fiestaturbo.com

[Ollybee]

OMFG!

[muz]

Cue welsh accent: Bloody Lovely Butt!

[jonboisescort]

great car looks mint now
great engine plans

[Turboboy67]

Nice choice Jimmy

Looks like they dragged it all the way across the Atlantic on the end of a rope

I'm sure you will get it looking spanking mate

[jimmyesh]

Lol CarbonBoy you cheeky git!

It's just the way the alloy rocker cover has corroded just like the old silver-top Zetec was prone to, that pic shows the engine still in the focus in America, those guys clean everything up before it's shipped and I'll be replacing that cover with the black type once I get the engine built up to the correct spec.

It's setting sail on tuesday so should have it in a couple of weeks

[Brammer]

Amazing project

[rs-tom]

nice one mate n good look on tour

[Ghost]

Looks like another great project!

Will keep an eye on this!!

[purple_fiesta]

sure itll be wicked once done! good luck over there mate

[xrsi]

nice one mate n good look on tour

do you mean luck???

excelent idea i must say tho using a duratech and another first more than likely!

[rs-tom]

nice one mate n good look on tour

do you mean luck???

excelent idea i must say tho using a duratech and another first more than likely!

lol yeah summat like that

[Excursion]

The cover is like that because the engine has been rained on. Once swapped will be fine.

[jimmyesh]

The cover is like that because the engine has been rained on. Once swapped will be fine.

CheeRS mate, I cant wait to get the bits underneath the cover sorted first!

[luca]

Good afternoon Jimmy

Exciting times for when you return mate, and again you have raised the bar for fiesta modifications.
Look forward to this when the build swings into full action, going to be wicked.

[jimmyesh]

Good afternoon Jimmy

Exciting times for when you return mate, and again you have raised the bar for fiesta modifications.
Look forward to this when the build swings into full action, going to be wicked.

CheeRS Luke, yeah I just fancied a change from the CVH/ZVH/ZETEC-Turbo route etc - Although they are a very good engine and well-proven, (got that in before I start getting death threats from die-hard ZT fans! ).

I realise what I'm doing is quite a new thing (with regards MK3 Fiestas) - I just hope no one else beats me to it while I'm sweating my b*llocks off in Afghan! Fair play to anyone that does though - I'll have to race them!

[luca]

Fear not mate there are not many folk with the vision/nuts to do it, im pretty confident your be in the lead.

What date are you due to return, or is that something you dont know till nearer the time

The cosworth parts avaliable for these engines is stunning too.

[RST-CRAZY]

U know something! i got a mag from burton power there last week and am in the process of finding can that engine be turbo'd, now i know it can, that was [ERRR] i was thinking of going for my fezzer.
they say that the cranks are strong but the rods and pistons are not, they say that it can be tuned to 300bhp with no mention of a turbo, but that means serious rebuild though. and a lot of money.
good luck with it mate i am goin to keep an eye on this one for sure. i really hope it works out, but ull be finished b4 me.

here is a picture of it, looks good but not so sure about the plastic look though. but can be tuned to more power than the zetec.

Duratecengine5.jpg (61.63 KB) Viewed 17169 times

[jimmyesh]

U know something! i got a mag from burton power there last week and am in the process of finding can that engine be turbo'd, now i know it can, that was [ERRR] i was thinking of going for my fezzer.
they say that the cranks are strong but the rods and pistons are not, they say that it can be tuned to 300bhp with no mention of a turbo, but that means serious rebuild though. and a lot of money.
good luck with it mate i am goin to keep an eye on this one for sure. i really hope it works out, but ull be finished b4 me.

here is a picture of it, looks good but not so sure about the plastic look though. but can be tuned to more power than the zetec.

Duratecengine5.jpg

Yeah you're right there about the Duratec producing silly power even in N/A form - SBD got 304 bhp from a 2.0 without forced induction!
As standard it's a "squarer" engine than the zetec in that the bore is bigger and the stroke slightly less (similar to V*xh*ll XE Lump). This, combined with the fact it already has massive valves and a very good flowing head (originally for emissions puroses ) allows the engine to reach high revs easily and breath very well.

