Mk2 Fiesta Xr2 ZT, gt30, now breaking :(
05-05-2011, 08:37 PM
#1
Mk2 Fiesta Xr2 ZT, gt30, now breaking :(
where do i start, had this car for around seven years now, bought it as a turbo technics converted xr2 with g-max suspension and very few other mods.
loved it to bits and got it cheap.
few things broke down and ended up leaving it for a couple of years doing nothing, then decided to rip engine out and replace due to cracked bore
bit of a rebuild and work on fitting front mount, mondeo servo and master cylinder
i had a few issues with turbo's and oval bores in blocks and went for a 1.8 zvh
the exterior looked like this for a time:
i changed the powerflow system built for the original setup and modified a maxnex system off an erst when i chaged turbo to a t3 instead of the t25 from the tt setup. this meant a few things had to change, namely the radiator and fan setup:
front mounted erst fan i modified a little to get the depth down by 5mm over the standard item.
then it ran well for a while, apart from a timing issue due to dizzy.
then i did this into the back of an A6
so i decided to build it back up and go to cossie turbo and megasquirt, gaz coilovers, various injectors were used and settled on dekaIV 630cc ones with a peak of 23psi of boost. i did all the work mslef throughout this so even sprayed it and a loose fashion.
i fitted an external fuel swirl pot in the rear and a red top facet to feed it and later a cosworth fuel pump 579 IIRC
It ran well till i had a laptop crash whilst mapping and it messed up the map and ran really lean damaging one of the rings and ended up with cylinder 4 beaing slightly down on compression.
so i decided to fix it, then i got offered a zetec area six head, so i began improving yet again to what i'm currently building now.
It now has a 2.1 blacktop bottom end with forged pistons, steel rods, arp main studs and conrod bolts. Top end is a blacktop head and has light porting, area six turbo spec cams, uprated valve springs and aluminium retainers.
turbo is a TB04 turbo with 0.63 exhaust housing and ball bearing cartridge good for 450 bhp on current housing.
modified 200sx exhaust manifold ("crazycage" gary) with external wastegate (done by myself) and further modified for mk2 fiesta bay.
a focus RS gearbox and custom made driveshafts out of 40 rockwell steel (one of the hardest out there), along with hydraulic clutch setup, 6 paddle clutch and custom mounts for the box.
dash had to be changed due to gearbox so opted for escort ghia binnicle and slamme da stack speedo and rev counter (£430 worth).
used a HO zetec manifold and modified the fuel rail from that along with an alfa 155 one to make something useable for top feed injectors since i had 630cc ones already.
there are lots of other little touches along the way, but it has been a mission to get everything in there whilst trying to make it look as standard as possible on the outside.
even down to having to move washer bottle to get air filter in has plagued me throughout.
i even made the 3" 316 stainless exhuast using mandrel bends, really is a passion for the last few months making it into what it will become
Anyhow, enough talk, current pics follow and there is still a fair bit to do as of yet:
cage fitted, just doors bars to fit after interior finished
bottom end
modified breather
six paddle cosworth clutch and FRS cover on brand new 2.0 flywheel
engine built up ready for fitting:
engine and box fitted
pic of remote mounted frs clutch master cylinder (pedal worked over also)
had a few issues with water pipes and boost pipes so bought more mandrel stainless bends and created a work around and trial fitted the ITG airfilter. so this is where i'm up to now:
i'm hoping for way too much power to say the least, but it's a toy at the end of the day.
i will update this chronologically going forwards but the complete story is on the following link: http://xrtwo.speedcentral.co.uk/viewtopic.php?t=41968
thanks for reading my story, i'm sure i've missed loads out, but there's 56 pages on another forum so far, so difficult to trim it down.
cheers
sean
loved it to bits and got it cheap.
few things broke down and ended up leaving it for a couple of years doing nothing, then decided to rip engine out and replace due to cracked bore
bit of a rebuild and work on fitting front mount, mondeo servo and master cylinder
i had a few issues with turbo's and oval bores in blocks and went for a 1.8 zvh
the exterior looked like this for a time:
i changed the powerflow system built for the original setup and modified a maxnex system off an erst when i chaged turbo to a t3 instead of the t25 from the tt setup. this meant a few things had to change, namely the radiator and fan setup:
front mounted erst fan i modified a little to get the depth down by 5mm over the standard item.
then it ran well for a while, apart from a timing issue due to dizzy.
then i did this into the back of an A6
so i decided to build it back up and go to cossie turbo and megasquirt, gaz coilovers, various injectors were used and settled on dekaIV 630cc ones with a peak of 23psi of boost. i did all the work mslef throughout this so even sprayed it and a loose fashion.
i fitted an external fuel swirl pot in the rear and a red top facet to feed it and later a cosworth fuel pump 579 IIRC
It ran well till i had a laptop crash whilst mapping and it messed up the map and ran really lean damaging one of the rings and ended up with cylinder 4 beaing slightly down on compression.
so i decided to fix it, then i got offered a zetec area six head, so i began improving yet again to what i'm currently building now.
