2.1 Zetec turbo RWD engine build
09-01-2011, 04:00 PM
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2.1 Zetec turbo RWD engine build
After starting this engine build in uni 2 years ago for a project its now time to actualy man up and put it all together!
09-01-2011, 04:37 PM
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this project started as a quick budget build with calibra pistons and decompression plate but has now snowballed into high spec (and expensive!) build 
while at uni i got a little to excited at seeing all that loan money in my acount and phoned ian howell each time the loan went in which resulted with me buying these items....
CP pistons with eagle con rods 2.1
Pectel T2 ECU pre mapped to 380bhp and one of ians looms
i also had a set of cams off him and the doube valve spring conversion!!!
iv had the block machined and bottom end balanced by a local engineer who does all the machining/balancing on the BDA engines for the company i work for so definetly knows his stuff!!!
i have collected 90% of the bits required and am aiming to have the engine on the dyno next month
while at uni i got a little to excited at seeing all that loan money in my acount and phoned ian howell each time the loan went in which resulted with me buying these items....
CP pistons with eagle con rods 2.1
Pectel T2 ECU pre mapped to 380bhp and one of ians looms
i also had a set of cams off him and the doube valve spring conversion!!!
iv had the block machined and bottom end balanced by a local engineer who does all the machining/balancing on the BDA engines for the company i work for so definetly knows his stuff!!!
i have collected 90% of the bits required and am aiming to have the engine on the dyno next month
09-01-2011, 04:45 PM
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it's most probably going to be into a sierra for ease of fitiment unless i find a mk5 rwd converted escort or similar...but whatevers about when the engines ready as i want to take the car to ultimate street car at santa pod in august!
just uploading more pics of what i have to photobucket but its so slow!!! >
just uploading more pics of what i have to photobucket but its so slow!!! >
09-01-2011, 08:48 PM
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in order to go rear wheel drive i have bought a retro ford 'motorsport' sump which i then made an oil return pipe on the lathe in work
and then welded into/counter sunk into the sump
because of the original block breather beinng such a big unit it has to be removed to allow room for the manifold so i made a blanking plate and fitted a -6 fitting into so it can go to the catch tank
as far as assembly goes the ARP main bearing stud/nuts have been installed along with the crank so that i could measure the compression ratio this afternoon
tomorrows job will be to finish cutting/shaping the 200sx manifold ready for welding to the flange
and then welded into/counter sunk into the sump
because of the original block breather beinng such a big unit it has to be removed to allow room for the manifold so i made a blanking plate and fitted a -6 fitting into so it can go to the catch tank
as far as assembly goes the ARP main bearing stud/nuts have been installed along with the crank so that i could measure the compression ratio this afternoon
tomorrows job will be to finish cutting/shaping the 200sx manifold ready for welding to the flange
09-01-2011, 10:13 PM
#6
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this project started as a quick budget build with calibra pistons and decompression plate but has now snowballed into high spec (and expensive!) build
while at uni i got a little to excited at seeing all that loan money in my acount and phoned ian howell each time the loan went in which resulted with me buying these items....
CP pistons with eagle con rods 2.1
Pectel T2 ECU pre mapped to 380bhp and one of ians looms
i also had a set of cams off him and the doube valve spring conversion!!!
iv had the block machined and bottom end balanced by a local engineer who does all the machining/balancing on the BDA engines for the company i work for so definetly knows his stuff!!!
i have collected 90% of the bits required and am aiming to have the engine on the dyno next month
while at uni i got a little to excited at seeing all that loan money in my acount and phoned ian howell each time the loan went in which resulted with me buying these items....
CP pistons with eagle con rods 2.1
Pectel T2 ECU pre mapped to 380bhp and one of ians looms
i also had a set of cams off him and the doube valve spring conversion!!!
iv had the block machined and bottom end balanced by a local engineer who does all the machining/balancing on the BDA engines for the company i work for so definetly knows his stuff!!!
i have collected 90% of the bits required and am aiming to have the engine on the dyno next month
thats one of my looms , as i build all of ians , hope you like lol and good luck with the project
cheers paul
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10-01-2011, 07:15 PM
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only one question about it and thats what are the red connectors labled 'boost' suposed to be connected to?...bet its really simple and im missing it!!! lol
10-01-2011, 07:18 PM
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10-01-2011, 11:35 PM
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cheers mate , they are to run a amal valve so you can have 2 way boost switch ie low and high , or you can run a digital boost controller or air injectors basically what ever you want to control the boost with
hope that helps
cheers paul
pm me as i have a nearly new amal valve for sale if you aregoing torun one
11-01-2011, 05:11 PM
#13
The photographer I was with took loads of good pictures, I'll put them up when they get sent in to the office.
11-01-2011, 06:15 PM
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Saw the car today; REALLY nicely done. Currently running a Pinto and will be finished as a driving car in the next month or so and will be put up for sale. 5 linked rear with an Atlas axle, massive cage, Sierra struts and crossmember.
The photographer I was with took loads of good pictures, I'll put them up when they get sent in to the office.
The photographer I was with took loads of good pictures, I'll put them up when they get sent in to the office.
cheers buddy!
11-01-2011, 08:41 PM
#15
Saw the car today; REALLY nicely done. Currently running a Pinto and will be finished as a driving car in the next month or so and will be put up for sale. 5 linked rear with an Atlas axle, massive cage, Sierra struts and crossmember.
The photographer I was with took loads of good pictures, I'll put them up when they get sent in to the office.
