fiestaturbo.com

[RS rob]

well this week my engine was with well known Harvey Gibbs @ scs on the engine dyno
with all connections made such as exhaust, air, water etc etc
then they built the oil pressure up before starting for the first time since the full rebuild
and was run in properly

also i've gone for air injectors for boost control supplied by harvey


today was mapping time
had some figures at different times of the day during the mapping
220bhp @ 3k revs
310bhp @ 4.5k

the escort series 2 exhaust manifold was the first restriction which got the temps up
when it made 365-370
so it was turned down, and map was trimmed for smoothness

so an upgrade exhaust manifold may be sourced at a later date if the power is'nt enough
but i'll deal with what i've got first


final peak power result was
358bhp and 357ft lb of torque boosting at 26psi at the crank


a massive thanks to ian howell who spec'd and built the engine
and harvey gibbs that run the engine in and mapped the pectel t2 ecu

the results show ian is a superb engineer and knows what works, flow rates, cam profiles etc
still shocked how early the t38 made power


will have a power graph soon when i collect the engine

[SLEEMAN]

very good result there mate, bet you're well chuffed and really want to get it all up and running!!!

[jonyb4]

Impressive

[Ratspeed]

Thats some very good figures mate!

I bet you cant wait to drive it!

[FRSJON]

nice one rob good figures

[Excursion]

Bloody marvellous

[RS rob]

well the results i given for the engine over the phone were only slightly out,
358bhp and 365ftlb torque

thought i'd show some images of my lump on the engine dyno @ scs
big thanks to jimbo for taking pictures for me







some pictures of the vehicles there when i went to collect the engine

[jonboisescort]

looks awsome mate

great power too

[EUFez]

Fooking awesome! Love it...

Great looking cars outside aswell. Love the Sierra's and that Focus!

[jonyb4]

ooh thats a bag of tricks that dyno aint it

[heeman10]

Cracking stuff Rob, great to be able to bolt it in good to go now! A better manifold would probably release another 20bhp before you even started cranking the boost up again - what additional scope for power did Harvey think there could be with a better exhaust manifold on there and whatever extra boost the turbo can muster?

[RS rob]

the power sheet from harvey, just for you james

with a different manifold they think 400-410 is achievable, aslong as the temps stay safe
its been mapped for the 350bhp goal, but engine spec'd to take more if wanted
see how the driveability is first before i go figure chasing.

you can see it makes full boost at 3k
then been trimmed down gradually, so more potential there hopefully

[Ram]

Thats great power mate

[russ-RST]

thats very impressive bet your well chuffed, youv got a great looking car and now a very nice engine with it, ENJOY

[Excursion]

Absolutely splendid Rob, really delightful.

[heeman10]

Good strong 3,000rpm-wide torque band there, should pull sweetly through every gear! That'll be a strong one to drive!

[RS rob]

thanks for the approval

[niracka]

Savage!!!

[RS rob]

something i've been meaning to do for a while is wax the shell,

so the wax of choice was the 3M stuff used in my fords bodyshop




using this gun on the airline




quick picture of the shell

[jonyb4]

probably best to do that now aye

[3lward]

This will never see the salty winter roads of wales lol

[Excursion]

something i've been meaning to do for a while is wax the shell,

so the wax of choice was the 3M stuff used in my fords bodyshop




using this gun on the airline




quick picture of the shell

The most important step yet

I used a diluted mix to start with to improve the chances of it seeping into seams and preventing air pockets. I endued using a colossal amount and it worked a treat - 5 years on it was still perfect.

[RS rob]

This will never see the salty winter roads of wales lol

not much point in winter anyway,
cold dark nights I'd rather be in the house haha

[Smo]

Wow, Rob, those are impressive figures Looks like it's going to be amazing to drive

You've worked so hard on this and it's been a very interesting project to watch along the way, so well done for where you're at so far

[jonyb4]

This will never see the salty winter roads of wales lol

not much point in winter anyway,
cold dark nights I'd rather be in the house haha

rob somethign thats got me in a muddle

i was recently rereading the early bits of the thread (for Si inspiriation really) and on the rolling roade you had the si on, it says you had three hikes in power, one around 93, another in the 90's and another just shy of 130bhp
is the 130bhp refereing to when you fitted the 1.8? because it doesnt actually say what engine

it used to confuse me when i was younger because i thought the 1.6 was with that power, but i was quickly assured they cant really reach that figure

[RS rob]

