fiestaturbo.com

[Excursion]

Excellent post, always nice to see a bit of R&D in progress!

[fiecos dan]

Cheers lads...

What Kent springs you are using?

i also thought the sprongs could be a reason why some CVH's dont rev.


i was using Kent 35 cam kit springs, but they are 35k miles old, so most prob very weak.

[fiecos dan]

Update.


1-03-07


- My new modified RST ex mani fold is finished, flowed, refaced and painted
- My T3 turb has been flowed, checked over, modified in a few places for ease of removal once fitted, and painted.

The manifold mod's i have carried out have relocated the turbo
-slightly closer to the alternator by around 5mm,
- closer to the engine, so more room to the rad, between 10.5-20.5mm at different corners of the turbo flange face, with a Ave of 15.5mm in the centre of the turbo flange face.
- the turbo has also been leveled out slightly, where i have raised the exhaust side higher, and the comp housding lower.

The total cost/time spent on the Turbo and mani mod's are about 15-17 hours, £75 in costs alone.





12-03-07

- The new mani and turbo is fitted, and airfilter, and boost pipes have been modified to suit the new turbo.
- I've fitted a boss on the manifold side of the turbo, so i can check the egt's and back pressure before and after the turbo.
- i've started making flange plates for the new exhaust.
- I resprayed the inner wing, after the welding i done @ xmas time.
- i removed the sump, to replace the gasket, but i got abit carried away, as i do. And ended up spending today, designing, making a new baffled sump, and i'm very happy with the outcome, pics to follow.



Some pic's.



Std RST mani and my new modified rst mani.

















And this was my old T25 setup.

[siesta]

gotta say just total respect.....your got some nice cars there mate

[BUTRE]

I was hoping that you were going to design a new ex manifold


After welding the ERST manifold you gave it any heat treatment to prevent cracks next to the seams?


Also, do you know how stiff are the valve springs that you use (from the CVH35k cam kit)?
I've found on a website that std ford ones are 220 lbs at full lift... full lift of std ford cam I guess (going to measure my cam to know how much lift this is).

[Choosey]

Just read this from start to finish and it's been an amazing read! I won;t deny that some(read most ) of the info has gone over my head and even without pics(restricted net at work) it's been very interesting!

Can't wait to see these pics when I get home. Keep it up!

[fiecos dan]

gotta say just total respect.....your got some nice cars there mate

Just read this from start to finish and it's been an amazing read! I won;t deny that some(read most ) of the info has gone over my head and even without pics(restricted net at work) it's been very interesting!

Can't wait to see these pics when I get home. Keep it up!

Cheers.

After welding the ERST manifold you gave it any heat treatment to prevent cracks next to the seams?


Also, do you know how stiff are the valve springs that you use (from the CVH35k cam kit)?
I've found on a website that std ford ones are 220 lbs at full lift... full lift of std ford cam I guess (going to measure my cam to know how much lift this is).

Yeah it got treated.


i dont know about the spring rates.

[fiecos dan]

12-03-07 Some pic's of my new Baffled sump.













New down pipe been made on sunday, (18-03-07).

i've made it to fit my magnex system for the time being, as i wanted to check the differences from the turbo and mani change only, then i'll make a full 2.5" system.

Also fitted sump, and made a polished alloy alternator heat shield.




Some pic's


My New St/St down pipe













My new Alternator heat shield.









And the engine bay all back together. Now with T3.

[fiecos dan]

The xr2tt back on the road and M.O.T'd. as of this morning.




Things i done yesterday.

- sorted a gear oil leak, and replaced the o/s gearbox oil shaft seal,
- replaced both o/s cv boots and all boots cable ties, and re greased both o/s joints,
- refilled engine oil and gear oil,
- welded the fuel tank, leak cured,
-Underbody sealed under the front inner arches, seals, floor pan and rear end,
- cut, modified and strengthed a std xr2 fan to fit.
- Mot check over.


Stuff still to do.

- Dash off, replace broken items, heater matrix replace, water leak, and new gauge pod/placement
- New inter cooler and Rad setup with new fan
- Newmans Cam kit
- body work sorted and resprayed.

