fiestaturbo.com

[andyhardy]

found this stuff ...
http://www.enginemanagementsystem.com/ecuspecs.htm
wot do you lot reckon.

cost is about 500 but no uk dealers yet but some of the dealers wud ship to uk but wud anyone map it??

TBH you can get systems like Omex, SECS S8 and some of the cheaper branded ECU systems like Megasquirt or Emerald for around the same money which are guaranteed to work with your car and have plenty of people who will touch them here in the UK.

If you're going to spend alot of money on the engine then spend the most money on the management as failure of that WILL cause destruction of the rest!

Cheers,

Andy

[heeman10]

Matt - Don't be disgusting

Rawli - I don't lower myself to your standards (I draw the line at 2 year old seals, that one is only 8 months )

RS TURBO S2 - I am spending a third of what the engine cost me to ensure the ECU is correctly mapped. Too many people spend a bomb on the engine and other major parts and leave nothing left to get it properly-mapped, and suffer the consequences!

[RS TURBO S2]

i agree its no point spendin a few k on an engine and not get it mapped, you may as well borrow ya mums rover 25 and go down the mc D's car park.

i am very interested in the omex stuff really as i npw a few who run it altho no one with a zeturbo

plus i will be putting aside a good 600 notes for mapping as i have herd it can a long process

[heeman10]

Well, update time! I came home from uni on Friday night and got cracking the next morning, and have got a great deal done!
1. Opening rear quarters in
2. Dash off
3. Interior totally stripped bar carpet
4. Old loom out
5. XR2i loom in place, partially connected
6. Fuel tank off
7. Cossie pump installed in FRST tank
8. C pillar trims modified and installed

Now waiting on braided hoses, radiator, intercooler and a few bits and pieces till I can really get the very important things going. Anyway, piccy time!

"Nutserts" now properly riveted in place. I ordered the tool from the USA a few weeks back, and of course all the insert adaptors were imperial So I cut a nice new M4 thread on the imperial shaft:


And put the two nutserts in the B pillar on each side of the car:


Then assembled the windows etc:


Top banana! They look 100 times better than the standard windows.

Modifying the FRST pump cradle to accept the Cosworth fuel pump (and modifying my finger ):


Cosworth pump all ready to go:


Earlier in this thread I mentioned the rubbish inlet arrangement with the CVH-Zetec spacer plate. It was obstructing the injector spray paths a little in my opinion, and there was a pronounced step going from the inlet side to the spacer plate.

This picture shows the gasket overlapping the injector spray paths:


This shows the arrangement now I've ground the gasket back:


Much better! I also filed back and profiled the parts of the spacer plate which were creating steps. I see modifications like these as the attention to details that make people say "I have the same spec as you, why does yours make 10bhp more?"...so the more the merrier!

Inlet assembly (lower half) ready to go, though I think (once I have confirmed it with Stu @ MSD) I'll start it up on the Mustang injectors...better to run rich than lean, and the Mustang injectors flow quite a bit more than the standard FRST blues I have in now:


I'd never taken my dash out before, so that was an adventure:




A VERY satisfying discovery - THE DREADED FIESTA DASH RATTLE/SQUEAK! We all know about it, and I think...no, I'm pretty damn sure, I've found the culprits!!


Where the corners of all the vents touch the dash soundproofing, they squeak and creak when you move them! So I've cut out the sections where they interfere, and all seems well now:


Fingers crossed I'll have a quiet dash now

A sight to make any grown man cry


Made a bit of a mess again!


The car as it stands now:


Need to get some braided hose for the fuel tank to car connections, then the tank can go back on, followed by the exhaust probably

I'm very pleased with what I've achieved so far, in just two and a bit days, and I've learned a lot. Off to a scrappy and Ford tomorrow for some new bits, and I'm expecting the intercooler and radiator to appear in the next two or three days

James.

P.S. Any pic requests while I have things off, let me know

[RS_Rawli]

good s**t jimbo, your mounts should be here on monday too

[dannyboy]

Thats alot of work for one day While the interiors out you may aswell remove the carpet too and check its all solid under the sound deadening.
Talking of pic requests, I would'nt mind a few of the braided line you plan to use, something I wana do myself

[MAD_Adamski]

james man you gotta clear up that mess!!!! and WTF are all those illuminus wires ??? and my loom i gave you work ok yer ???

[Sphinx]

whats with the leopard skin pants?!