Although I love screaming N/A engines for balls-out fun, I want this one turbo'd as it's nice to have an engine that idles like a standard car and has loads of useable torque in the low/mid range to make it a nice car to use on our busy roads as well as the odd track-day. Being just over 2.3 (once re-bored for the new pistons) it should have an abundance of torque!

Decided on transmission now too- The mondeo 1.8 & 2.0 Duratec SCi MK3's came with the same Getrag MT285 'Box that the Focus ST170 & Mini Cooper S use (the one I had fitted in my previous Fez the "Manj"). I need to find the Mondeo variant though as it has the correct bellhousing for the Alloy Duratec.

Bye for now

[jimmyesh]

As expected, this project is throwing up a few hurdles which I fully welcome as I love a challenge!

Just won these Focus RS Clocks on Ebay (after some punk outbid me in the last 5 seconds on another set I was after! ).



One of the first problems was the fact I'm using the Getrag MT285 6-Speed Gearbox (standard kit for ST170/ Mini Cooper S/ Mondeo SCi) and this was never fitted with a mechanical speedo-drive as it's a modern gearbox so it never needed that facility. CTS told me that it's not really possible (or cost-effective!) to retro-fit a mechanical drive.

I then decided I'd fit Focus clocks (as I did in my previous project) as they're electronic and can be used with the VSS (Vehicle speed sensor) of the ST170 'Box. The problem this threw up was that the focus VSS output goes to a black box called the GEM (Generic Electronic Module) which converts the VSS pulsed output into sine & cosine waves to drive the speedometer, this module also controls everything from the dash to the anti-theft system to the wipers! Therefore there's tons of wiring, incoporating a Data "Highway" which carries the converted signal to the dash (blimey what a mouthful! ).

Although I fitted the whole Focus loom from an ST170 successfully before in the "Manj", it's just not practical for this car as I'm using standalone management and don't want all the extra weight and clutter from all the Focus loom/fusebox/Ecu/Gem...

The other difference is that the MT285 6-Speed 'box has a VSS output of 89 pulses per driveshaft revoultion, whereas the Focus RS 'Box (MTX 75) has 26 pulses/rev. With 195/45/15 tyres my VSS frequency output from the gearbox sender will be 3.78 KHZ @ 165MPH @ 270 degrees meter (MAX) deflection. NOT that I'm planning on doing 165MPH on VR-rated 15's though!!

I've managed to find a chip that's specifically designed to drive electronic speedo's and tach's by converting the VSS pulsed outputs into sine & cosine inputs for the meter. Basically, the component values surrouning this chip are calculated for my specific frequency and there will be a potentiometer fitted to allow calibration for different wheel size etc.

When I return from Afghan (I fly out next Wednesday) I will be bench-testing a prototype of this circuit by using a good old Army-issue signal-generator to simulate the Gearbox VSS sender output and will be able to trim out any gremlins there (hopefully!).

Sorry for the essay to those with a short attention-span

This car will have a few "never-seen-before-on-MK3" Mods and I'll be doing them all myself (with the odd bit of help from workmates )

[heeman10]

I clicked on this thinking it was for the Mk2 Escort...I don't think I'd realised you were going to turbo a 2.3 What a laugh! What are your power aspirations Mr Esh? Commandeered yourself a handy shed yet?

[jimmyesh]

I clicked on this thinking it was for the Mk2 Escort...I don't think I'd realised you were going to turbo a 2.3 What a laugh! What are your power aspirations Mr Esh? Commandeered yourself a handy shed yet?

Ah, hello James! The silver one is tucked away in my old garage at my last unit in Berkshire with a good friend looking after it while I'm away. I've sourced a car trailer and van to move it daaarn Essex once I return, then I've got a MASSIVE workshop (way bigger and better-equipped than when I built the Manj ) that my boss says I can use out-of-hours (just got to keep my marriage in one piece then!

