fiestaturbo.com

[868999879]

lol is it the psg kit or another kit, i presume the metal between the wide arches and the engine bay has bee cut away for wide wheels ?

[fiecos dan]

Yeah its a psg full setup.

the original metal outer arches have been modified alot for clearance.





Sold the turbo off the xr2tt yesterday.



i fitted a slightly modded std T3 today,
but will be going stg2 or 3 next.

[fiecos dan]

Striped cossie engine tonight,

its spun No 4 big end,

So needs another rod, and crank.


not sure if will just do that, or do a full rebuild. will sleep on it.

[fiecos dan]

Been working on the Xr2 to get ready for the TOTB qualifiers for PF.com and FF mag (was meant to be in cossie, but run out of time)


Fitted a 2wd cos turbo with cossie 0.48 bolt ex housing today.

Had to

Spin the housing, drill and retap 7 snapped bolts.
modifie actuator bracket,
modifie the down pipe.
i also flowed the ex housing,
and welded a new lambda boss and EGT boss in Down pipe.

Went out in it, and it does pull well after 3500 rpm.

as i didn't have my det cans fitted, i set the boost at a safe 15 psi,

Heres boost/rpm for my last 3 turbos fitted, on on the same engine, cam, ignition and fueling.

-RPM = Hy t25=T3stg1 = 2wd T3
2000 = ------ = 05psi = 1.0psi
2500 = 07psi = 16psi = 5.5psi
3000 = 9.5psi = 15psi = 10psi
3500 = 14psi = 15psi = 14psi
4000 = 15psi = 15psi = 15psi
5000 = 15psi = 15psi = 15psi


Also the EGT's have dropped slightly as on the T25 = 1480oF, and 2wd t3 = 1400oF






I also fitted my new Kent 35 cam last night, along with new springs and anti pumps,
It now rev's to 7000 rpm.




but to compare the xr2 cam to the 35, on same 12' ign, and boost controll setting.

@ 2500 rpm = both the same @ 5 psi,
@ 3000 rpm = xr2 = 10 psi, 35 = 8 psi,
@ 3500 rpm = xr2 = 14 psi, 35 = 12 psi,
above 4000 rpm both = 15 psi.

it now rev's to 7000 rpm, but isn't pulling to great, think its due to the boost problem.(see below)

I then went to raise the boost. but i hit a wall, a leaky wastegate seems to be hold boost back.

with a -31 and pipe diconnected, this is all the boost i could get.


2500 = 5psi
3000 = 10psi
3500 = 17psi
4000 = 19psi
5500 = 21 psi.

seems like the ex housing cracks are causing this. Nothing i can do, till another housing is sourced.



But i was out early this morning testing before i went to work, and i slightly cooked the engine, (header cap slightly loose, and droping 2ltrs) and might of caused the H/G to start letting pressure into the coolant.

So i'm just going out to check it. if its good,

i need to fit a new ign system, map it, rejet the carb, fit a coolant gauge.
clean, pack. So lots to do.
_________________

[fiecos dan]

Some pic's of the cossie, and engine








Xr2tt, new turbo, downpipe and cam.

[heeman10]

Remind me what went wrong with the YB Danny? I hadn't noticed the air injectors before And what are you going to be changing about its spec over the course of the rebuild?

Good job you're not running water through the XR2's turbo The silver paint doesn't half tidy things up though, it lasts pretty well too, if you don't touch it!

[BUTRE]

At least this happened heeman

Can the cossie crank can be regrinded? I know evo crank's can


It will be running in no time

[heeman10]

I can see the big end bearing's been lunched, yes, but I wondered why, what other damage was caused, and in what way the engine is being improved when he rebuilds it.

[fiecos dan]

Some cossie 200 blocks suffer from oil starvation @ 7800+ rpm.

and on the night it went, i was mapping it @ 8000 rpm, when i siezed on let off.

Its spun the shell, and took the crank and rod with it.

i'll be fittin another crank in her.



Mod's at the same time of rebuild,

New inj's, inlet, might do some turbo mod's, new inter and rad.

[andyhardy]

Shame to hear about the Cossie Dan, but at least work on the XR2TT is progressing

Is there anything you can do to prevent oil starvation on the YB block in the future?

Andy

[heeman10]

Is there anything you can do to prevent oil starvation on the YB block in the future?

My question also.

