fiestaturbo.com

[MFkev]

Heeman10's theme toon

That is a wicked tune!

If I had a garage I'd go listen to it in there

[heeman10]

Ian - The price I was asking was lower than it all added up to. I wouldn't expect brand new calipers to start rusting, but I'll bear it in mind when O re-trim my seats in pink.

xrsi James - The interior-engine bay plug was different on the XR2i loom, so I'll find a FRST one and be done with it. Gonna be very satisfying re-laying the wires and using Ford connectors for things like c/l and other bits I've put in myself

Matt - The driveshafts were never separated from the hubs, so they'll still be tight. It is an LSD box, I still don't know why it was grinding like that though. Good idea with nuts + cylinder = race won

Mandy - Will have to listen to that little song when back at uni in a few days

[Mikee_RS]

lookin good james


u done well this xmas

very well

looks good in ur bay

[FezzR]

Ian - The price I was asking was lower than it all added up to. I wouldn't expect brand new calipers to start rusting, but I'll bear it in mind when O re-trim my seats in pink.

the brand new calipers WILL start rusting, and in about a year they WILL be corroded.
if new calipers didnt rust how does virtually every car end up with rusty calipers

[heeman10]

You must buy cheap cars because none of ours have rusted

[FezzR]

i want proof

[heeman10]

Ok well it's raining like anything today, but will try to take pics of Landcruiser, Golf and Polo and Fiesta ST150 brakes to prove Southerners know nothing

[heeman10]

Well I forgot about your poxy brakes photo's, but my pillar pod came today after finally deciding to use one. I was going to have another pod made up to house gauges in the tray in front of the passenger, but I'd rather keep the dash tidy, and be able to see the gauges properly, so pillar pod it was.

Pillar pod, showing "new" steering wheel too. Boost gauge shopped in just for an idea of how it'll look, but my new gauges should be here tomorrow Excuse the mess!!!

[xrsi]

xrsi James - The interior-engine bay plug was different on the XR2i loom, so I'll find a FRST one and be done with it. Gonna be very satisfying re-laying the wires and using Ford connectors for things like c/l and other bits I've put in myself

you sure mate?

there is no extra wires to go into the car on a turbo!

its a common loom mate!

if your right then i stand to be corrected but i am 101% certain its not a diff interior loom for the efi cars as every extra plugs into the main loom (electic pack etc)

[MAD_Adamski]

xrsi James - The interior-engine bay plug was different on the XR2i loom, so I'll find a FRST one and be done with it. Gonna be very satisfying re-laying the wires and using Ford connectors for things like c/l and other bits I've put in myself

you sure mate?

there is no extra wires to go into the car on a turbo!

its a common loom mate!

if your right then i stand to be corrected but i am 101% certain its not a diff interior loom for the efi cars as every extra plugs into the main loom (electic pack etc)

i'm sure he's right heeman!!! honest as i was told the looms were identical just the engine looms differ...

[heeman10]

I think I need a better look at it all on a sunny day with a full stomach, preferably with someone who knows their looms Cheers for that though Jimbob.

[heeman10]

Well, after over a month I finally cleared my uni work enough to get home on Thursday night, and had Friday, Saturday and Sunday morning to work on the car Things had been coming in the post and mounting up a bit, so my bedroom was like christmas:



The Radtec intercooler:


Complete with fans:


Took the exhaust manifold off and wrapped it:


I don't know if others had the same problem, but I couldn't wrap the centre-right primary without the heat wrap looking a mess, and slipping at a later date, so I settled for a tight neat wrap missing out that small section.