This will never see the salty winter roads of wales lol

not much point in winter anyway,
cold dark nights I'd rather be in the house haha

rob somethign thats got me in a muddle

i was recently rereading the early bits of the thread (for Si inspiriation really) and on the rolling roade you had the si on, it says you had three hikes in power, one around 93, another in the 90's and another just shy of 130bhp
is the 130bhp refereing to when you fitted the 1.8? because it doesnt actually say what engine

it used to confuse me when i was younger because i thought the 1.6 was with that power, but i was quickly assured they cant really reach that figure

all with the 1.8 lump, k&n air filter and longlife catback exhaust all on the same rolling road at different times

-first result was 105ps spec engine running on the 'SI 1.6 ecu (this just felt like alot of torque)
-then changed for the 130ps cams and throttle body on a 2.0 ecu and maf
-then final figure was when i got hold of a proper rs1800 ecu and maf and decat

[jonyb4]

ahh right cheers that clears it up

was that gotboost?

i really should get my Si down there soon, mind you the £50 price for a single car aint much to pursuade me

[RS rob]

nope tommy's in abercynnon a470
he's very oldschool

used to go up there alot for club rolling road days

sw-cc have now used gotboost for the last two years
after westec in Newport shut down,
25 a run aswell,

[jonyb4]

hmmm might sign up on there, never even looked at it, mind some of the cars going round port talbot doesnt really boast mucha bout them, but hopefully there just the runts of the litter

any planned RR days soon with them?

[RS rob]

ignore the people with the stickers, the club forum aint mega busy but thats because all the chives have gone to cruise forums
but the club holds track days at llandow, rolling roads etc

there are some real cars,
400bhp seat ibiza,
205 rally 16v pushing 180bhp
mk2 ibiza gti with 207bhp
i could keep going, but go have a look yourself

[3lward]

ahh right cheers that clears it up

was that gotboost?

i really should get my Si down there soon, mind you the £50 price for a single car aint much to pursuade me

Get a few of you when me and a couple of other people went down it ended up being £35 a run, but thats at his old place dont know if hes gone up in price

[jonyb4]

think it was £40 each with a group of 5-10, anything over 10 was £35

or £50 for upto 5

ill check out the website then

[RS rob]

about a year or two ago i bought a CTS stage 2 + gearbox for the car,
which is a BC' box but with larger ib5 bearings, shot+peened gearset and a quaife ATB diff

but after finding out recently that the bc' box suffers with case flex, which could lead to allowing the bearings to move
and basically kill the box,

the ib5 gearbox is a development of the bc' box design
stronger casing, bigger bearings, better syncro's, starter motor at the back of the engine instead of the front etc
also because the gear stick centralising spring is inside the gearbox
this allows me to upgrade to a puma / mk5 fiesta gear stick selector
as the old bc box has the centralising spring in the selector itself,

so with a gearbox package sorted from a good mate on fiestaturbo.com
the plan was to swap the internals and diff over from one box to the other,
so that i'd have a ib5 with shot peened gears and quaife diff with all the advantages of the ib5

but due to lots of bearing size differences, it was decided to simply just swap the diff over to the ib5
which works out better in the end because i've kept the better syncro's


so a roadtrip was needed to collect the gearbox so that i could have the internals swapped over by two good mates in work,
i then borrowed the other halfs car and the company of a good mate mr wolze for the 450mile trip
it got a little dirty on the way with all the salt/grit and snow about





here's a picture of the two gearbox internal swapping legends, without them i'd be buggered
mr Wolze on the left, mr Potter on the right




heres the two box's ready to have their insides swapped




got new ford gaskets, bolts and 5th gear cover plate ready




the two box's mid operation




the quaife atb on the left, the standard ib5 diff on the right




with the swap over complete it was time to clean the ib5 up
with the help of another mate kenny and mr wolze, we got bungs for where the driveshafts go
and gave the whole box a scrub with parafin then blasted it off
heres a pic showing the bungs

[RS rob]

now the box was clean from grease etc
it was time to scotch pad the casing box
you can see the difference it made alone with only the top half done




heres the box covered in a nice coat of etch primer on the freshly scotched box,




heres the box after its first coat of satin matt black
i choose black as its easier to keep clean than silver, also goes with the black engine block





then with the 5th gear cover/plate and bolts after it had dried

[jonyb4]

good work, gotta love a good long road trip


i thank you for that differential picture, ive always wanted to see how itlook, i finally understand how they are swapped from the S2