No other damage bar the inner faces of the shells, the crank and rod then?

[fiecos dan]

The block will be modified for oil flow, and no other damage done.

[fiecos dan]

Update on Cossie.


Engines completely stripped.

- i stripped the head and cleaned it this morning before work, and droped it off to be skimmed, which has been done, and i collected tonight. Was 138.42mm ave, but now 138.20 ave.

- The crank is at its 2nd engine machine shop, As the 1st one, (that i usually use) wasted 3 days, and didn't bother telling me to i chased, even tho they knew it was urgent to get done in 2 days before i took it there.
Anyway, it should be 'ground' for tommorrow night, and shells will be ordered to suit, allong with new piston rings.

-The clutch had killed itself, along with the flywheel, so i had the flywheel skimmed 1.8mm, which now is 24.6mm thick. (std is 27.6+mm)
The clutch was sent off to Helix, to get refurb'd, but They said the cover and paddle wasn't worth it, so brought a new kit.

- The Dome plated front diff was sent to Dennis @ Dome, and It also has seen better days. It was meant to be fresh from a rebuild when i brought it off Some Pikee bloke called 'Pete Roberts' (named to shame),
Dennis said its had a hard life before i got it, and there was no way he's looked at it for a fair few years.
And told me its one of his 1st 10 plated cossie front diff's and is about 10-13 years old.
Anyway the good news is the 909 thick wall housing, crown and pinion are all good.
So he's gonna fit new plates, and get the cracked inner housing welded, and believes it should drive like new.
And thinks the cracked housing with the worn plates was causing the plates to twist and lock, which could be the reason my car like to swap ends under engine breaking.

- Also got a new transfer box chain comin from fords, which will cure the issue of it jumping.



Hopefully, i should have built the engine over the weekend, then i'll be waiting on the chain and diff to come back early next week before, refitment.


i have new 1000cc Rochestor injectors coming from USA, but they are f-cking me about for the time they said before i paid.

New Sealey electronic det cans comin, to aid the det checking, as the Dog box really makes it hard.

The new inter should be coming in the next week or so for a trail fit, along with new rad.

[fiecos dan]

Got few more parts thro in the last 2 or so days,

new tranfere box chain, shells, seals, piston rings, Alt belt,

also got crank back all ground and polished.


All i'm waiting on now is my Front diff to come back, 1000cc inj's and Det can's. New Rad and trail fitment intercooler should be here on Tues.

Start doing the engine build tomorrow morning.


Been out in garage tonight, and have design'd my new Front ARB adjustment setup for Castor adjustment, using modified 4wd ARB, with 2x insitu adjusters

Should only take me 3 hours at most, then another hour or so to set the castor. Which should aid the handling no end.

[heeman10]

I hadn't seen the last update - sounds like it's going to be a completely different car when you have it back in one piece and running hard again! Sounds like a flipping costly month or two

[HCS PIMP]

i like alot especially the cossy engine nice i would say that is my dream car made real

[fiecos dan]

Cheers guy's.


Yes, a very expensive week, and got insurance to get yet.

[MAD_Adamski]

saw someone's fresh cooler today too with the new magic core

[fiecos dan]

You been up @ Alex's then?


anygood? should be getting it in next day or so.


Get a update to do, but will do when abit more time.


But cut a long storey short, i wont make TOTB, but should be at Ford Fair on the FF mag stand.

[MAD_Adamski]

it looks nice mate the new cores look amazing ...

my stuff will be done in the near future as theres no urgency as mines goin in for work so not being driven... but the new stuff will be on mine when they have time to swap them over

there gonna be designing my fuel tank next i think and my air box

[fiecos dan]

Recieved the Rad and inter today.

Not put it near the car yet, as just got home from work, but am going out there in abit.


Also Headgasket on Xr2tt has finally let go fully. So that needs sorting before cossie. so gonna be pushed to be fully setup for FF.

[MAD_Adamski]

Recieved the Rad and inter today.

And don't they looks the dogs dangly's

[fiecos dan]

to be honest they arent as good as the 1st one's.


The rad needs going back as Alex forgot to put mounts for my turbo rad on it, But will trail fit them 1st.

[jimmyesh]

Crikey some SERIOUS work going on here!

Impressive stuff, can't wait to see that cossie animal

[nathfez]

love both cars especially the fiesta cossie! that is my dream car
and i will own one no matter how long it takes! top class cars mate

[MAD_Adamski]

to be honest they arent as good as the 1st one's.