[fiecos dan]

Been out in the TT tonight.

with 11 static timing.

- With bleed tap fully in = hit 9 psi, hold 7 psi @ 5300 in 5th,
1650 oF EGT's before turbo, 15oC ACT's, with 11.5:1 AFR
-Tap = 2 turns, 14psi @ 2500+ rpm, 1650 EGT's, surge at 2000ish rpm.
-Tap = 3 turns, 8 psi @ 2250rpm, spool up 2300-2500rpm, 19psi @ 2500rpm, boost flickering between 16-19 psi = 2500-5300rpm in 5th (think i have a bost leak somewhere), No det, and 11.9-12.2 in 5th gear 4000rpmto 5300rpm.
- Tap = 3.5 turns, 2500rpm = 20psi = surgeing
- Tap = 5 turns, 2500rpm = 25psi = massive surge, poping and banging.


So outcome,
T3 turbo-
ACT's are the same, for same boost/ambients,
spool up is mega improved, but it dont feel very fast and boost is flicking above 15psi, so think i have a boost leak, which i will sort this week.
It dont feel very fast, but that could be either the boost leak/issue or that the turbo isn't producing the power my old T25 was.

Cut down fan-
Its enough to stop it cooking, but doesn't cool the temps, just stops/slows it from raising

[Brammer]

19psi @ 2500rpm, boost flickering between 16-19 psi = 2500-5300rpm in 5th (think i have a bost leak somewhere), No det, and 11.9-12.2 in 5th gear 4000rpmto 5300rpm.

That must be quite impressive what sort of power and touque do you estimate at this level dan??

[fiecos dan]

Hi


at the moment about 190 bhp, lb/ft.

with a new cam i will be looking for 200 bhp @ wheels, and 200 lb/ft.

[Project_XR2i_Trackcar]

Hello mate

bloody good effort there, on both accounts. I am impressed.

I've only very briskly flicked through the whole thread so I'm assuming you do all the fabrication yourself. If so, would you be prepared to fabricate a baffled sump for a zetec and if you can, what would you charge for doing so?

Cheers
Chris

[fiecos dan]

Hi, cheers.


i can do baffled zetec sump, matters what you want. i have done 3 before, but they had a tight budget, and they were £100 each.

But i can do anything you want.

if your intrested, pm me, and i'll sort out some pic's.

[Project_XR2i_Trackcar]

You've got a PM

[fiecos dan]

Reply'd.

[bakewell001]

Excellent stuff mate

[heeman10]

Exhaust manifold looks handy, and that downpipe is very tasty indeed! Intercooler, radiator and bodywork sorting will be very nice treats I'm sure, and I'm pleased to hear you've sealed some of the underside - long live the Mk2!

[fiecos dan]

Cheers lad's.

[666ellis]

love that fiesta cossie seen it untold times in mags did it take u long to build?

[fiecos dan]

cheers,

it was built originally in 2000/1, and been a changing project since.

[fiecos dan]

No work been done on my cars, but here's


some pic's for previous updates.

Modified std xr2 fan to fit new tight gap, due to T3.






My fuel tank.

[fiecos dan]

I've brought a new ignition system for the xr2tt.

Which will enable me to set the timing alot more advanced in most area's.




On the 26-03-07 i wrote this,

So outcome,
T3 turbo-
spool up is mega improved, but it dont feel very fast and boost is flicking above 15psi, so think i have a boost leak, which i will sort this week.
It dont feel very fast, but that could be either the boost leak/issue or that the turbo isn't producing the power my old T25 was.

Spent an hour on my TT tonight, 1st time i worked on the TT for a month or so, as i havent had the time to drive in, let alone work on it, so all the teething problem of the T3 hadn't been looked at.

But today i've sorted the boost issue, and now it hit's 18psi and holds it.

[heeman10]

What was the boost issue then? You can't say "sorted it" without telling us what it was!

Which standalone ignition timing module do you have? Any pics of the unit itself and its operation/adjustment?

[fiecos dan]

Slight unsmooth Wastegate movement. weren't even sticking, just abit notchy at one point,

free'd it up, by playing with it for 5-10min's till it was smooth, then lube'd it with WD40.


