweat and some 2.0's make 300BHP N/Asp on 'bodies. 2.3's are up to 340bhp Normally-Aspirated by some tuners


Here's a quick pic of the standard Duratec Pistons & Rods VS my new uprated lower-comp items - My Eagle rods look positively obese next to the svelte Duratec items (although the standard Duratec items look good and almost race-like they're well known as being rather weak, the same goes for the standard "slipper" pistons.

[paulgrs2]

Them standard rods look nasty mate, nearly as thin as you lol

[jimmyesh]

Them standard rods look nasty mate, nearly as thin as you lol

Shut it Porky!

[Chris 2i]

nice, do you think you're going quickly enough?

quality project, can't wait to see it finished

[FlashXR2i]

Amazing project Jimmy

Have you prepared some goodies for traction improving..?

[jimmyesh]

Have you prepared some goodies for traction improving..?

Not yet mate!

I've spent a hell of a lot just accumulating the parts I have collected now so other than for "niggly bits[" (such as aeroquip fuel hoses etc) I won't be spending out on anything else expensive until the new year what with Crimbo coming up fast

I will be fitting a Quaife ATB but to be honest it'd probably pay me to be patient and hunt down a Focus RS 'box 2nd-hand and buy that, as the Quaife ATB alone is £500 (+ Diff bearings) so it'll make more sense to get FRS 'box that already has it fitted then just swap the bellhousing over from my existing Mondeo Duratec MTX75 onto the FRS MTX75.

Gonna need all the help I can get with those piddly little 15's laying the power down!

[FlashXR2i]

FRS box with duratec MTX bellhousing sounds like a very good option, especially considering the cost of Quaife ATB alone!
So by all means it's best to be patient and try to find good FRS box.

To be honest, achieving a good traction will be a major problem with all the power you'll get,
and that's my only concern regarding this project.

[White2i]

depends what management you going to use and the budget also depends on traction issues, i mean the autronic sm4 has gear mappable boost to help with traction but it cost 1600 quid for the ecu and you still need to have a loom made or make one yourself for it.

a good suspension set up will help get the power down aswell and stick tyres

will be interesting to she how well it does put the power down though and the developments that go with trying to get the traction better will be interesting to read and very helpful i reacon.

[jimmyesh]

I collected my block from Cober Precision Engineering in Colchester today, freshly bored & honed to 88mm and now awaiting reassembly



There is a spanner chucked firmly in the works though - in the form of my ARP Head & Main studs which I ordered from America (significantly cheaper). The guy I ordered them from didn't have them in stock so I'm still waiting for them and also my Pumaspeed Fez ST Turbo exhaust manifold...

On the plus side, I have prepared my fuel rail for fuel-return operation (to make it more of a a straightforward fit into my Olde-Worlde Fiesta) and is having -6 male fittings welded onto each end to allow me to use some nice Aeroquip hoses . This is now in the capable hands of a mate at work who is far neater at welding than me!

[Alan12112]

Fantastic project Jimmy

I have a 2.0 duratec turbo in my fiesta running 260 bhp and 260 lb/ft @10psi

Was thinking about goin low comp in the future and your car is inspiring me to get my foot out of my ass!!


Don't worry though as mine is in a mk6 fietsa so you are still the first in a mk3

[jimmyesh]

Don't worry though as mine is in a mk6 fietsa so you are still the first in a mk3

Crikey, when I read the first part of your post I was in a state of shock - Wasn't until the "MK6" Part that I allowed myself to relax again!

Sounds like a nice conversion you have, 260 BHP on standard rods/pistons and comp ratio That's going some but I know the st170 supercharger conversions make 260 on a standard lump so it must be a relatively safe figure when correctly mapped, I'd always prefer to fit stronger rods & pistons along with slightly lower comp though - get it done and get into the 300's mate!

[FRST SILVER]

my best projact car on this site by a long way....

love it mate,, top job,,

NO PENNY PINCHING HEAR

and best of all shes SILVER

[jimmyesh]

my best projact car on this site by a long way....

love it mate,, top job,,

NO PENNY PINCHING HEAR

and best of all shes SILVER

Blimey, cheers for the very kind words!

I wouldn't say it's the best one though - there's some very comprehensive builds going one here lately, such as M4DYETI's & Excursion's to name two...

