fiestaturbo.com

[Excursion]

Thought this CR was too high all along mate, sorry it ended up like this. Personally I would spend some time on the head and adapt it to your inlet, there's more than enough on the inlet face to do this.

Bores should be fine, just hone them.

Good luck with the rest

PS seems a shame to fit that awful FRS Log manfold to this nice engine!

[StreetDragster]

piston looks cleaner, are you sure that injector of that particular cylinder is firing ok or an air leak? Too lean mixture maybe, it would be shame to fry next piston too... What about spark plugs, are they all ok?

Hi Mate,

Car seemed to run fine, even made good power on the rollers! The spark plugs look ok, maybe a little discoloured but i assume that would be due to that cylinder not running correctly due to the missing piston section. Injectors are all new and have been flow tested by Ford when dispatched, but i'll check them before fitting the new piston.
Air leak, hummmm, don't know if it had one of those, most of the stuff has been stripped down now unfortunately

Thanks

Matt

[Captain Tightpants]

It looks almost like an impact wound in the photographs to me. Has the piston actually melted then??!

Steve

[StreetDragster]

Thought this CR was too high all along mate, sorry it ended up like this.

Do you think its due to high CR ratio? According to the spec ont he pistons they are designed for turbo applications at 8.2:1 compression ratio, surely if thats what they are going to quote then it should be strong enough. Anyway, doesn't matter now, i won't be using them again ever, i'm just lucky that more things havent been destroyed by it! Arias all the way.

Personally I would spend some time on the head and adapt it to your inlet, there's more than enough on the inlet face to do this.

Got plenty of time now whilst waiting for the rod bolts so i'll probably do that

It looks almost like an impact wound in the photographs to me. Has the piston actually melted then??!

Steve

Doesn't look like it, when i looked at the piston close up and the head too, it looks like the bit has broke off the piston for some unknown reason, then been battered about in the bowl between the top of the piston and the head. I'll check the valve arn't bent and relap them in too.

Thanks

Matt

[Hartza]

Did you actually calculate CR for this engine? Those pistons were imported from US, am I right? I mean if the head has beem skimmed earlier or the pistons CH is too high, this might happen...

[StreetDragster]

If i'm honest, nope, i didn't calculate my exact CR, i didn't want to waste a gasket getting the compressed thickness and i had bined the old one in error.

I'll learn from this mistake! Although i still think that it may be a dodgy piston rather than high CR/Det damage, but i'll find out once its out of the block.

Thanks

Matt

[Excursion]

If i'm honest, nope, i didn't calculate my exact CR, i didn't want to waste a gasket getting the compressed thickness and i had bined the old one in error.

I'll learn from this mistake! Although i still think that it may be a dodgy piston rather than high CR/Det damage, but i'll find out once its out of the block.

Thanks

Matt

Looks that way mate, but also there are small det marks around the top of the piston. It's a bad crack anyhow, so demoralising having to build an engine up again!

The Arias pistons should have a nice smooth bowl, none of those sharp lines that can cause det

[StreetDragster]

Looks that way mate, but also there are small det marks around the top of the piston.

Don't suppose you'ed mind anotating my picture to show them? Just so i know if i see them again

There's a few marks on the other side of the cracked bit that appear to be due to the piston bit getting mashed between the head. COuld be wrong though

P.S One more post for me, and i may become an 'Elite Post Master' wahoo.

[Excursion]

The rough, crumbly like edge to the piston is typical of detonation. Also mate, is it me or have both 2 and 3 come into contact with the head?

[StreetDragster]

Hummm, not sure, pretty sure 3 was the only damaged bore. I'll check when i'm home tomorrow

Thanks

Matt

[mrviper]

how far below the deck is the pistons on tdc?

and how much meat was there between the 1st ring and the top of the piston

could it posibly be detonation when mapping the engine?

[StreetDragster]

Engines now back out. Got one of my mates round to have a look at the pistons, he's a lecturer at the local college for motor vehicle technology and stuff. The current opinion is that it wasn't detonation that took it out, you cant see it very well in the pictures but the top of the third piston is bent in towards the sump a little bit. Also, the flat edges at the front and back of the pistons are actually higher that all the other pistons faces when put to TDC.

So the theory is, that number three got really hot for some reason (Unsure on cause) but it bent inwards, caused a fracture around the valves, which then broke off and got mashed in the chamber, inbedding in the piston. The little pitting marks appear to be impact rather than detonation marks apparently.

So, not sure why the third bore would get hotter than the rest, the injectors are new, coolant level and mix was fine, water pump was ok, mapping should have been fine etc etc. All will be rechecked before refitment to prevent it happening again.

On a side note, the bonnet looks like it's goingto be modded by either grafting on a Peugeot 205 Auto bulge, and keeping the RST vents, or by grafting on a Delta Evo bonnet bulge and loosing the vents (Assuming i can find a doner bonnet!) May be off the road for some time now though as i source the finiances to pay for the bottom end/turbo/ancillaries.

Can anyone baffle zetec sumps?

Thanks

Matt

[heeman10]

Ask Paul Dunnell about the baffling thing, and Ian Howell of course. Ian's probably going to be the best to help isn't he?

With regard to the piston....my first port of call would be the conrod spray jet. If that's blocked/missing or not working for whatever reason, that would cause big heat build-ups.

Are you looking for a bulge to give clearance or airflow? I'm on the lookout for a vent (Delta Integrale vent looks one of the best so far) to allow the exhaust/turbo to expel heat straight upwards when at a standstill.

