alby1ltr

Right, I think it's about time I make a thread on my latest project.

I've got a 1.3 fiesta I took as px for a car I sold a while ago and want to drag it out the barn and do something with it. I've also got itchy fingers and need to get on with building something

I've ordered a few parts over the weekend for the fezzi so just waiting for them so I can put some pictures on hear for all you guys/girls to follow progress, and hopefully help out others who want to do similar.

Right then, bits I've ordered are;

Fiesta rs turbo OFAB loom and ecu

2mm laser cut decompression plate witch by my calculations shall lower it down to, give or take 8.4:1 so should be fine.

Zetec breather blanking plate.

Not everything but ill get there within the next few months.

I've already got a t3 escort rs turbo exhaust manifold that I will just drill and tap onto the head, ill also shape the ports to match but I shall include pictures to make it all clear.

I've also got the adjustable fuel pressure regulator from another project.

Brought a universal intercooler off a mate this weekend with all the pipe work and gubbins. He also gave me a ally oil breather catch tank as his nice like that

I only went for the 300mm mondeo st brakes he had for sale so was a right result

Ill add pictures of my hoard of parts as and when I get them and when I work out how! Lol.

Any questions or suggestions would be very welcome and I'm not one of these who won't tell what I did out of spite!

Aforbes88

Will deffo be keeping an eye on this as I am also building a 2ltr zetec turbo engine I was going to go the decomp plate route but going for st170 bottom end forged rods and pistons ect as want to take it to 300bhp hopefully. I'm torn as which car to put the finished lump in though itl ether be a escort or a mk5 zetec s be handy to see what you do engine mount wise.

Cheers Andy

alby1ltr

I'm going for the 1.8 at for the time being as I hear you have to use the 1.8 water pump, sump, oil pick up ect ect anyway on the 2.0.

Yeah I was thinking about the st170 bottom end but as I'm trying to keep costs down to a minimum (since when does that ever stick)

I've got a few plans as for mounting the engine in my head but ill cross that bridge as I come to it as they say.

Tying to work out how to putting pictures up is proving tricky at the moment but hopefully shall have some up soon.

Tom.

Aforbes88

Yeah I started off trying to keep costs down and failed haha

You should try photobucket for photos bud

Andy

Aforbes88

How you doing your engine breather system?

From cam cover to catch can
From block to catch can
Then from catch can to sump?

That's how I was thinking of doing mine

Andy

alby1ltr

alby1ltr

Looks like that didn't work, however ill get onto the works computer tomorrow lunchtime and see if its just an apple problem.

Regarding the breather system, I have a core plug on order that's hopefully the right size to just knock in then I shall drill/tap into the back on the block the new breather to go to the catch tank, also the rocker cover breather will go there as well.

I'm not too keen on the idea of putting the breather into the sump as in my mind breather is to release pressure from the engine from the little boost that leaks past the piston rings.

Tom

alby1ltr

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alby1ltr

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alby1ltr

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Think I've finally worked out this whole image uploading malarkey.

Hears the monster breaks, not sure what wheels I'm going to need but we shall soon see when I trial fit them this weekend.

alby1ltr

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I'm sure everyone's seen one of these before, but not many are uncracked like this one, result!

alby1ltr

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And hears the beast! Some of you may of seen it on eBay a while ago but I decided to keep it for a 1.7 puma conversion but that would of been farrrr too easy to do. Already on coilovers when I got it so all is good there and is actually the only reason I decided to keep it and zetec turbo this shell.

Don't know why some of my pictures are upside down so no, I haven't rolled it and taken a picture after!

Aforbes88

That looks cool! Made me think now wether to go for a normal looking fiesta and not a zetec s as itl be more of a sleeper.

Whereabouts are you going to drill the block? Il just wait and hopefully youl be so kind as to put a pic up for me lol

Them brakes will work a treat you going to have to custom make brackets?

It's gunna be good watching progress and get some hints and tips ect

alby1ltr

I've dropped the rear another 10mm since this pic so sits a more level, had to remove the front anti roll bar completely as the drop links seemed to just bend to nearly 90 degrees!