As for penny-piching, I think I am guilty of that I'm afraid! It's not costing all that much to do this conversion - partly because I get all my storage, welding and fabrictaing for nothing at work and have sourced a lot of ancillary parts 2nd-Hand

I'll park near yours if we meet at any shows!

[Alan12112]

Don't worry though as mine is in a mk6 fietsa so you are still the first in a mk3

Crikey, when I read the first part of your post I was in a state of shock - Wasn't until the "MK6" Part that I allowed myself to relax again!

Sounds like a nice conversion you have, 260 BHP on standard rods/pistons and comp ratio That's going some but I know the st170 supercharger conversions make 260 on a standard lump so it must be a relatively safe figure when correctly mapped, I'd always prefer to fit stronger rods & pistons along with slightly lower comp though - get it done and get into the 300's mate!

I though it'd give you a shock fella when I wrote it!

Very impressed with the stuff you have so far very good spec list mate and well done on getting the caterham inlet, i've been after one for ages but they are so so rare!!


Thinking of going all out low comp next year or the year after, knife edge crank, pistons, bigger turbo, intercooler everything basicallY!!

Hoping to see 375 bhp and a similair torque, but then I need a gearbox aswell!!

I'm excited to see you results mate and good luck! What are you doing for management as mine runs on SCT and is very good, the dreamscience boys deffo know what they are doing.

Also is yours fly by wire or cable throttlebody mate as the main prob with mine was getting the bloody FBW throttlebody to respond as quickly as the injectors which are uprated mustang ones which meant the car had loads of petty and no air!! Thats been fixed now though


Good luck mate and sorry for the long as hell post! If you need to know anythin I have amassed quite abit of know-how on the turbo side of these engines and there are alot doing it in the states who are willing to help

[jimmyesh]

Hoping to see 375 bhp and a similair torque, but then I need a gearbox aswell!!

What are you doing for management?

Also is yours fly by wire or cable throttlebody?

Hi Alan, I'm going to use Omex 710 management as it is cost-effective and proven kit. Also it drives coil-on-plug ignition too which will be great for my ignition setup.

Mine has a conventional "cable-operated" Throttle Body, (albeit a nice 70mm one stuck on the end of my Caterham Cosworth plenum! )

They're good figures you're aiming for - I'm not going that wild myself - 300BHP will be plenty for what I'm after. I'm not building this to break any speed records or have the ultimate power, just doing it to be a bit different and try something a bit leftfield with regards modding MK3 Fezzers

[Ram]

love it. good going

[jimmyesh]

At last, the car is collected!!

I hired a car trailer for just £40 from Wesbroom Engineering in Colchester and borrowed a mate's Transit then completed the epic 250-mile round-trip from Colchester to Arborfield (nr Reading). It was a boring, slow old slog but every time I saw the silver Fez in the mirror it cheered me up no-end

The existing running gear is all being removed in work tomorrow for the guy who bought it on ebay to collect and I'm pleased to announce that I now have all the parts to reassemble the engine - the ARP main & head studs arrived today from the states.



Will be assembling it during the days next week on leave, while Mrs Esh is back at work and Mini-Esh is at the childminders.

Whilst trying to buff the "Caterham" writing from my inlet plenum I found that they were bonded on rather than cast as part of the manifold - no worries though as it made things easier for me - I carefully re-bonded the "Power By Cosworth" writing in a more central position where the Caterham writing was...



Stand by for some more photos of the actual car (when I remember to take my camera to work ) and the engine rebuild.

[FRSJON]

all looking good jimmy...

[White2i]

looking good mate, will be seeing some quick progress then in the next week or so

[jimmyesh]

More progress:- Last night I removed the CVH Engine, Gearbox, Gear linkage, Driveshafts, Exhaust, Rad, Fan, standard loom & ECU.

Some lucky b'stard got it all for £72 on ebay!

Have a nice virgin engine bay to abuse now

[Luke1990]

More progress
Have a nice virgin engine bay to abuse now

dont think you can call it a virgin Amazing project though mate, cant wait to see it progress

[Ruishy1]

More progress:- Last night I removed the CVH Engine, Gearbox, Gear linkage, Driveshafts, Exhaust, Rad, Fan, standard loom & ECU.

Some lucky b'stard got it all for £72 on ebay!