It now has a 2.1 blacktop bottom end with forged pistons, steel rods, arp main studs and conrod bolts. Top end is a blacktop head and has light porting, area six turbo spec cams, uprated valve springs and aluminium retainers.
turbo is a TB04 turbo with 0.63 exhaust housing and ball bearing cartridge good for 450 bhp on current housing.
modified 200sx exhaust manifold ("crazycage" gary) with external wastegate (done by myself) and further modified for mk2 fiesta bay.
a focus RS gearbox and custom made driveshafts out of 40 rockwell steel (one of the hardest out there), along with hydraulic clutch setup, 6 paddle clutch and custom mounts for the box.
dash had to be changed due to gearbox so opted for escort ghia binnicle and slamme da stack speedo and rev counter (£430 worth).
used a HO zetec manifold and modified the fuel rail from that along with an alfa 155 one to make something useable for top feed injectors since i had 630cc ones already.
there are lots of other little touches along the way, but it has been a mission to get everything in there whilst trying to make it look as standard as possible on the outside.
even down to having to move washer bottle to get air filter in has plagued me throughout.
i even made the 3" 316 stainless exhuast using mandrel bends, really is a passion for the last few months making it into what it will become
Anyhow, enough talk, current pics follow and there is still a fair bit to do as of yet:
cage fitted, just doors bars to fit after interior finished
bottom end
modified breather
six paddle cosworth clutch and FRS cover on brand new 2.0 flywheel
engine built up ready for fitting:
engine and box fitted
pic of remote mounted frs clutch master cylinder (pedal worked over also)
had a few issues with water pipes and boost pipes so bought more mandrel stainless bends and created a work around and trial fitted the ITG airfilter. so this is where i'm up to now:
i'm hoping for way too much power to say the least, but it's a toy at the end of the day.
i will update this chronologically going forwards but the complete story is on the following link: http://xrtwo.speedcentral.co.uk/viewtopic.php?t=41968
thanks for reading my story, i'm sure i've missed loads out, but there's 56 pages on another forum so far, so difficult to trim it down.
cheers
sean
Last edited by xr2wishy; 20-11-2012 at 01:46 PM.
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06-05-2011, 10:15 PM
#10
had an hour and so got boost pipes sorted, just need welding up now (low on gas so will wait till i've got exhaust tacked till i risk running out of gas till monday/tuesday
now i can fit oil cooler up front and open valance up a little more to get some airflow to it at last, will get some longer hoses and mock it up before getting ends finished off properly.
hopefully get exhaust finished after work tomorrow, 316 stainless 3" pipe using mandrel bends, one silencer and flexi, only flexi forwards to get done now including lambda and egt boss's
now i can fit oil cooler up front and open valance up a little more to get some airflow to it at last, will get some longer hoses and mock it up before getting ends finished off properly.
hopefully get exhaust finished after work tomorrow, 316 stainless 3" pipe using mandrel bends, one silencer and flexi, only flexi forwards to get done now including lambda and egt boss's
08-05-2011, 01:25 PM
#12
i heard a rumour about another garic44 inlet on the market, now/soon.
i'll have to have a peek at it before i think of changing over, probably best to just get it running first though.
on that note, i've moved the external wastegate to clear rad pipes, tapped a fitting on compressor housing for boost controller and worked on the manifold a little to get the bolts for turbo to hold since i've had to tweek a bit to get turbo where i wanted it and primary pipes were in the way for a nut on one fixing.
next day off will see the exhaust butchered together lol
i'll have to have a peek at it before i think of changing over, probably best to just get it running first though.
on that note, i've moved the external wastegate to clear rad pipes, tapped a fitting on compressor housing for boost controller and worked on the manifold a little to get the bolts for turbo to hold since i've had to tweek a bit to get turbo where i wanted it and primary pipes were in the way for a nut on one fixing.
next day off will see the exhaust butchered together lol
08-05-2011, 11:30 PM
#16
it'll do lol!