Really gutted yours has turned out this way, it seemed sure to work well. Still, like I keep saying, it's good to know you'll have big, easy-to-make power Did I tell you my LSD packed in? The box is being dismantled tomorrow, and I'm finishing off the interior while that's being done. Once the box is done and in I'll MOT it and see when MSD can squeeze me in. I'll pop round when it's mapped anyway if you're in, and will drop off your fan switch adaptor

[StreetDragster]

With regard to the piston....my first port of call would be the conrod spray jet. If that's blocked/missing or not working for whatever reason, that would cause big heat build-ups.

Ah yes, good thinking batman!

Are you looking for a bulge to give clearance or airflow? I'm on the lookout for a vent (Delta Integrale vent looks one of the best so far) to allow the exhaust/turbo to expel heat straight upwards when at a standstill.

Both, i want a bit extra clearance between the crossover pipe and the bonnet as i'm paranoid, but also i want to expel heat. I was thinking of cool louves, but they are pretty expensive for what they are. the integrale one looks great for me, but having looked at a few pictures, it looks like only the 'Evo' ones have the bulge, which i imagine will make the doner bonnet Very expensive!

Really gutted yours has turned out this way, it seemed sure to work well. Still, like I keep saying, it's good to know you'll have big, easy-to-make power.

Poo happens is my view on it, you don't learn by getting people to do things for you!

Did I tell you my LSD packed in? The box is being dismantled tomorrow, and I'm finishing off the interior while that's being done. Once the box is done and in I'll MOT it and see when MSD can squeeze me in. I'll pop round when it's mapped anyway if you're in, and will drop off your fan switch adaptor

Think you did on the phone, but i'd had a few shandys and cant quite remember what we talked about Gutted mate, not fun or cheap to service diffs Cool, see you soon

Thanks

Matt

[heeman10]

There are a few aftermarket Delta vents, but I think the only ones I've found so far are the grille types (which is what I'm looking at) and not the bulges. They could be out there though Shandies

[StreetDragster]

StreetDragster.com Zetec Turbo Built Guide Updated a bit, page two added

http://www.streetdragster.com

Thanks

Matt

[heeman10]

Good stuff, just had a read through it all. I so wish I'd gone the Ian Howell route now too Want to go halves on a small wall to bang our heads against?!!

Did you ever find out if there were any problems with the oil spray jets on the conrods?

[StreetDragster]

Cheers

My brothers a brick layer, we could get one built on the cheap!

I didn't, but i'm sure if there is, Ian will spot it and let me know when the engines ready

Thanks

Matt

[heeman10]

Cool, you get the wall built, I'll supply builders' helmets for health and safety

[StreetDragster]

If your thinking about DIY'ing a Zetec Turbo i wouldn't bother, go and see Ian Howell and do it right first time.

List of damaged parts that need replacing due to the piston 'accident' now include-

Oil Pump
Big End And Main Cap Shells
Crank

Tw@ting ferking engines. Luckily for me i have a crank that has done jsut 30 miles spare, or that could have been mucho expensivo.

Thanks

Matt

[heeman10]

Tw@ting ferking engines.

But you're so right! I forgot to mention to you....about the CTS in the front/bottom of the stat housing. Excursion said the Zetec and CVH senders put out different signals anyway, so with CVH clocks we needed to use the CVH sender. The temps the Zetec sender was giving me certainly seemed believable, but I didn't want to risk using it permanently.

Looks like I might be driving down now, so might need collecting etc if you think you'll still be available. I'll no doubt know for sure a few days beforehand, I hope that's enough notice Wanna go for a pub lunch with Scort if he's up?

[StreetDragster]

Sounds like a plan, would be good to all meet up, i'll get Chris to come along too.

Thanks

Matt

[RS_Rawli]

i might be able to do some chaufeuring if yout let me know when it is heebob

[heeman10]

Yeah cool, show them what the North's like! I bet it rains

Crawlinson - Matt lives just a few minutes from MSD, so if he's still free, the plan was for him to come in when I'm there, then at some point drop me off at the station....I think! It'd be miles for you to come up, thanks a bunch for the offer though Feel free to come up by all means if you want! 23rd would be a better date though, that's when I get it back Will be hanging around in Preston a bit on that day too, so come on up if you want to play

[StreetDragster]

Matt lives just a few minutes from MSD, so if he's still free, the plan was for him to come in when I'm there, then at some point drop me off at the station....I think!

Thats the plan!

Thanks

Matt

[CRF]

16th best for me, will be in preston on the 23rd though if you fancy takin me out for a spin!!!

Matt you need a bonnet vent like the one at the front of this scooby bonnet...................

[CRF]

Ok just fcuking ignore me, was thinking the 23rd was a friday for some reason.

May just have a little hangover on the 23rd then!!!

[Max M4X WW]

That vents perfect!

[javablu]

That vents perfect!

And ugly

[Max M4X WW]

Not really Would be very functional anyway.

Looks quite cool IMO, slightly sticking out but thats all you need.

[andyhardy]

Would work well in the summer, but i wouldn't want to get caught out in the rain, the water would get straight onto the HT leads!

Cheers,

Andy

[StreetDragster]

I like the vent, hate the scoop, bet thats plenty expensive.

[heeman10]

Yeah the vent looks good, think we're ignoring the scoop on this one

Andy - HT leads are out of the way for us

Chris - Dumbass Yeah we can go for a spin in Preston, I'll need to make sure it all works no doubt!

[CRF]

[FezzR]

could make a blanking plate to mount under the vent and have a drain off to one side