Have a nice virgin engine bay to abuse now

what do you expect selling it with a credit crunch and this close to crimbo

You could have tripled your money easy if you waited a month or 2

[jimmyesh]

You could have tripled your money easy if you waited a month or 2

Yeah I would have preferred to wait a bit longer too but I've already maxed-out my available storage space at work with the parts waiting to go in to the car and the boss would have been moaning if I had left the old stuff loafing on the shop floor!

[Andyfloss03]

more pictures..


id love to be able to have the time and space to do summat like this..... used to small engine haha... my 2.0 seemed enough when i got it ...now i only want more....

only 18 though so you know haha budding engineer:)


really looking forward to seeing more of this build mate.. congrats on everything so far... how your misses puts up with it i will never know... all i get is.. ",cars,cars,cars,cars,cars,cars,cars,cars," hahah

[jimmyesh]

more pictures..

how your misses puts up with it i will never know... all i get is.. ",cars,cars,cars,cars,cars,cars,cars,cars," hahah

The Mrs is generally good with respect to my tinkering with cars but I do "screw the nut" as well in that we both work and have a baby so I know I need to put being a good Dad & Husband before building fiestas! I know she got pissed off with the amount of time I spent at work on the "MANJ" so I'm trying to get this one mostly done during my post-tour leave from Afghanistan. That's the best of both worlds - getting a full wage whilst building my Fez

Off to the Scrappy tomorrow for some MK3.5 Front hubs, as from previous experience with building the Manj, I'm pretty damn certain that my Focus outer CV Joints don't fit the old MK3 Hubs

The ARP Mains and head studs are now installed into the block, as soon as I can find where I put my piston ring compressor (D'oh!) I can get going with the engine rebuild...

I will remember my camera!

[jimmyesh]

Blimey, what a day!

First thing this morning I took a trip to G&L Auotospares in Colchester and ripped the front hubs, carriers and shocks from a MK3.5 Fiesta Si, the guy sold it all to me for £20! - Top bloke, I always go there for my spares now

Here's the hubs & shocks (I only bought the shocks as they'll be useful to allow the car to be moved around during the work that's happening and also buy me some time to save for a decent coilover kit).



Confirmation if anyone needs it - A Focus 2.0 Zetec Driveshaft & CV Joint fitted into a MK3.5 Fiesta hub, MK3 are a no-go...



Poor Car feeling sorry for itself under the cover - at least it's indoors though



Cosworth Upper Main Bearings installed (after thoroughly cleaning the surfaces with Loctite cleaning solvent). ARP Main studs fitted.



Cosworth Lower Main Bearings installed.



Crank Fitted, "Plasiguaged" then re-fitted, ARP Nuts torqued with ARP Moly Lube.



Pistons & Rods fitted using ring compressor and copious amounts of oil - Massive care had to be taken not to break any rings here!



Here's all 4 fitted, ARP big end bolts and Cosworth bearings used throughout.



Here's my modified Duratec Fuel-Rail that now allows for fuel-return (compatible with the MK3 Fiesta's fuel system) Has -6 male fittings on each end ready for Aeroquip hoses (Yes I know it needs paint! )

[White2i]

looking good mate, reli starting to come together now, how long before you will have the enmgine all to gether and ready to eye up in the engine bay?

[jonboisescort]

coming along mate this will be a beast wen done

[M1K3Y_B]

I haven't looked at this thread before.

Just had a quick read through and you have done a brilliant job of saving a sorry looking Fiesta and turning it into a beast, well done

[XRMike]

I really admire the work and prescison you put into your cars mate.

[jimmyesh]

Cheers for the kind words guys, much appreciated - might even take the cover off the car tomorrow!

Should hopefully have the rest of the engine assembled tomorrow, aside from the sump which is having a -10 alloy male fitting welded on for an oil-return for the turbo and also a smaller -6 one for a drain line from the oil catch-tank. Also, I'm keeping the cam cover off for now as I'm painting that gloss black.

A blanking-plate for the balance-shaft assembly oil-feed will also be manufactured as I'm not re-fitting this assembly. From what I've learned from people that have tuned the 2.3, the general consensus is that these engines run just fine without it - (the 2.0 doesn't have it). Plus it's just more rotational drag and weighs 5KG!

[FRSJON]

nice one jimmy.... ...all coming together very quickly....

[FlashXR2i]

Quite nice update Jimmy!

Keep up the top work mate!