fiestaturbo.com

[jimmyesh]

Right, make yourselves comfortable because there's about 16 photos to get through here!

Worked like a bloody Trojan today, even skipped lunch and my daily trip to the gym!

First off I installed the cosworth head gasket:





Torqued the ARP head nuts to specified torque with ARP "moly lube":



Installed Cams and torqued caps up to correct torque:



Note these Duratec Cams have a hexagonal section to hold the camshaft with a spanner whilst tightening the pulleys - useful feature, can't remember if Zetecs have it?



Installed Oil Pump:



New Oil Pump drive-chain & tensioner fitted:



New Camchain tensioner fitted - note the grenade-style pin that you have to pull out once fitted!





New Cam Chain & Guides fitted:





Once Cam sprockets torqued to spec, a bead of gasket was applied to the front cover, this was then fitted:



Thermostat (bet you never expected it to live on this part of the engine eh? ) and water pump outlet fitted:



Block Breather & Oil filter housing fitted. Standard "save the planet" Injectors removed:



Thought I'd go mental at this point and trial-fit my Cossie inlet manifold! Note that the power steering pump, alternator, tensioner & Idler pulley are all fitted too.





The cam-cover is waiting for me to paint it (still can't decide on the colour - Moondust Silver, Gloss Black or Green to match the FRST Stripes and the boost/coolant hoses that I'm getting? ), for now it's just resting on the head at the moment to keep s**t out of the engine. The sump is with the metalsmith at work getting the oil returns welded on. Still waiting for my exhaust manifold from Pumaspeed...

Bye for now!

[jonboisescort]

coming along nicely mate

will look sweet once the cam cover is done

[White2i]

looking good mate, thats alot of progress for one daymate well done,at this rate will be done in no time at all, cant wait to see the pics of it being fitted in the car

[filtra]

Comprehensive build! Are the coil-on plugs standard on the 2.3?

[jimmyesh]

Are the coil-on plugs standard on the 2.3?

Yeah mate, they're standard on the Yank 2.3 Focus not too sure about the UK market though? The latest UK mk4 Mondeo 2.3 has the same lump as mine, that may have coil-on-plug ignition but I know that the Fiesta ST's, Mondeo 2.0 MK3's have normal HT leads.

I have both setups, so I can use either depending on what engine management I can afford - Omex 600 can't run individual coils but the Omex 710 can (but it's £300 more expensive! )

I'd rather keep the individual coils TBH, as I think the look but also are a nice, modern touch

[FRST SILVER]

love it mate.......

coming along well......

[jimmyesh]

More pics

I fully cleaned then rubbed the manky cam cover down today and gave it a few coats of primer - Painting it Ford Modena Green tomorrow



Modified Fuel Rail was painted gloss black - In addition to having -6 male fittings on each end it's also had the standard pressure regulator and pressure sender ports ground off and welded over as I'm using a Sytec adjustable regulator.




Sump waiting for my mate at work to weld the oil returns on - should be done by tomorrow...



Couple of pics of the actual car! My RS2000 rims are still round a mate's house in Kent, I'm keeping these nasty rims and chunky 195/50 tyres on it whilst it's being worked on.









Today I also measured the total width from cv joint-end to cv joint-end with Focus driveshafts fitted into the mtx75 'box - I made it 1570mm whereas the the Fiesta measurements were 1480mm - this pretty much matches the dimensions that I used when building "The Manj". Although the Focus driveshafts are supposed to be "equal", one is actually about 30mm longer than the other, last time I fitted the shorter one where the longer one was originally fitted, then had the longer one shortened by around 90mm and fitted on the passenger (near side) side. I'll be getting Cober Precision Engineering, Colchester, to sort me a shortened 'shaft soon.

[jonboisescort]

lovely paintwork mate

[jimmyesh]

lovely paintwork mate

Cheers mate

Still need to get hold of some new bonnet hinges as the old ones are a bit bent from a mishap the previous owner had I don't what the availability of them is like - if they're not held by Ford anymore I'll just have to straighten them out myself.