Looks top notch tho, i envy your work space i want an area under cover to work in!

[MAD_Adamski]

whats with the leopard skin pants?!

yer thats wot i thought??? i bet he just got a bit excited and forgot to put his pants back on before he took the pic

[heeman10]

Firstly, I think I must address the issue of the leopard skin underpants My dad bought a bag of rags from ARCO, a big bag full of scrap, torn-up clothes...they do not belong to me! They're drenched in diesel too...best thing for them!

Rawli - Glad to hear it! And my lights?

dannyboy - The carpet's been up a couple of times. I did a soundproofing run on the car in summer, which included fitting a second layer of the standard sound proofing down, and it's all perfectly solid and shiny under there About the braided hose...I was only planning to use it to travel from the tank to the hard fuel pipes at the back of the car. After talking to my dad, he's certain that no-one within a 50 mile radius will have braided hose, so I'll just have to settle for standard rubber fuel hose for now as I can't stay home much longer than ten days (uni coursework ) and don't have the time to sit waiting for things. Sorry!

Forgot, I also fitted a nice new FRST throttle cable today Provided the loom's all in good shape, I can pick up the engine and gearbox oil I need tomorrow from Halfords ( ), and Radtec get my cooling setup to me in time, I hope to be able to try starting the engine at the weekend! If it fires up ok, I'll have a few checks, take it for a very slow drive, then get straight on the phone to MSD as long as all seems well, get a concrete live map booked! :D:D:D:D *Getting very excited now*

[Captain Tightpants]

Nice work mate, you have been doing loads!

Keep up the good work mate.

Will hunt out that CPS for ya, and get it to you by the weekend.

Steve

[MAD_Adamski]

TOP STUFF JAMES!!! real good the loom will work!!!! and i am getting braided hosing soon if you want me to get some for you in a few weeks???

and personally i dnt believe the old ''rag story''

[StreetDragster]

Whats the nutsert do, for, etc?

Looking good, everyone loves progress

Thanks

Matt

[MAD_Adamski]

Whats the nutsert do, for, etc?

Looking good, everyone loves progress

Thanks

Matt

the nutserts are because he didnt have opening rear 1/4's you need these in the pillar's to mount the brackets too

[RS TURBO S2]

merlin motorsport sell the nut setting tool.....

with both metric and UNF nut bits

http://www.merlinmotorsport.co.uk/catalogue/workshop.htm

had one for yeasr now and cant belive how handy it is

[heeman10]

Scort - PM's replied to, thanks a lot all the same matey

ad - I picked up hose today thanks. Not braided, but hose nonetheless! No time for waiting for things to come in the post etc at the moment, I really don't have much time!

Matt Drag Queen - The nutserts are threaded on the inside. The narrow end of that tool bit in the pic above is screwed into the nutsert, and the fat end of the bit has a left handed thread on it, which screws into the tool (looks like a pop rivet gun), held in place by a threaded stopper which butts up against the nutsert head. The shaft of the nutsert is inserted in the hole, and the tool is compressed by hand. This flares out the nutsert inside the hole, and the tool is then unscrewed etc, leaving it in the hole. You can then screw into it Lots of people use pop rivets instead, but I wanted to be able to remove them properly if need be.

Update
I'll post some pics up tonight of what I've done today. The morning was spent at Ford, motor factors and scrap yard sourcing parts. I didn't have the correct spanner for the fuel rail drain fitting on a 1.6 Zetec Escort I found, so had to take the entire fuel rail, including injectors

Wilwood calipers should be here shortly, Radtec intercooler and radiator aren't expected till Friday, Saturday or next week The exhaust system needs another mount, and I'm thinking of devising something using rubber and a custom mount to bolt onto the underside of the car, rather than welding things onto the chassis. Watch this space! The fuel tank's on now, with its new lines. Think I'll go and take the spare wheel carrier off now and give it a couple of coats of anti-rust primer as it wasn't too healthy! Pics later

[Jon_mk4]

This thread's a great read

Quality project coming along there - look forward to seeing the finished results

[andyhardy]

Glad to hear it's coming along well mate

I look forward to reading on your progress during the next 9 days or so?

Cheers,

Andy

[heeman10]

Pic time! Like I said, this morning had to be set aside for sourcing parts etc, so I only had this afternoon/evening on the car. It's been a fairly unproductive day for one reason or another. The tank really needed sorting before I put it in, so I got to that first thing so it would have time to dry before I fitted it.

