Focus RS Ongoing Project.
07-04-2007, 10:14 PM
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Focus RS Ongoing Project.
2005
OK after loads of nagging, Nash has finally convinced me to do a project thread for my ongoing Focus RS project.
The car was bought standard in Feb 2005 with 18,000 miles on the clock. It was then left alone for four months while I went on holiday to the Falklands.
Some pictures taken when I came back in July 2005.
I intended to keep the car standard, however after a passenger ride in Nath R's Focus RS which was running Bluefin, Mongoose decat and exhaust and K&N Gen II the standard car plan went straight out of the window.
Ford Fair 2005 saw the start of the mods. Superchips London had an offer on the Bluefin. This was installed in the car park and the journey home was worth every penny.
National Day 2005 saw me get a good deal on a Miltek decat and exhaust from Pumaspeed, which Nash used as a pillow on the journey home.
With these mods fitted, the car was superb, and really enjoyable to drive.
November 2005 and i had the car rolling roaded at Emerald, making 255 bhp and 270 lb/ft.
The only other thing to be fitted in 2005 was the Samco boost hoses and Magnecor leads.
Will update this thread with 2006 stuff and more pics tomorrow or monday.
OK after loads of nagging, Nash has finally convinced me to do a project thread for my ongoing Focus RS project.
The car was bought standard in Feb 2005 with 18,000 miles on the clock. It was then left alone for four months while I went on holiday to the Falklands.
Some pictures taken when I came back in July 2005.
I intended to keep the car standard, however after a passenger ride in Nath R's Focus RS which was running Bluefin, Mongoose decat and exhaust and K&N Gen II the standard car plan went straight out of the window.
Ford Fair 2005 saw the start of the mods. Superchips London had an offer on the Bluefin. This was installed in the car park and the journey home was worth every penny.
National Day 2005 saw me get a good deal on a Miltek decat and exhaust from Pumaspeed, which Nash used as a pillow on the journey home.
With these mods fitted, the car was superb, and really enjoyable to drive.
November 2005 and i had the car rolling roaded at Emerald, making 255 bhp and 270 lb/ft.
The only other thing to be fitted in 2005 was the Samco boost hoses and Magnecor leads.
Will update this thread with 2006 stuff and more pics tomorrow or monday.
07-04-2007, 11:25 PM
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Yeah I'll come along for a look will have the focus if its back together and the saph isn't ready.
Hopefully the saph will be back or Nash will be a miserable git all day!
Hopefully the saph will be back or Nash will be a miserable git all day!
17-04-2007, 07:06 PM
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2006
First things added were the K&N gen II induction kit, and the creative carbon fibre splitter, this could of been simple to fit, however i had to do it the hard way and this was the end result.
Next up was to get some of the dash flocked and fit my SPA oil pressure / water temperature gauge.
The car was then left due to loads of exercises etc with work.
First things added were the K&N gen II induction kit, and the creative carbon fibre splitter, this could of been simple to fit, however i had to do it the hard way and this was the end result.
Next up was to get some of the dash flocked and fit my SPA oil pressure / water temperature gauge.
The car was then left due to loads of exercises etc with work.
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17-04-2007, 07:18 PM
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2007
The car has been getting loads of attention.
USA rear clusters fitted, which were quite a simple mod to do, just requiring a bit of work with the dremel.
Then the Pro Alloy Air-Air Intercooler kit. The car after the charge cooler was stripped out.
After the fitting.
Throttle body elbow was also painted cheers Nash.
Still to come, brakes, manifold, avc-r and turbo!
The car has been getting loads of attention.
USA rear clusters fitted, which were quite a simple mod to do, just requiring a bit of work with the dremel.
Then the Pro Alloy Air-Air Intercooler kit. The car after the charge cooler was stripped out.
After the fitting.
Throttle body elbow was also painted cheers Nash.
Still to come, brakes, manifold, avc-r and turbo!
18-04-2007, 12:01 PM
#18
Originally Posted by Charlie Chalk
Originally Posted by pd689
I really need to get the pro alloy header tank now as that plastic one looks crap. 
As for Power its should be around 330bhp once all set up, sure Paul will put it on the Rollers once hes happy with it.
As most people can tell i love this car and love working on it.
18-04-2007, 05:48 PM
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Heres the specs for the new turbo for those interested...
'The HI Response Turbo for the focus RS
Manufactured to fit Ford Focus RS 2.0 Turbo 2002->
Replaces Garrett Turbo Part No: 722979-0002 Ford part No: IM506K682AE
Hybrid turbocharger Part No. MD398
All units are hand built and blueprinted to exacting tolerance for each customers needs.
Specification
1. 52 trim, GT32 specification 71mm high flow compressor wheel.
