ZetecSX

AWESOME...will make apoint of looking at this at Ford Fair

moondustka

Thanks to all

Fingers crossed I'll get it back together in time!

rsjonny

iTrader: (1)

Seems a really good conversion tbh and a lot of hard work has gone in to this well done!

One questions though with removing the front cross member if you have an accident isnt it going to just destroy the front of the car and injure the driver? I thought the cross member was there as impact protection?

moondustka

Thanks!

Yea, don't get me wrong - this car isn't exactly world's best in safety. However, I built it for different reasons. I did think about it, but thought I didn't have much chance before. The car has no airbags. I think I've made the front stronger to be honest, so more than likely damage another car more. Don't really want to think about front end impacts... the time, effort and money I've spent on it, to lose it would be sickening!

rsjonny

iTrader: (1)

yeah cool no worries its a great little sleeper was just the first thought that cam into my head when I saw it !

Ken_ZS

loving that front fab work, i have a 2 litre sitting around and been thinkin of doin a Ka sleeper as me mate is building a 1.7 puma racing one (the old pumabulld or pumaspeed ka in a new shell) and was gonna turbo it with the turbo at the back box but the extra room you have made there is great stuff.

anyways get the clutch done n atuator sorted and lets have some new power figures and videos please, top work and il be keeping me eye out for this one, also have you any plans on running it down the quarter? would love to no what it can do in street trim with that power

just a question, have you done much strengthing to the shell? how well does the chassis take the power? i will probly seam weld one if i do build it but id like to get away with not caging it if i the chassis is good enough with just some welding and strengthening plates if needbe

moondustka

The extra room is hard to find but can be done Its nice to do different projects that are unique. Your idea is pretty cool. I will run it for quarter mile when i get the chance. All that holds me up on this project and moving it forward is money!

It's fine mate.. It needs some braces - I haven't got any at the moment!! I want to put in a top rear one and bottom lower one as I think that'll make so much difference to cornering on top of what I've done now. Not sure I can fit a front top one in, unless I get creative!

Since I've been carrying around the show gear I've left it in the boot, about 30kg or so. Makes it much more stable at high speed. Think I just need to soften the rear suspension for road use to cure it without the extra weight.

atm

great project mate!

got a focus rs myself, go for a forge actuator.

a reliable 350 bhp is so easily achievable with these engines too, once youve got a map, actuator, uprated manifold, decat and hybrid turbo.

you should see 300bhp just with a map, actuator decat and manifold

Dan_RS500

Excellent project! Really liking the ideas you come up with. Good fab work and keeping it mint!

kevboy6

great work mate well done

rsmark86

iTrader: (3)

what a great project....

it will be a flyer witht the right bits..

my frs was 288bhp with 314lbs and it had a full exhaust system/decat/actuator and remap.... now that in a ka would be wicked.

moondustka

It will make much more power once I get a clutch that can hack the torque and an actuator that can hold 18 psi of boost Then it'll go for a re-map.

But it's all about Ł800, and that's if I do all the fitting myself. Which to be truly honest I've lost a bit of interest for. I can see me handing the clutch job to someone else when/if funds allow.

It's pretty quick as it is now really! On some days the clutch doesn't slip and it's mental. The boost tailing off isn't great though.. It holds 12-14! haha

Thanks for the comments

silky16v

iTrader: (1)

looks like a Technicrap clutch which will just be a standard pressure plate painted up

moondustka

know anything I can get that will take over 300lbs in 220mm?

I was told a helix 4 paddle would be better, with an extra heavy duty cover..

After that it would be a custom job?!

moondustka

So here goes.. Unfortunately got none of the new gearbox mounts and all these photos are previous to fitting. I fitted them the day before Trax!

Anyway, enjoy..(maybe!)



























My mate's leon and my photographer!!





I've given the Ka a lot of abuse in the last couple of weeks! And everything is ok touch wood! Clutch isn't slipping anymore either :-? I can get it to slip if I try, but it doesn't slip just under load, although haven't tried 5th gear, 1500rpm, foot to the floor yet. Boost is awful, 18 psi peak and holds 12-13. Still feels quick just not quick enough :devil:

GaryHurn

iTrader: (1)

i run a helix 4 paddle with one of there pressure plates been fine at nearly 400bhp and 375 ftlbs on the nova

moondustka

What size is it though Gary? I've never heard anyone having trouble with clutches when they use focus ones at 240mm.

Can you buy direct from Helix or do I have to go through a dealer?

Cheers!

Roadsport

That's one very nice Ka !

GaryHurn

iTrader: (1)

on my nova it is 228mm friction plate

www.mardigras.co.uk are main dealer great prices

marky_g

lookin good ne more plans

moondustka

Thanks gary

Yea a good few if money was no object!

As it i at the moment to make it run sweet, it needs a forge actuator, new clutch, a remap and could do with a new timing belt.

After that, the wish lit is never ending!! - New turbo (GT28RS or something like it), exhaust manifold, MTX75 box (which will need custom mounts and could go for better clutches anyway) comp alloys to fit over brakes and allow 888s when I wanted them, leather re-trim for recaros.. could go on forever. I'm sure there's loads of people thinking what a waste on a Ka !!

Hobomassiv

No way!

moondustka

Before I went to Brands for the performance ford day.. I had a knocking and was determined to find it. It ended up just being an extra 3/4 turn needed on the rear gearbox mount!!

Still, prior to this I thought it was the CV joint!