The rad needs going back as Alex forgot to put mounts for my turbo rad on it, But will trail fit them 1st.

think thats down to the fact that lars and martin does the welding normally and alex only does it occasionally and i believe alex welded them alex should have got alars to do it really but they will be more than up to the job trust... these new cores are meant to really work

[fiecos dan]

Cheers lads,

Cossie

I recieved my new Cosworth oil pumpo yesterday, and brought some LSD gear oil for my plated front diff. will proseed today with engine.


Xr2tt

Headgasket has been replaced, i fitted new non strench bolts and Payden rst gasket,
the old gasket (8months old ford rst item) had failed water ways around 1 and 4 bores on both head and block faces. (due to me cooking the engine last month)
The non strench bolts i replaced were 6-7 years old, and had be re torque'd a good 25-30 times on different specs, so thought they have had better times.
I also checked the Kent cam, and there isn't any bad wear.




Adam,

Yeah i know Alex welded tham, and i think Lance done last ones.

The worst point in right on eye slight at the top front of the inter. i might re weld it myself as i want it looking good.



Lets hope they perform, , as i'm having to chop the car big time to get them the inter to fit,
as the new inter is Alex std design with my mounts, where before i designed the end tanks to fit my car.

[MAD_Adamski]

next time ask for lars to do it ignore alex , but yes these flow about 20% more should be looking to cope with about 800+hp which in my eyes is plenty for the likes of us

[fiecos dan]

Be honest, the welding was better on 1st one, but the amount of times it went back due to not being as i drawn.


matters on insulation, and what ACT's you call ok, and how the ACT's are measured.

but i dont think it could cool enough for 800 bhp, might flow, but not cool.

[fiecos dan]

update.

i'm weeks behind on the cossie, but the last 2 weeks, i havent been bothered about getting it running, and gonna do it in my own time now.


Cossie,


- New 1008cc Rochester injectors have arrived.
- Cossie crank is still bent, so need to source another, or strip my spare std 4wd engine i have, and rap it of its crank.

Crank issue's and checks i have carried out.

i CC checked the piston and bores, and due to the cc's being out, i checked the stroke of the crank.

No 1 = 77.15mm stroke = 8.33 c/r
No 2 = 76.81mm stroke = 8.16 c/r
No 3 = 76.68mm stroke = 8.13 c/r
No 4 = 77.34mm stroke = 8.52 c/r

I then checked the stroke whilst taking up the play in the big end shells,
and pushing the piston down whilst @ BDC and pushing the rod up @ TDC.
and it added 0.04mm onto No2 stroke, and similar to No4's stroke.

i was adviced checked the flywheel for trueness, so i did this morning,

it runs +/- 0.1mm out on the diameter, and +/- 0.30 on the back and front faces.

At the point its -0.1mm on the hieght its +0.3mm on front face, and -0.30mm on back face
At the point its +0.1mm on the hieght its -0.3mm on the front, and + 0.3mm on the back face

Which shows it has bent, and even if the crank has been straightern'd on the grind, the flywheel face hasnt.





xr2tt


Boost test on new turbo on xr2tt.

4wd T3, with cossie .48 ex housing. 1.6 turbo, 35 cam, P+F head. Reno 5 carb, and very retarded xr2TT ignition setup.

With 9psi actuator, on 10mm preload, and actuator pipe disconnected.

2000rpm = 2psi
2500rpm = 5psi ------ 5psi
3000rpm = 10psi ---- 10psi
3250rpm = 18psi
3500rpm = 24psi -----17psi
4000rpm = 22psi -----19ps
5.5-6rpm = 19psi -----21psi


boost on right is my last 2wd t3, with alot more crack's in the ex housing.
from 14-6-07, all the same spec, and test was done in same way.


Then i fitted a spare -31 actuator and done same test.

@ 2500 rpm 8psi,
@ 3000 rpm, hits 12psi then slowly builds upto to 20psi,
@ 3500 - 4000 rpm 28psi.

[HCS PIMP]

lol problem after problem well worth for when ur finished if even again i love ur car

[jayrs]

got it sorted yet mate?

[fiecos dan]

Cossie's not been touched in a few weeks, and it wont for at least another 2 weeks.

[jayrs]

how come

[jayrs]

how come