The photographer I was with took loads of good pictures, I'll put them up when they get sent in to the office.
were you with classic ford then? graham said they were goin up for a feature of the place
15-01-2011, 09:38 PM
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made a fantastic purchase today and bought 'Liams' from this sites area 6 inlet manifold, been after one for ages so im well chuffed!! 
also dropped the 200sx exhaust manifold and zetec flange off with my buddy to weld on for me when he gets some free time in work.
dug some more bits out that i've been collecting for the project as well
flywheel is a retro ford 'zetec to cosworth' weighing just over 4kg and the clutch is AP racing
measured my compression ratio to be 8.28:1 last weekend
also dropped the 200sx exhaust manifold and zetec flange off with my buddy to weld on for me when he gets some free time in work. dug some more bits out that i've been collecting for the project as well
flywheel is a retro ford 'zetec to cosworth' weighing just over 4kg and the clutch is AP racing
measured my compression ratio to be 8.28:1 last weekend
15-01-2011, 09:47 PM
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oh yeah i re-painted my rocker cover as the brush on engine lacquer had a shockingly shit finish let alone being a crap colour...and i decided im bored of blue rocker covers!
shitty blue
fixed!
shitty blue
fixed!
07-02-2011, 09:23 PM
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right then its time for an update!!!
the bottom end is pretty much built up but not without a little bit of head scratching!!!
after getting the crank pistons and rods inn and all torqued up i thought id jus have to pop the oilpump and sump on and i'll be flying along...and then found i'd been given the wrong oil pump gasket so work stopped for a week while waiting for ford to sort out the right one...anyway right gasket came so put the pump on and then went to fit the retro ford sump kit and found that modification was required to the oil pick up pipe as i wasnt using the modified main end bolt supplied with the kit as i am using the ARP stud/nut conversion...the problem was as follows....
due to this i decided that the simplest and best way to solve the problem was to cut the mounting bracket off and weld it back of closer to the oilpump where it could reach the neighbouring stud...
Re-fitted
and some random pics of the set up and 'finished' bottom end
have bought liams area6 inlet manifold so will be using that now insted of a modifed rover one i was going to use. just waiting for my exhaust manifold to come back from being welded and then i can sort the ports out and get it all together!!!
the bottom end is pretty much built up but not without a little bit of head scratching!!!
after getting the crank pistons and rods inn and all torqued up i thought id jus have to pop the oilpump and sump on and i'll be flying along...and then found i'd been given the wrong oil pump gasket so work stopped for a week while waiting for ford to sort out the right one...anyway right gasket came so put the pump on and then went to fit the retro ford sump kit and found that modification was required to the oil pick up pipe as i wasnt using the modified main end bolt supplied with the kit as i am using the ARP stud/nut conversion...the problem was as follows....
due to this i decided that the simplest and best way to solve the problem was to cut the mounting bracket off and weld it back of closer to the oilpump where it could reach the neighbouring stud...
Re-fitted
and some random pics of the set up and 'finished' bottom end
have bought liams area6 inlet manifold so will be using that now insted of a modifed rover one i was going to use. just waiting for my exhaust manifold to come back from being welded and then i can sort the ports out and get it all together!!!
Last edited by dazzboyee1986; 07-02-2011 at 09:35 PM.
06-03-2011, 08:59 PM
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just a quick update, progress has been a little slow but have managed to get the head, inlet and water pump fitted but having difficulties getting the exhaust manifold welded
few pics sorry about quality they're off my phone, will take betterones this week when i time it all up
few pics sorry about quality they're off my phone, will take betterones this week when i time it all up
20-03-2011, 09:55 PM
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bought the pulley off ebay ages ago, think it weighs about 1.2lbs. was around Ł30 i paid for it i think.
progress is going slow due to having to buy a new car to get to work but wont be long till the engines finished and put on the dyno but thinking i might end up selling it after all this work and expense!!! :'(
progress is going slow due to having to buy a new car to get to work
but wont be long till the engines finished and put on the dyno but thinking i might end up selling it after all this work and expense!!! :'(
which cambelt kit?!
12-04-2011, 08:53 PM
#28
Is it a Silvertop head then?
I fitted a Blacktop head on a Silvertop but not seen it done vice-versa. Just get a tensioner kit for both engines are try and mix and match the two; it's what I did originally.
I fitted a Blacktop head on a Silvertop but not seen it done vice-versa. Just get a tensioner kit for both engines are try and mix and match the two; it's what I did originally.
Last edited by XRT_si; 12-04-2011 at 08:56 PM.
13-04-2011, 06:20 PM
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i took the waterpump off a silvertop myself as i was told i needed one :-/
iv got a cambelt kit which has 2 idler pullys and a tensioner, theres ony one mounting place on my current set up for a idler and in the cambelt kit i have there is a bolt/anchor for the tensioner spring but no threadded hole to put it in!...did buy the kit a long time ago so mabe its wrong....
iv got a cambelt kit which has 2 idler pullys and a tensioner, theres ony one mounting place on my current set up for a idler and in the cambelt kit i have there is a bolt/anchor for the tensioner spring but no threadded hole to put it in!...did buy the kit a long time ago so mabe its wrong....
18-04-2011, 09:42 PM
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now to order some more goodies so i can dyno it at last!!! big thanks to zetaboostboy522bhp for his spot on help!
27-04-2011, 08:42 PM
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27-04-2011, 08:55 PM
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cambelt sorted and all timed up!
finally have an exhaust manifold sorted so fitted that and the turbo, few pics but crappy quality as i keep forgetting to take my camera to work!!
now got to mess around and find an actuator and bracket :-/
finally have an exhaust manifold sorted so fitted that and the turbo, few pics but crappy quality as i keep forgetting to take my camera to work!!
now got to mess around and find an actuator and bracket :-/
27-04-2011, 09:21 PM
#40
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nice build and glad you got the timing belt issue sorted , isnt that turbo externally gated ? , if so external wastegate mate and not a actuator and exhaust manifold modded to fit the external wastegate
keep up the good work
cheers paul
keep up the good work
cheers paul