[White2i]

if you cant get them from ford then give me a shout got a pair on my old shell still mate.

[muz]

Looking good jimmy. I bet that car didn't know what was in store for it when it rolled out as a humble 2i.

[paulgrs2]

looking good mate, keeep up the good work

[Smo]

Looking good, Jimmy - Some nice progress there, and even though it's just sitting there, that inlet plenum just makes it look like it means business Is it going to clear the bonnet, though? Looks very high

Also, how much is your 'shaft-shortening' costing you? If you don't mind me asking

[jimmyesh]

Looking good, Jimmy - Some nice progress there, and even though it's just sitting there, that inlet plenum just makes it look like it means business Is it going to clear the bonnet, though? Looks very high

Also, how much is your 'shaft-shortening' costing you? If you don't mind me asking

I agree, the plenum does look high up in the pics, I'll just have to wait and see with the dummy-fitting once I have turbo & manifold on as well...

Not sure what they want for the shortened 'shaft yet - I'll ask them this week

[Ruishy1]

i cant imagine it will be too expensive mate, i got a prop made up by a company near me, skyline yoke with 200sx flange, lengthened by 25mm and balanced. it cost 100 quid.
So id imagine it would be less then that

[jimmyesh]

Another day, another update!

Today I sprayed the Cam Cover Ford Modena Green - goes very well with the FRST Green trim



I removed the MK3 Hubs and replaced them with MK3.5 ones, look at the difference between them below - Mk3 are on the right, notice the smaller splined hole?



I also fitted the MK3.5 front suspension, just standard Si shocks with lowered springs to see the project through - I'll put some decent suspension/brakes on once it's running...

Pitiful state of an engine bay! Don't worry it will be immaculate before the powertrain is installed



I removed the standard manual steering rack and replaced it with the MK3.5 Si power steering rack and steering column, not as straightforward as you may think - the hole in the bulkhead where the column mates up with the rack needs enlarging slighty to allow the power steering column to exit properly.

Pics of power steering vs manual steering components below (PAS parts at the bottom of the pic):



PAS rack fitted:



I also removed the MK3 pedal assembly in order that I could compare it to the MK4 item I have ready to fit with Hydraulic clutch pedal system. As you can see, the bolt patterns are a bit different! It's not all bad though as the part that's protruding from the top of the new pedal box with the 2 bolt holes was only bolted to the pedal box - once removed it left two holes in exactly the same location as the MK3 one! Just got to do some careful measuring & Mig welding on the other face to put the other 4 bolt holes in the same place as the MK3 one and also make a hole in the bulkhead for the Hydraulic clutch inlet & outlet.



That's all for now everyone - It'll be a few days before I get on with it again as I have lots of home DIY that Mrs Esh is badgering me about!

[FRSJON]

love the progress jimmy... ..not sure on the green yet but it'll probably grow on me... .. the MANJ'S rocker cover is coming off soon for paint...in the best colour ford do....red...

[jonboisescort]

give the bay a good clean and a lick paint
and will look great

liking the cam cover

[jimmyesh]

love the progress jimmy... ..not sure on the green yet but it'll probably grow on me... .. the MANJ'S rocker cover is coming off soon for paint...in the best colour ford do....red...

The Manj's cam cover will look good in red, Jon - I'm sure you'll love my green one by the time it's all finished!

give the bay a good clean and a lick paint
and will look great

liking the cam cover

Cheers mate , I can't even think about painting the engine bay until I've dummy-fitted the engine, 'box and driveshafts then welded in the engine an transmission mountings points - hopefully that won't be too far away, all hinges on when my exhaust manifold finally gets here as I need everything mounted to the engine in order to checjk clearances properly - things are gonna be tight with that mahooosive inlet plenum but from the measurements I took today it should fit...

[FRSJON]

im not going to go mad on the engine bay but want to tart it up a bit...im really after the plug lead cover in carbon.. cant find one any where... might have to get one made... ... keep up the good work...