2. 0.60 A/R high flow compressor housing C.N.C. machined for maximum airflow capability.
3. Left hand thread shaft with GT28 series 76 trim low inertia Inconel turbine wheel, fitted with a racing Staggered Gap total seal ring to stop oil seepage caused by large bore or low backpressure exhaust systems.
4. Modified bearing housing fitted with angular contact twin roller bearing cartridge for maximum thrust load capability and fastest spool time.
5. Specially modified turbine housing, 0.61 A/R with ported & polished inlet throat.
6. Optional uprated actuators (any pressure) can be fitted.
7. Compact GT28 bearing housing assembly for optimum water and oil cooling efficiency.
Note. Requires modified oil feed pipe and oil drainpipe. Oil feed adaptor fitting and oil return flange supplied with turbo.
What you can expect for your money!
1. Boost pressure starts @ 2,000 R.P.M.
2. Full boost (limited) 2.1 BAR @ 2,500 R.P.M.
3. No drop in power @ 6,700 R.P.M.
4. Increase in torque and horsepower over the GT17 unit through the entire rev range.
5. A conservative 320-340 BHP potential.
Re-mapping is a must with this unit, as the standard ignition map will not keep up with the fast spool up time of this unit. Performance will vary depending on engine specification such as camshafts etc.'
I'm running actuator pressure only at the moment while i get the mapping sorted, this is 14 psi. At 16 psi on a similar spec car its 300bhp, so mine will be short of this!
'The HI Response Turbo for the focus RS
Manufactured to fit Ford Focus RS 2.0 Turbo 2002->
Replaces Garrett Turbo Part No: 722979-0002 Ford part No: IM506K682AE
Hybrid turbocharger Part No. MD398
All units are hand built and blueprinted to exacting tolerance for each customers needs.
Specification
1. 52 trim, GT32 specification 71mm high flow compressor wheel.
2. 0.60 A/R high flow compressor housing C.N.C. machined for maximum airflow capability.
3. Left hand thread shaft with GT28 series 76 trim low inertia Inconel turbine wheel, fitted with a racing Staggered Gap total seal ring to stop oil seepage caused by large bore or low backpressure exhaust systems.
4. Modified bearing housing fitted with angular contact twin roller bearing cartridge for maximum thrust load capability and fastest spool time.
5. Specially modified turbine housing, 0.61 A/R with ported & polished inlet throat.
6. Optional uprated actuators (any pressure) can be fitted.
7. Compact GT28 bearing housing assembly for optimum water and oil cooling efficiency.
Note. Requires modified oil feed pipe and oil drainpipe. Oil feed adaptor fitting and oil return flange supplied with turbo.
What you can expect for your money!
1. Boost pressure starts @ 2,000 R.P.M.
2. Full boost (limited) 2.1 BAR @ 2,500 R.P.M.
3. No drop in power @ 6,700 R.P.M.
4. Increase in torque and horsepower over the GT17 unit through the entire rev range.
5. A conservative 320-340 BHP potential.
Re-mapping is a must with this unit, as the standard ignition map will not keep up with the fast spool up time of this unit. Performance will vary depending on engine specification such as camshafts etc.'
I'm running actuator pressure only at the moment while i get the mapping sorted, this is 14 psi. At 16 psi on a similar spec car its 300bhp, so mine will be short of this!
19-04-2007, 09:31 AM
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Originally Posted by Stoo
Interesting read, lovely car
You've obviously put alot of thought into each mod
You've obviously put alot of thought into each mod
Theres plenty more to come before i'm finished its just waiting for funds to become available.
24-04-2007, 07:47 AM
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Re: Focus RS Ongoing Project.
Originally Posted by pd689
I intended to keep the car standard, however after a passenger ride in Nath R's Focus RS which was running Bluefin, Mongoose decat and exhaust and K&N Gen II the standard car plan went straight out of the window.
Looking good bud, a very nicely spec'd FRS.
24-04-2007, 11:09 AM
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Originally Posted by StickerPaul
I take it this is Hangar 15 Tuning then
Good work mate
Good work mate
Paul
24-04-2007, 11:33 AM
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In all fairness i actually owe Nash a big thank you for all the help especially when I've been getting pissed off because something won't work and also for all the hours he's put in on a car that isn't his!
for all the help especially when I've been getting pissed off because something won't work and also for all the hours he's put in on a car that isn't his!
24-04-2007, 12:03 PM
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Next bit.
Now that the intercooler was fitted, I could start again on getting more power out of the engine, so the next step was to fit a tubular manifold. The standard ford item is pretty restrictive and can free a lot of torque when replaced.
Standard item...