I only ever build sleepers, adds to the element of surprise a bit more when you leave them behind

I know where I'm going to drill it, on the rear of the block, I'll post a picture for sure as and when I pick up the engine and sort it out.

Luckily my mate had the hubs they were fitted to so should be able to put them on them although I do believe they will fit mine with minimal fettling.

Ill take some more pics of the intercooler ill be using tomorrow and the other bits I'm using.

Think I've got a picture of those brakes when they were on the old car with 17" alloys. The pic I put up really don't do them justice!

alby1ltr

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Last pic of the night of the brakes on the old car when it had 17s on it!

alby1ltr

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Haven't cleaned it up since I got it at the weekend but may get round to it over the weekend, still undecided as to wether it goes black or not just for that extra stealth look? Ideas welcome on that one

alby1ltr

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Ill get round to giving it a good polish up but hears the oil catch tank. Not 100% sure what the small connector is for? Maybe just a breather for the catch tank itself....

Aforbes88

I'd keep it silver to give cars going the other way something to think about lol

Hmmmm was that a intercooler on that fiesta?

Yeah I'd say that little pipe is a breather

alby1ltr

Yeah that's true haha ill have a look what it looks like on the trial fit this weekend in silver with a clean up.

Hopefully have all the bits come through the post this weekend then make up a list of what I need to finish the job.

Thinking about using the 1.3 box for the first couple miles just to see what happens.

A mates older brothers got a escort rs turbo gearbox with the LSD that's only done 22k! He doesn't want a lot for it but unsure if my shafts will fit so ill have to do a bit of research on the matter.

alby1ltr

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Received this in the post Friday, real pleased with it and a bargain at Ł20 new!

alby1ltr

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Had some problems getting pics from my phone to the iPad this weekend so this has been slightly delayed.

Deffo going to keep it silver, still real subtle but noticeable if you know what to look for just how I like it lol.

Rally wanted to fit the breaks this weekend but brought a motorbike so really didn't have time this weekend but ill try get round to it this weekend, probably just as well as I haven't got any wheels big enough anyway.

Also sorted out the adjustable fuel pressure regulator and a core plug the right size for the breather hole on the front of the block so getting there slowly although I'm getting a bit worried about the frst loom and ecu as I won it over a week ago off eBay and still no sign of it and can't get a response from the seller. Sounds like someone can't handle letting something go for a bargain price. If it doesn't get sent ill just have to get a refund via PayPal and go megasquirt, not something I want to do but needs must and I very much doubt ill see another OFAB set up at that price! Fingers crossed!

CrOwSoN15

Be aware with the drilling/tapping for the RST fanimold, there's a very high chance you'll break into an oil way causing a constant seep.

alby1ltr

Haha fanimold! Never herd that one.

Yeah I've herd there's only about 9mm or so of meat in the head so chances are you'll drill into the oil way no matter what. I've got some industrial strength thread sealer that I used on some diesel hoses and worked a treat with those so ill slap a bit of that on the 'fanimold' threads and fingers crossed that'll work fine.

CrOwSoN15

Yeah I've heard a thread sealer works, I think Devil Developments press stainless steel inserts into the head and then tap them, though for the power you're after I think that's a little OTT.
Even then I'd say you'd be better off going for a tubular jobbie.

Good luck with it mate.

alby1ltr

I can only describe this one as being liquid rubber, ill get the name of it when I'm next over the workshop.

Ill more than likely get a tubular one when its all built up and I get bored of the power. I'm doing this on a budget, really I want to do the whole lot for around Ł500. I know there will be people who bang on about it can't be done for that but ill give it ago.

I'm having a bit of a problem trying to find a t3 erst downpipe, or just the flange and flailed bit. Does anyone know where I could get one? A mate had a whole system on his mk5 escort rs turbo (yes it was a mk5) that he sold only about 2 weeks before I decided to do this and sold it for Ł50!!

Also I'm still looking for an engine if anyone has one laying about that want to sell?

I'm a bit worried about driveshafts and wether mine will fit, I've herd I have to use mk5 escort long shaft and a mk5 fiesta zetec s short shaft so any solid info on this would be good!

Thanx, Tom.