As for power I'm hoping it will be 300-350BHP which really isn't a massive ask from a 2.3 (It's actually "only" 2261cc in standard 87.5mm bore but I'm having it rebored and am using 88.5 pisons for a "real" 2.3). It so happens that Mazda have revised this engine for their 2009 range and are making it 2.5 litres and still the same physical size as the 2.0 & 2.3. So if an upgrade is required I know where to look!

Engine Spec list - at the moment (subject to change at any time my messed-up head sees fit! )

88.5mm Wossner 8.5:1 Pistons
Eagle Forged steel Rods
ARP Fasteners throughout
Cosworth Duratec Main & Big-end bearings
Cosworth Duratec Valve Springs
Cosworth Duratec d-power Inlet manifold
Cosworth Duratec 67mm Throttle Body
Cometic Head Gasket
Focussport Turbo Manifold & Downpipe
Garrett GT28RS
Wideband Lambda
Omex 710 Management
Coil-on-plug ignition
Focus or Mondeo Duratec Engine mount.
Pro-alloy Intercooler & Rad

Drivetrain

SPEC or Fidanza Flywheel & stage 3+ clutch (ST170 {14-Spline, 1"input shaft} friction plate
Getrag MT285 6-Speed Gearbox from (2002-2005) Mini Cooper S (gearchange mech smaller than st170 so won't foul servo)
Mini Cooper S gearshift cables, gearshift mechanism and gearlever... (and gearknob!)
Mondeo SCi Bellhousing & Hydraulic Release Bearing
ST170 Driveshafts (one custom shortened one made from billet steel)
Quaife ATB Diff
St170 Gearbox mounts
Fiesta MK "3.5" or MK4 Front Hubs & carriers (Direct fit for ST170 'shafts)

There is more than all this mate, just wish that I could just crack on with it all now and get it done but I've got this tour to do first, but then I need the tour to save the cash, D'oh!!!

[jimmyesh]

Hi everyone! I'm back on a week's R & R from and (much to my wife's annoyance) have aquired some new parts for the beast.

I have decided on using an MTX75 Mondeo MK3 Duratec 5-speed 'box and managed to find an '03 plate one on Ebay for the princely sum of £70 + 15 delivery!!

I also bought some MK2 Focus 2.0 Zetec driveshafts complete for £30 each side, one will be shortened of course...

Here's today's haul:







I have also ordered a SPEC Stage 3 clutch for the Yank Focus 2.3 and a Fidanza Flywheel from the States, In addition to this I'm buying a Quaife ATB diff for this Box (same as FRS). See, not Too much cost-cutting!

I've ordered some steel Rods and ARP con-rod bolts from the good ol' USA too, along with some new Cosworth Big-End bearings and a new Cam-Chain + Head Gasket.

Pistons are coming from Focussport as they do special forged Turbo items for around $700 which sounds fine to me. I did try Wossner as the 2.0 Duratec & 2.3 share the same bore-size but unfortunately the deck-heights are different

As for Ignition, I'm reverting back to the traditional single-coil setup as then I can use the Omex 600 rather than the more expensive Omex 710 that I would have needed for the Coil-On-Plug setup. As such I've got a Mondy Mk3 Ignition setup from Ebay, along with starter motor etc.

That's all for now, just to let you know that there is progress here and the car will be done for FITP 2009!

[FRST SILVER]

wicked project mate....

you no silver are the best

[Rhinopower]

Nice update, glad to see its moving in the right direction. You can still take it further at a later date

As for getting the snip i've been old by too many people its not worth it

[jimmyesh]

you no silver are the best

They certainly are!! CheeRS mate

Nice update, glad to see its moving in the right direction. You can still take it further at a later date

As for getting the snip i've been old by too many people its not worth it

It has to be the snip, my ticker (and wallet) can't take any more surprises!

[garyhurn77]

great project!!!!

[xrsi]

going to be a very similar setup to mine (mtx 75 with quaife diff, fidanza flywheel, arp throughout, omex 600) apart from im running a 2ltr zetec black top not a duratech.

Better get a shift on and finish building the ead up so my box is in before yours

Looking good so far tho mate!

[jimmyesh]

This arrived in the post today... every little helps



Still waiting on the flywheel, clutch and con-rods - I'll probably get stung on import duty again, D'oh!!