Sprayed:


Before and after:



A view with the intercooler hanging loosely in place:


The idea of this weekend was to dummy-fit the cooler and see how things measured up. I maintained from the beginning that I didn't want an EVO3-style cooler that came out over the bumper or dominated the front of the car and took too much away from the standard front end, so it was a pity, when I'd been promised it would sit below the top face of the bumper, to see it look like this:


So the cooler's going back to Radtec with my own dimensions to place it exactly where it needs to be, and they'll make the radiator up at the same time. Hopefully have them both back in a couple of weeks

I decided to stick the new injectors in, and on removing the FRST blues that were in it, one of the four injectors was missing the rubber nozzle cap! Three options; didn't have one in the first place, dropped on the floor, or was now in the cylinder head/inlet manifold! I couldn't see it on the floor, so took the throttle body and inlet manifold off, but still no rubber cap. (It turned up on the floor a few moments later) The main discovery was this mess:


I had no idea the inlet-spacer plate-head was such a bad mismatch. There are far too many steps and diameter changes for my liking, so I aim to make my own spacer plate and port it to the inlet manifold.

This pic shows just one of the masked injectors, which get covered over by the gasket!


So a new spacer will hopefully allow me to correct some of these flow disturbances.

This pic shows the difference between the FRST injector and the Mustang injector nozzles:


And this is a pic of my new gauges, just stuck in the holes to get an idea of the look


It was good to do some more work on it, keep it all moving forward. I removed all the engine bay wiring loom from the diesel setup, and generally dismantled everything in sight in the end

And yes, the weather was as kind to me as usual -2 degrees plus whatever you add for having snow blowing against your back all day :lol:



Signed, a pretty happy James

[Max M4X WW]

Nice! Looking good. Wheres this other bumper i thought you had though

[heeman10]

In my sister's bedroom

[andyhardy]

Glad to hear there's been some more progress with it all mate - despite the weather!

[Andy.B]

Good good stuff, glad to see it comming along so nice. Any chance of sending that boost guage take off???? Wanna see if i have a fooked actuator as it seems to have developed a boost surge and no boost at times

[RS_Rawli]

looking good jimbo, need to have a word about something that may be in your interest

[StreetDragster]

looking good James!!

Mines on 400miles now, it'll be half way to run in by the weekend!!

Now i just need to get some Cosworth injectors for my management and it'll be low boost mapping soon

Thanks

Matt

[Classkeeper]

Looks good mate, hopefully be finished in the near future.

[FezzR]

nice one mate, nice you noticed the inlet
cylinder 3 branch of the manifold should be alright, short and direct flow

[t2rst]

james how much did it cost you to have the cooler made up do you think you can post the dimentions of it

id be interested in a cooler that doest need any chopping to be fitted

so am i right in thinking that mikee isnt building the zt in his car now or am i getting confused

nice progress


dave

[STOKE7UP]

Looking good mate and think i reconise one of those parcels hope its all good for you !

[heeman10]

Andy.B - I sent you a text when I got back yesterday or this morning. Spent forever rootling through piles and boxes to find you the minute bolt, even a boost take-off! So send your address and I'll post it off to you

Rawli - What was in my interest that we spoke about tonight?

Matt - That's great news! What flow rate/impedance do the injectors need to be? Might be able to save you quite a bit, just let me know

Ian - I couldn't really not notice that thing, things need to be done there!

Dave - The cooler they sent was their own FRST front-mount intercooler, which off the top of my head is 645mm long, 260mm high and 60mm deep, but they're not certain dimensions. They cost £325. It will need some material removing from the back of the bumper to fit, and some from the top so it'll sit around the cooler (if you get one like mine that stuck over the top, not sure if they're all meant to be like that ). Call Radtec, best way to get info etc, great guys down there

Mikee is still building his, just had a couple of hold-ups with some minor things, and MOT is the next step, plus he's pretty busy. That 270bhp animal will be on the road before too long though

[RS_Rawli]

Rawli - What was in my interest that we spoke about tonight?

no, something else i forgot to mention

[StreetDragster]

Matt - That's great news! What flow rate/impedance do the injectors need to be? Might be able to save you quite a bit, just let me know

Looking at Cosworth Light Blues at the moment, they flow approx 440cc, allowing 87hp each and should be around 2.3 Ohm's according to the Injectors.pdf Have you got something similar?