Before:


After, with new pipes just before it went back on:


I left the underside to save time, and will do that at a later stage. Only crucial things are being completed at the moment, as I'm aiming to have it all completed and ready to roll down to MSD mid-May at the latest really

Zetec fuel rail I nabbed off an Escort, purely so I could nick the fuel rail return fitting! Anyone need a 1.6 Zetec fuel rail?


I trial fitted the exhaust for the first time today. It needs an extra mount or two, as you can see below:


I'm thinking of making one up myself, bolted to the floor of the car and suspending the exhaust with hooks and short rubber straps. Interesting!

The backbox - Mongoose's 3.5" rolled in for subtlety and "enlarged standard" look:


After seeing this pic, and the naaaaaasty state of the spare wheel carrier, it HAD to come off and get some treatment!


Rank. Mucho scrubbing, raking, bashing and kicking later:


Only had time to get the anti-rust primer on tonight, so the black coats will have to go on tomorrow. I would've preferred to powder coat it, but time being as it is....Hammerite will have to do:


So that's today. I hoped I could check the fuel pump was working ok, and determine which fuel line was pressure and which was return, but I think it must need the ECU plugged in. So tomorrow I'll focus on sorting the loom. It's confusing with so many plugs on the XR2i loom when the diesel had so few, but I'll get there in the end

[heeman10]

Mandy - Sadly I can't set aside nine days. I was going to call it a day and go back to uni on Thursday or Friday, but having heard today my brakes, cooler and rad should hopefully be here by the weekend I couldn't say no! I'm getting so much done in such a short time at the moment....it hurts to imagine how long I could've been driving the car if I didn't go to uni!!

[Max M4X WW]

Looking good. Not posted in a while but everything is looking lovley

[heeman10]

Update again!

Calliper brackets turned up today, thanks Vinnieboy I'm hoping with all my fingers crossed that these will support my new callipers in the right place, and give me the correct offset. All signs point to yes at this stage!


The spare wheel carrier's done now - that was just an "on-the-side" job really. So that's scrubbed up ok, with two coats of anti-rust primer and two coats of black Hammerite:



As I've said (and shown), then exhaust needed another mount in the middle of the car. To do this, I'm going to use longer bolts for the two rearward front seat frame mounting bolts, and offer up this bracket (below) and retain it with washers and nuts:


A standard Ford exhaust rubber will slide along the bracket, and the bottom half will slide onto an exhaust mount, which will be welded onto the exhaust tomorrow by an exhaust specialist dude.

I connected up a few more things today in the hope that I could check the fuel pump was working. When I plugged in the ECU and tried the ignition I got nothing...then noticed a "hot" smell coming from the ECU I have no idea why, or if this fault was already there....but it doesn't look good. I haven't taken the time to work out which pin it's connected to, but it looks as though the joint's gone now:


Any ideas??

Later on, I turned my attention to the interior loom again, working through all the wiring diagrams and stripping off wires and connectors I don't need. It'll make it a neater job when I come to attach it all to the dash, and cause less confusion in the future. It may still look a mess, but bar soldering about 10 wires, it's ready to take the dash again. Annoyingly though, I need an ECU bracket before that!


Off to Ford tomorrow for more parts (CPS, vacuum hose, fuel filter bracket and bolts, fuel filter fittings etc) and to get the exhaust welded. Then hopefully I can mount that tomorrow, get the spare wheel carrier on and get the car back on the ground Still concerned about the ECU though....

[STOKE7UP]

looking good my shell has been concined to death now rolling around
in lazy arse pies old cabby and still looking for a good p plate shell

[heeman10]

Yes, another update! I think people are getting bored of all my updates now, good job I'll be going back to uni in a couple of days!

Fiddled under the car yesterday, made up the flat steel bar you can see in the pic below, and determined exactly where the bracket needed welding. Got it welded on at an exhaust place today:


And bolted it up to the car. It couldn't have worked any better really, perfect position:


The Metro is now my mobile parts van!


And at long last, my calipers and pads arrived from the US of Gay!



I would've liked to fit them tonight, but neither the mounting brackets nor the calipers were threaded, so I need to sort that, plus machine 3mm off the mounting brackets to give the calipers the correct offset. A few more pics:



Pad clamping arrangement:


And an idea of how they'll look:


The box containing both calipers and all four pads weighed a noticeable amount less than one of my old calipers on its own. I will weigh the old ones when they're off the car to compare them to the 1kg weight of the Wilwood calipers.