[jimmyesh]

Some more goodies have arrived in the post for the Silver One ....

Eagle Forged H-Section con rods with ARP 2000 Fasteners:





Focus 2.0 MTX 75 Transmission Mount:



Still waiting for the flywheel, pistons and Spec 6-Paddle clutch to arrive - Gordon Brooon is probably rubbing his hands with glee at the thought of swindling yet more import duty from my unhealthy wallet!

Also got a Mondy MK3 2.0 Duratec Starter and Coil/HT-leads so that I can keep my options open with regards ignition (i.e C.O.P or conventional H.T leads).



Seeing all the parts accumlating is filling me with confidence for cracking on with the build when I return in October, I've found a brilliant engineering shop within walking distance from my house that can manufacture shortened driveshafts and bore my block to 88mm for £35/bore so all is well

[garyhurn77]

coming togther nicely mate

[jimmyesh]

I've been given another week off as something happened back at home, everything's ok now thank god

Here's the prototype Speedometer driver circuit that converts the gearbox speed sensor (VSS) pulse output into sine & cosine waves for the FRS Clocks. I still need to build a duplicate circuit to drive the Tach yet. Normally the tacho and speedo signals go via the Focus ECU to the GEM which processes them into the suitable signals to drive the instruments, these circuits will save me the hassle of having to fit a whole Focus loom etc just to run the clocks (If it works! )

I have yet to fit the correct size potentiometer for the MTX 75 VSS output as I originally planned for the Getrag MT285. It'll be hooked up to a signal generator when I return to calibrate the speedo.

[garyhurn77]

good work mate fingerscrossed the circuits work ok, and you dont have to fit a focus loom again to another fiesta!

looks well though engine should be awesome

[jimmyesh]

I was wracking my brain trying to decide which alternator setup to use, I was all set on forking out for Burton's Duratec Alternator kit (£450 inc Vat! ).

Ridiculous price-tag aside, I was also swayed away by the fact that I'm converting the Fez to power steering from the MK3.5 (I know, I must be GAAAAY! ) so am using a Fiesta ST150 Power steering pump with all MK3.5 Fez Power steering pipework and rack.

I have purchased a Mondeo/Focus Duratec 2.0 Alternator from Ebay (hurry up Royal Mail ) and said ST Power steering pump.

As you can see, the block still has the idler and tensioner pulleys present, the alternator goes at the top on the rear and the power steering pump goes at the top on the front so along with a non-aircon Focus 2.0 Duratec drive-belt, I should be laughing (for a quarter of what Burton's effort would have cost me)

Side view of my 2.3 Duratec.

[jimmyesh]

Hi everyone, just to let you know the project is still moving in the right direction!

I come home from tour in a few days and am eager to get cracking with the oily-partsof this conversion.

Whilst I've been out here I've managed to buy the following items on the 'net and (much to my wife's disgust) they've all been delivered so are waiting for me to get my grubby mitts on them

The haul so far (in addition to items already shown earlier in the thread):

1. Cosworth inlet manifold.
2. Pro-Alloy full-width radiator & Fan.
3. GRS Front-Mount intercooler.
4. Garrett GT28R Ball-Bearing turbo.
5. Mondeo MK3 2.0 Duratec Engine mount.
6. MK3.5 Power steering pipework.
7. Fiesta ST Power steering pump.
8. "Duratec Inside" Sticker for the rear 'screen!

Still got to buy:

1. Pumaspeed Fiesta ST Turbo Garrett GT Turbo Exhaust Manifold.
2. Fuel Injectors.
3. Management.
4. Fuel Pump.
5. Quaife ATB Diff.
6. Coolant/Boost/Fuel Pipework.
7. Map Sensor.
8. Decent FRST Exhaust (& some kind of downpipe )
9. Pay the machine shop to bore my block to 88mm and also shorten 1 driveshaft.

Probably missed a few bits there but things are looking optimistic for the Silver One - Stand by for pics when I return!

[Chris 2i]

nice, can't wait to see this one come together