There are a few people making tubular manifolds for the focus rs, however Primary Designs have to be the best with a history of producing exhausts for F1 and WRC teams, i decided on an inconel ceramic coated tubular manifold, not the cheapest but you get what you pay for.
I decided that it would be easier to remove both the manifold and the turbo at the same time, as the manifold to turbo bolts can shear quite easily and the turbo needed to be sent away for modification anyway. Easier to do it all now than have to remove the turbo later for upgrade.
The manifold was wrapped in bubble wrap (to stop it getting dirty) and fitted to the head with a ferriday thermal exhaust plate which is supposed to keep the temperatures down in the head. The plate came with studs and K-nuts which made fitting the manifold easier as there is not a lot of space to get tools into, to tighten the head nuts.
Now that the intercooler was fitted, I could start again on getting more power out of the engine, so the next step was to fit a tubular manifold. The standard ford item is pretty restrictive and can free a lot of torque when replaced.
Standard item...
There are a few people making tubular manifolds for the focus rs, however Primary Designs have to be the best with a history of producing exhausts for F1 and WRC teams, i decided on an inconel ceramic coated tubular manifold, not the cheapest but you get what you pay for.
I decided that it would be easier to remove both the manifold and the turbo at the same time, as the manifold to turbo bolts can shear quite easily and the turbo needed to be sent away for modification anyway. Easier to do it all now than have to remove the turbo later for upgrade.
The manifold was wrapped in bubble wrap (to stop it getting dirty) and fitted to the head with a ferriday thermal exhaust plate which is supposed to keep the temperatures down in the head. The plate came with studs and K-nuts which made fitting the manifold easier as there is not a lot of space to get tools into, to tighten the head nuts.
24-04-2007, 02:14 PM
#31
Originally Posted by pd689
In all fairness i actually owe Nash a big thank you for all the help especially when I've been getting pissed off because something won't work and also for all the hours he's put in on a car that isn't his!
for all the help especially when I've been getting pissed off because something won't work and also for all the hours he's put in on a car that isn't his! I enjoy working on yours more than mine tbh, think its probably the fact mine hates me
18-06-2007, 09:31 PM
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Ok some more work.
While I was waiting for the turbo to come back from Turbo Dynamics, the brakes were uprated ready for the power upgrade.
EBC ultimax discs from Performance Stars, Ferodo DS2500 pads on the front, Redstuff on the back and Goodridge Braided lines from GGR.
Once it was back together we still had to push it about the place until this turned up.
Only a baby turbo in the grand scheme of things but gives good gains by maintaining boost higher in the revs.
To fit it the oil feed and return needed to be modified, new hoses were bought for the oil and water feeds and the oil return required the bolt holes to be increased from M6 to M8.
Cheers
While I was waiting for the turbo to come back from Turbo Dynamics, the brakes were uprated ready for the power upgrade.
EBC ultimax discs from Performance Stars, Ferodo DS2500 pads on the front, Redstuff on the back and Goodridge Braided lines from GGR.
Once it was back together we still had to push it about the place until this turned up.
Only a baby turbo in the grand scheme of things but gives good gains by maintaining boost higher in the revs.
To fit it the oil feed and return needed to be modified, new hoses were bought for the oil and water feeds and the oil return required the bolt holes to be increased from M6 to M8.
Cheers
12-07-2007, 07:05 PM
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Dyno'd today.
Well today was the day, i got to find out the exact results of all the work that has been put into the car by myself and Nash.
Firstly a big thanks to Christian and Gary at APT for fitting the car in this morning.
Flywheel figure and Torque.
Wheel power and Boost.
All in all i'm really happy, its not the biggest power FRS in the world but i'm over the moon with how it drives on the road.
Firstly a big thanks to Christian and Gary at APT for fitting the car in this morning.
Flywheel figure and Torque.
Wheel power and Boost.
All in all i'm really happy, its not the biggest power FRS in the world but i'm over the moon with how it drives on the road.
13-07-2007, 06:58 AM
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hmm for a bigger turbo just so low power?
A friend of mine
stock turbo
1,3 bar
ford motorsport manifold
milltek decat and flexy pipe
denso itv22
bluefin
305 hp / 515 nm
A friend of mine
stock turbo
1,3 bar
ford motorsport manifold
milltek decat and flexy pipe
denso itv22
bluefin
305 hp / 515 nm
13-07-2007, 11:28 AM
#40
Originally Posted by - Sim -
hmm for a bigger turbo just so low power?
A friend of mine
stock turbo
1,3 bar
ford motorsport manifold
milltek decat and flexy pipe
denso itv22
bluefin
305 hp / 515 nm
A friend of mine
stock turbo
1,3 bar
ford motorsport manifold
milltek decat and flexy pipe
denso itv22
bluefin
305 hp / 515 nm