Aforbes88

Alright Tom

Bit late replying ect coz didn't get emails saying you'd added to the thread!!

Intercooler will look subtle behind bumper! That decomp plate was a ruddy steal!!

I got a full black top lump for Ł200 posted on eBay bloke had 2 engines forsale want me to link you ?

Andy

alby1ltr

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Finally the OFAB loom turned up today, took the ecu apart in the hope of a chip being in there but no such luck

alby1ltr

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Oil feed and the adapter to go into the back of the block for a steal of Ł10!!!!

Yea I've put the interwarmer behind the bumper and looks pretty smart

I think the bloke must cut them out on his lunch break or something as he seems to cut out anything you like

Well there's one on fleebay for Ł100 or make an offer so I'm thinking about offering him Ł60 just to be cheeky has to be done as I'm on a strict budget not I've got this bike to sort out aswell

So as far as I know all I need now is obviously the engine, head gaskets, few sensors inc. map sensor and downpipe....

......and wheels and turbo... And...... And .......annd

alby1ltr

Right.... Been a while since I posted on hear but I've been flat out at work ect so haven't had any spare time to update on hear.

Soo.... I managed to get a turbo, already starting to regret it slightly but Ł19 for a r5 ggt is worth anybody's money, still, a t2 will almost certainly be far too small considering I was after a t3. On a plus the ggt turbo downpipe will be simples to fab so saves me getting a erst downpipe and fab that to fit.i should have it begginging of Next week fingers crossed.

Also I got the bargain of the century last night on our favourite auction site. An 1800 zetec lump with fully rebuilt head, seals and core plugs, new oil filter ect for the grand total of Ł21!! Ment a 2 and half hour round trip but it was worth every second as the bloke who was selling it had a mint mk2 escort tucked away in his garage!

Sprayed aload of that ferntan or whatever it's called (rust killer) all in the inner arches a couple weeks ago to help kill what usually kills the mk5s and mk4s so would be nice to see some lovely clean metal and a load of 'black powder' for rust as the product says. Ill post pictures of it if someone, if anyone wants a look.

Ill start getting pictures of the engine ect today but I got home at 11 last night so was slightly dark.

Feeling motivational today so may get her up on axel stands and put the new hubs, breaks on her ready for her new shoes when I find some. I'm after some 15" mondeo or rs2000 5 spokes if anyone knows of any? Ill rip the head off ready for fitting the fanimold aswell ready for next weekend, need to pick up an m6 tap iirc to tap the new studs. Also I need to port the exhaust ports out to Match the mani so and tips on this ie what method is best to do? And should I use those 'stone' drill bits to grind away the ally?

That's enough for now, I may even miss the f1 just to get some more bits done wich is seriously unheard of!!!

alby1ltr

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Hopefully the picture isn't upside down but hears what I've been up to today. Had some problems with the rs2000 hubs tho, first of all it seems the rs ball joint is tapered as is the driveshaft splines as it would go in half way then stop. Also the rod end on the rs seems larger. Not a problem as I went to the workshop and drilled the fiesta hub calliper mounting holes out to 12.5mm to allow it to all fit. There's NO way the wheels are going to fit and think I may even need 16s to fit over the calliper

alby1ltr

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Bores look ok, my guess that it's a high mileage engine as no honing marks left on the bore. Ill sort that out next weekend when I get some time.

alby1ltr

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Head also needs a bit of work, filled the ports with fuel and within about 10 mins I lost it on 2 of the cylinders so a regrind is definitely on the cards for this weekend.

I'm hoping to have the engine together, mani ports ported out to match and new studs re tapped to hold it.

Had a bit of a brainwave regarding the breather system on the block. Could I not just make up a plate to blank off the hole and weld a tube coming out at a 90 degree angle? Would save buying a new fitting for the rear of the block and the faff of drilling and tapping. Ideas are welcomed on that 1.

alby1ltr

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So got the 't2' turbo today that turns out to actually be a t3 so result there. Very little play in the shaft so bonus.

Also got the head gasket set, hylomar, tap, grinding paste and 6.8mm drill bit so all set for the rebuild this weekend.

May post pics but I may not as It feels like I'm talking to myshelf on hear