[Ruishy1]

hold on.... ive just realised its a forward facing plenum setup,
i though it was the same layout as the zetec

[jimmyesh]

hold on.... ive just realised its a forward facing plenum setup,
i though it was the same layout as the zetec

Yeah that's the single biggest difference betweent the Duratec & the Zetec is that the hot and cold sides of the engine are reversed - that's no bad thing as there will be no roasting-hot turbo sitting a gnat's chuff from the radiator as you get with normal Zetec & CVH lumps but on the flip side it means a lot of thought has to go into heat-proofing various parts in the bulkhead area that would not normally get hot.

[Ruishy1]

is there sufficient clearnance on the bulkhead side of things ?
or do you need to cut and weld some new space into it
It is good for the cooling side, bad thing is if the turbo goes pop, makes it awkward to get too

[jimmyesh]

Couple more pics of my engine - cam cover re-fitted. I think it looks pretty damn nice in Ford Modena green

[Captain Tightpants]

Looking good mate.

It's nice to see something interesting and different going on in here. I'm almost bored of ZT's!! It's good to see some people thinking outside the box.

Love it.

Steve

[jimmyesh]

Looking good mate.

It's nice to see something interesting and different going on in here. I'm almost bored of ZT's!! It's good to see some people thinking outside the box.

Love it.

Steve

Cheers Steve Seems criminal not to use the Duratec to be honest, especially as it's no heavier than a CVH, gives a 44% increase in capacity and 8 more valves!

[FRSJON]

the green does look better in the light mate... so whats the plans for the inlet?/.. polished??.. painted??..

[jimmyesh]

so whats the plans for the inlet?/.. polished??.. painted??..

I'm actually going to leave the inlet as it is mate - If it's highly polished it'll just be high maintenance and need constant elbow-grease. If it was painted I think whatever the colour, it'd just be too much with the cam cover already painted.

[FRSJON]

polish it mate..ill bring the autosol to every show.....

[jimmyesh]

polish it mate..ill bring the autosol to every show.....

With an offer like that how could I ever refuse?!


By the way, your siggy makes it look as if Oddkidd creations built the Manj rather than my good self!

[FlashXR2i]

By the way, your siggy makes it look as if Oddkidd creations built the Manj rather than my good self!

Well spotted Jimmy


Amazing project mate... still waiting the 'traction part'

[jimmyesh]

Amazing project mate... still waiting the 'traction part'

That'll be in the new year mate - need to keep my pennies in the bank for Christmas holidays and moving house

[frstvanman]

shes gonna fly

[jimmyesh]

Had a busy and productive day today - Did a bit of cutting, welding and drilling and now have the MK4/MK5 hydraulic clutch pedal box all fitted

Firstly I elongated the two holes on the top of the pedal box to make them the same as those on the MK3 pedals - I know it's not mega neat but hey it's gonna be out of sight!



As you can see from the pic, as standard the front mounting holes on the MK4/MK5 pedal box are in completely the wrong place - the mounting plate is also too wide for the MK3.



A couple of seconds with an angle grinder rectified this



Next, a 2mm thick piece of mild steel was measured and cut to size on this nice electric guillotine...



...and offered up to the pedal box.



This was then MIG welded to the pedal box ( I know, must get neater! )





Using a cardboard template which I mocked up on the rear of the pedal box I then marked out the required area that needed to be removed for the hydraulic inlet/outlet connections - (Looks a bit like a kid's drawing of a 'conquering device' and balls don't you think?! )



After an outline of 4mm holes was drilled around the shape it was then punched out and the edges de-burred and filed smooth.



View from inside:



Pedal box now bolted in place and everything lines up! The edges were dressed in using a hammer and drift. They will also be rust-proofed and the whole engine bay is being re-sprayed so it should look good once done.

The MK4/MK5 fiesta pedal box hydraulic inlet/outlet area has a foam surround that seals against the bulkhead as the bolts are tightened, should anyone be wondering what the grey stuff around the black pipes is...





Just need to cut the hole for the brake linkage bar now and re-fit the steering column (again! )

That's all for now

[FRSJON]

lovely progress mate...sorry about the sig..a mate of mine on there did it for me.. if i knew how to change it i would....