Well as I went to pull the hub apart this happened





The hub fell apart! Luckily had a spare one! I'm guessing this happened because about a year ago I went around with a driveshaft nut loose for a couple of months till I found it, didn't know at the time and must have worn it.

I changed the CV joint too, as it had crack in it! no pictures of this though

*****************************

Broke the gear linkage saturday night!

It's supposedly a TAS Quickshift. It's broken inside the black box underneath the car where the gearstick pivots from.

My question is, can you take this bit apart? i thought it was sealed. But I have heard of people making standard linkages into a quickshift through modifying this part of it.

I do have an ordinary Ka linkage, but I think the throw is just, well too long.

Anyway the story if anyone is interested.. I was racing around, as you do and I kept missing gears. Thought it was shit driving It wasn't, because another time I was trying to hack through the gears it went a bit floppy. Parked up and borrowed a jack, had a look and it was all rattly inside that black box. On the motorway on the way home, I went to change from 5th to 4th and something snapped completely, leaving me stuck in 5th.. which was fine for the motorway, but meant I was a bit stuffed getting through the town and up to my parents, where I decided to take it seeing as it was broken!

Luckily about 4 sets of traffic lights were green, one was just about changing the other side, had to go round corners at ridiculous speeds! And managed to get up quite a steep hill, with a right angle bend at the bottom. Challenging!! Got it there at least.

Planning to sort it tomorrow, as I need it working - new clutch and timing belt on thursday

*****************************

All fixed Luckily Had a spare one. The black casing had cracked and was previously missing the clipped flap that holds one side together. Really, it was just a matter a time. Surprised it lasted this long. 2-3 years. I didn't realise but it's actually just a modded standard linkage, which changes the pivot point, giving less throw to change gear.

Cracked..



Casing hadn't been brilliantly modded. The top needs trimming down. Perfect on the belt sander



And this is 'quick shift' part



All fixed and feels better than before. Probably because it's properly secure!

P.S. Think the towel is from the 70s

*****************************

Genuine Ford 1.8 zetec Flywheel..



AP Clutch, fairly new on the market apparently. Also, not sure what material it is made from, supposedly not fully organic or cera-metallic ??



Cover plate - the important part! Very different to the one AP supply for the 4 paddle FRST clutch kit.







Many more spring plates here..



Fitting on Thursday. I hope it does the job! AP give no rating for this clutch. Largest torque it's been on is 355lbs, and not slipped.

whizzisat114

iTrader: (2)

Good update fella car's looking great

COLEYST200

iTrader: (3)

nice work mate wot power is it pushing as i bet its a hand full

moondustka

Still yet to find out. Back in June it was 249bhp/292 lbs torque and that's the most it got before the clutch started slipping the clutch gripped as the boost dropped due to the shitty actuator, that can only hold 12 psi.

After thursday, new clutch and timing belt will be on. Then I need to order an actuator fit it and take it for a remap.

To be honest, in the dry it's alright at the moment. But think it's gonna be quite dramatic when it holds 18psi or so

moondustka

I got let down at a garage and having taken the day off work, decided to do it myself!

Once the old cover and clutch was off I could compare them



Cover plate a bit ruined to be honest!



Flywheel got ruined as well!



Old vs new



New flywheel on, gearbox off.



I stopped taking photos after this point, cos I just wanted the thing back together! Took me and my brother to get the box back on, just couldn't do it myself!

I've tested it as much as I can, and the result is good Seems to be doing the job. So time now to order the actuator and get it booked in for re-map and timing belt, because I really don't want to do that one even though the clutch is probably worse!

GaryHurn

iTrader: (1)

how is dans coming along mate he still got it, i may buy another ka very soon

moondustka

Dan's is all done, but now broken! after 1000 miles the clutch went, same problem I had, except his is bit worse. Can't do anything more than 1/3 throttle!

This clutch seems good at the moment!

His came out with 269bhp, 311lbs of torque. With the short gears, they do shift pretty well!

Mines getting mapped again next friday not sure I'll get the same out of mine. He has a gas flowed head and some piper cams I think.

moondustka

Today was the day when it all came together, and actually worked as a whole for the first time

It made 266.6 Hp, 356 lbs/ft

Mental amounts of torque, power is lacking as the std turbo just can't flow enough air!

Clutch didn't slip which was the main thing!

Time to have some proper fun now it's all working as it should

Maxwell

holy fuck i have never wanted a Ford Ka as much in my life lmfao!!

awesome build, and you seem really handing at the welding!

hat of to you mate!

COCHYN

How cool is that

takeshiRejs

this is mad,really mad KA
need some video of that

Rsmat

iTrader: (2)

Awesome work mate.

Glenn_

iTrader: (1)

I love this car.Have you ever thought about painting the intercooler black and then put some steel wheels on it and go out and a have a play with some people.

turbomook

iTrader: (4)

Nice sleeper mate.. Good work!

COLEYST200

iTrader: (3)

very good BHP for a small car

Eigdoog

Think its really good what you have done but i just hate KA's, so cant really love it

moondustka

I have, but the black paint would get chipped too easy! The steelies however has crossed my mind!! I probably would have a set for shits and giggles.. but it's just money for the tyres and the right steels!

Thanks for comments

I found out I can pull away from an E46 M3 with ease, so pretty chuffed with that. There's nothing like getting beaten by a girls car eh!

cossie4i+

iTrader: (15)

Just spent ages reading the whole thread

Great work mate, its a credit to you.

Steve