*EDIT- Just purchased some Light Blues, so thats fueling almost sorted *

Thanks

Matt

P.S 492miles

[heeman10]

Ah I won't find you some cheap ones then! Glad you've got some sorted anyhoo. Is it starting properly now? Get those miles racked up!

[StreetDragster]

Yep, starting fine now, turns out it was just the engine being tight and this was overcoming the battery. Now its ran some miles put on the engine it starts every time, although the heat wrap and heat shield have definately helped it.
Its very smooth when running, until i apply a little too much go-go pedal and the jerking starts as i'm still on standard FRST management with no TPS! But soon the Secs will be the saviour

Needs a CV joint, hub and wheel bearing now though Bloody car

Thanks

Matt

[heeman10]

Good news about the tightness being the problem then, and yeah, I'm sure the heat wrapping and heat shield are an added bonus! Why the wheel bearing etc?

I had a quick look at the inlet arrangement tonight. The uni work's creeping back up again so just a quick dabble:

Current position:


Right port and left port:



The pic above shows the progressive overlapping into the injection spray path. By re-designing a spacer this overlapping should be almost eliminated:



And the right and left ports as they should sit with the new plate:



The current spacer plate has been machined so its ports match the CVH manifold ports. I aim to make the spacer plate's ports an intermediate size (ie between the manifold port size and the head port size) and will then port the spacer plate holes to match the head and manifold respectively, if that makes sense?

I drew up a very quick, rough idea of the plate just before, but this will be altered quite dramatically. Also, the current one is made of cast aluminium, and I feel machining it (possibly having it laser cut) from billet ally would be better in terms of thread tapping and porting.

Anyway, the very rough first idea:


So it will probably take about half an hour on CAD after measuring everything up and sketching out the concept, and then it'll be a case of calling laser cutters to get a price, then down to me to port and blend it all to match up. A worthwhile process altogether in my eyes

[FezzR]

anyone ever looked into custom gaskets?

[heeman10]

Yeah I tried to get people to make one for the TDI but they kept snubbing their noses Would be fairly easy to do but TBH a new spacer plate's the best option here, as I can get the port shape changes to match as well as making the gasket sit properly

Forgot, another update....brake discs are ordered so should have my full new brake setup before the middle of March Does anyone know where I can get plain discs grooved?

[rich_frst]

quality james!!! totally forgot you wre doing this!!!! keep updating us with pictures mate.....

rich

[heeman10]

I forget sometimes too Rich, it's so long in between visits back home. Open the shed doors...and OMG WTF is that in the engine bay?! Oh yeah, I put that there ages ago

[StreetDragster]

What about changing the inlet?
Maybe to an 1800 Zetec inlet or the Rover one?

Wheel bearing thing went like this,
1) Matt forgets to tighten up hubnut
2) Grinding sound heard then felt
3) Wheel inspected, found wheel bearing absolutely shot beyond belief, the cv joint had made contact with the hub carrier
4) Matt smacks forhead and lets out an almighty 'Doh!'
5) New wheel bearing fitted and hub retightened, new grease put in joint
6) Loud knocking sound now heard from RH corner, goes away when steering slightly to the right, suspect knackered CV joint and i'll replace the hub just to be sure

Moral of the story, check those hub nuts!!!

Thanks

Matt

P.S I'm you can PM me that injector stuff anyway, i may be able to use it on another project of mine

[heeman10]

That's an interesting little story! I'm happy using the current inlet setup, and don't have the time to fiddle around with changing it all over to be frank, plus I'll enjoy making up a good spacer to improve things

PM on its way!

[heeman10]

Random fairly boring update. Radtec will have the intercooler back on Monday or Tuesday, and I think they know just what I need now. Pics of the cooler on the car from last weekend:





Those are the pics I sent them. When the cooler's lowered there will still be around 35mm of space below, so I've asked them to stick another tube or two in the cooler.

There is enough room for a 535mm wide radiator, which is nice and huge, considering the GRS "Extra Large" radiator is 520mm wide.

Wilwood brake discs are now on order, as are PU ARB "race" bushes.