[whinge="heeman10"Good and a bad day really. My local auto electrican confirmed with a single sniff of my ECU that it is fried and needs replacing. Ford price = £315 + VAT, re-con price from auto-dude = £135. Looks like I'll have to get one, not very happy really.

I ordered a brand new CPS and original Ford adapter plugs (for post-92 FRST's), having been told the CPS I had was from a Zetec....and when I got back, I found I now have two FRST CPSs, neither of which fit No idea what's going on. I'm still missing lots of parts which I need to move forward, but I've run out of time, yet again, and will have to head back to uni maybe on Saturday. Radiator and intercooler still aren't here, so I can't trial-fit them to order the hoses etc that I need.

The car is now booked in at MSD from May 28th to June 4th. My MOT runs out at the end of May. GAY. Just a few things are niggling right now, and time just isn't on my side! [/whinge]

[scarlet_pimp_mobile]

are you purposely taking photos with those leapard skin pants in the background or do you have them everywhere

those wilwoods look real meaty

[Max M4X WW]

are you purposely taking photos with those leapard skin pants in the background or do you have them everywhere

FPMSL!

FOR RACE USE ONLY!!

lol

Looking good

[TomRS1800]

are you purposely taking photos with those leapard skin pants in the background or do you have them everywhere

FPMSL!

FOR RACE USE ONLY!!

lol

Looking good

You really are gay arent you Max

[RS_Rawli]

agreed, didnt even crack a smile that, think hes on drugs

[Max M4X WW]

Not on drugs/

[andyhardy]

Brakes look good my little leopardskin pant wearing he-behatch!

[Capri]

wow!

not been keeping up with this but just popped in now, and am seriously impressed at the amount of work going into that car! thinking back to the way it started, I'm amazed at the progress and at just how awesome things are looking Top notch, well done!

Keep it up - and good luck!

[heeman10]

scarlet_pimp_nob_mile - They just keep crawling in the side of the shots, I tell ya! Doesn't everyone else do their car work in the nude?

Max - Back to the rehab centre with you!

Capri - Thanks for that Yeah I've been working fairly long hours on it for this one week. I haven't got to where I hoped to, but I have done quite a bit. Now it's a case of getting all five uni assignments done early so I can get a Friday-Tuesday stint in during term time! It does seem hilarious, and very rewarding looking back at where it started from every now and then

Deflex gearbox mounts arrived today, along with starter motor wiring, big thanks to Rawli

Mandy - I think it's time for me to wear my "scared" face!!

[andyhardy]

Mandy - I think it's time for me to wear my "scared" face!!

As well you should James, as well you should...

[Captain Tightpants]

@ ECU,

Thought about repairing it mate?

You could salvage components from an XR2i ECU,

Probably easier to get a S/H ECU though.

Where did that one come from? Never seen one 'Blown up'!

Brakes look well sexy though mate!

Steve

[heeman10]

Steve - My main concern now is that if I get another, the same thing will happen. I've removed some wiring from the XR2i interior loom - e/w, c/l, b/r and the rear speaker wires, but would you expect this to happen as a result of that??? I thought about repair, but so many things on the board can be damaged by something like this, I think I'm best just getting a re-conditioned unit. Do NOT want to blow up a new one though.

Today's update anyhoo:

I had the charge carrier-to-ISCV pipe welded back where it belongs as standard, but it was a bit messy, and since I've decided to get the charge carrier chromed, I thought it could do with tidying up. So half an hour or so of patient file work's made it much neater.

Before:


After:


I thought...why stop there? So got rid of the heatshield/HT lead separator mounting stub, as that was just ruining the lines of the charge carrier, and I don't need it. The blob of weld on the bottom dog leg was messy too, so that was also attacked with files! The finished result:


It'll be getting a polish before chroming, so should look quite good afterwards

Fitted the new bushes to the ARB and new drop links, then fitted the ARB back to the car:


I know where the skinny hose goes, and guessed that the other hose ran between the top heater matrix pipe and the back of the thermostat housing...can anyone tell me where these two hoses go?




Will fit the FRST steering rack tomorrow, sort out dimensions for the gearbox cradle spacers I need to make, then clear stuff up so the Caterham trailer can be put back alongside the car.