When i say the boost was flickering, i mean fluactuating (sp), where it will be flicking between 18psi and 10psi, so the car was surgeing forward at 18psi, and i could pysically feel the difference in power as the boost was fluactuating.


The ignition system is a Micra Dyamics EMS 5.

http://www.demon-tweeks.co.uk/products/ ... de=LUMEMS5

[heeman10]

Well done for picking up that wastegate issue, I'm not surprised you felt it surging, dropping and finding 8psi!!

What exactly does that ignition module allow you to do? Increase/reduce the advance by a certain increment across the board? That DT write-up didn't describe it too well!

[fiecos dan]

it runs off a boost switch, and uses my std dissy advances, but trims it to what its been set up too.

- it then once on boost retards a set degree (0 - 3.5' per 1000 rpm)
- and then its got a readvance rpm (after det threshold), and then it starts to advance (as set amount).
- and its got a rev limiter too.


Here's what ignition timing i'm running now, and what it should be running once the new setup is sorted.


RPM = B4 ign -----New ign = boost

1000 = +12' ----- +8' = -10psi vacum
2000 = +18' ----- +18' = 5psi boost
2500 = ---0' ----- +11' = 20psi
3000 =- +2' ----- +13' = 19psi
4000 = -+6' ----- +15' = 18psi
4500 = -+8' ----- +10' = 18psi
5000 = -+9' ------- +9' = 18psi
5500 = +12' ----- +12' = 17psi
6000 = +14' ----- +14' = 17psi
7000 = +15' ----- +17' = 17psi

This is using a different dissy i have (tt) with 3.5' retard every 1000rpm,
and re advanced at 5000 rpm (this is done in %, so i sort of estimated it,
as dont know what its a percentage of, if its 3.5' per rpm, of amount its retarded @ last retard = 5000rpm). so i averaged it out.


As you can see its not ideal, but alot better than before.

[heeman10]

2500 = ---0' ----- +11' = 20psi
3000 =- +2' ----- +13' = 19psi
4000 = -+6' ----- +15' = 18psi
4500 = -+8' ----- +10' = 18psi

Those are some major jumps to be making! It's only running 0-8' advance from 2,500 to 4,500rpm at the mo?? Man, it's going to wake up enormously, surely???! Any chance of power graphs with it activated and de-activated?? I'd be really interested to see those!

[fiecos dan]

could do,


but that would take about half hour to do,

i'll have to see, when i'm ready to do some testing on a set of DD Rollers.



At the moment, those figure as quoted are all on boost figures, off boost they are between 15 - 30 degrees more advanced, matters on manifold pressure/vacum.
At the moment i'm running my own modified dissy, with different advance wieghts, and a boost retard capsule, that retards 19' 's @ above 17psi boost.

[heeman10]

Do you often hire DD rollers for your own testing purposes?

[fiecos dan]

Do you often hire DD rollers for your own testing purposes?

i have donw before, and plan on doing it again in a month or so for the TT.

i just pay for 2-3 hours hire or a operator and DD RR, then do what ever run's i want to do.

[heeman10]

Nice to hear of private "tuners" doing so Is Surrey Rolling Road the nearest Dyno Dynamics outfit to you? Stick up any results you get, sounds like a potentially experience-altering change coming up!

[fiecos dan]

Well i think it was,

but now there's Torque of the devil, and ATP.

So i'll have to speak to all 3, to see whats best for me.

[868999879]

any updates on the cossie mate ? a mate says you should be slapped silly for fitting two exhaust pipes :lol: :lol:

[fiecos dan]

There will be a update coming up in next few weeks for the cossie.


but yesterday i checked the geometry on the fiecos.


Front,

Toe = 2 mm toe in total,
Camber = 2 degrees (just under on o/s, and just over on n/s),
Castor = 1 degree on n/s and 3/4 degree on o/s.


Rear,
Toe = 1.75 mm toe in total,
Camber = 1 degree n/s and o/s


So i want to add alot of castor on the front, and add some camber on the rear.






As for you mate, he hasn't seen it spit flames out from both zorst's on Trackdays. So give him a slap back. lol