had to mess around quite a bit with it though due to clearance issues, one reason the turbo is reverse mounted, bloody bay is way too small, especially with the mtx75 box pushing engine 10mm further forwards than the bc box.
p.s. gary, tell me more about the new design of inlet, sneeky pics if you like
had to mess around quite a bit with it though due to clearance issues, one reason the turbo is reverse mounted, bloody bay is way too small, especially with the mtx75 box pushing engine 10mm further forwards than the bc box.
p.s. gary, tell me more about the new design of inlet, sneeky pics if you like
09-05-2011, 07:35 PM
#17
PassionFord Post Whore!!
it'll do lol!
had to mess around quite a bit with it though due to clearance issues, one reason the turbo is reverse mounted, bloody bay is way too small, especially with the mtx75 box pushing engine 10mm further forwards than the bc box.
p.s. gary, tell me more about the new design of inlet, sneeky pics if you like
had to mess around quite a bit with it though due to clearance issues, one reason the turbo is reverse mounted, bloody bay is way too small, especially with the mtx75 box pushing engine 10mm further forwards than the bc box.
p.s. gary, tell me more about the new design of inlet, sneeky pics if you like
11-05-2011, 09:53 PM
#21
finally got round to finishing the exhaust, real pain and still got the screamer pipe to go, but that's easy to sort.
it is made from 3" 316 stainless tube with 1.6mm walls with mandrel made bends and has lambda and egt probe take offs, i'm hoping it won't be too loud
battery died on camera so will get some in-situ pics from underneath later.
it is made from 3" 316 stainless tube with 1.6mm walls with mandrel made bends and has lambda and egt probe take offs, i'm hoping it won't be too loud
battery died on camera so will get some in-situ pics from underneath later.
17-05-2011, 07:49 PM
#24
boost pipes all done and screamer pipe made.
just not sure if i should heat wrap the screamer pipe and the exhaust from turbo back since i already have a load of high temp thermal wrap on my shelves.
also had some new braided hoses made up for relocating the oil cooler to front of bat just behind near side of the radiator.
might knock off a few more tasks in the morning before work, definitely clean some of the grinder dust that has rusted off the crossmember too me thinks, makes it look rotten
just not sure if i should heat wrap the screamer pipe and the exhaust from turbo back since i already have a load of high temp thermal wrap on my shelves.
also had some new braided hoses made up for relocating the oil cooler to front of bat just behind near side of the radiator.
might knock off a few more tasks in the morning before work, definitely clean some of the grinder dust that has rusted off the crossmember too me thinks, makes it look rotten
22-05-2011, 09:18 PM
#27
wrapped the screemer pipe the other day and spent the evening itching :blub:
so wrapped the rest of the exhaust today, fully fitted the turbo after locking the housings in place and knocking up an oil feed stub for the
top of the turbo along with getting a slightly longer feed pipe to the filter.
finished the boost pipes fully as one needed altering a little due to turbo sitting spot on and pulled into engine as i hadn't noticed it was slightly away at the bottom of flange before tweaking position. this then caused no end of issues with exhaust and screamer pipe hitting the gearbox and egt probe being really far into the pipe (which it still is, but should just about read right as it is in the middle of the pipe)
decided to mount the oil cooler behind the radiator on passenger side, but may actually fit it up to the right of the intercooler as pipes are a little longer than i estimated i'd need, otherwise I'll just send them round the engine a little round the houses.
air filter all fitted fully and only a couple of pipes need buying/connecting/making up now, iscv fitting as i've made the take off also today.
i have a loom to get it running hopefully before the week is out, then will get the dash finished off and interior all refitted.
so wrapped the rest of the exhaust today, fully fitted the turbo after locking the housings in place and knocking up an oil feed stub for the
top of the turbo along with getting a slightly longer feed pipe to the filter.
finished the boost pipes fully as one needed altering a little due to turbo sitting spot on and pulled into engine as i hadn't noticed it was slightly away at the bottom of flange before tweaking position. this then caused no end of issues with exhaust and screamer pipe hitting the gearbox and egt probe being really far into the pipe (which it still is, but should just about read right as it is in the middle of the pipe)
decided to mount the oil cooler behind the radiator on passenger side, but may actually fit it up to the right of the intercooler as pipes are a little longer than i estimated i'd need, otherwise I'll just send them round the engine a little round the houses.
air filter all fitted fully and only a couple of pipes need buying/connecting/making up now, iscv fitting as i've made the take off also today.
i have a loom to get it running hopefully before the week is out, then will get the dash finished off and interior all refitted.
23-05-2011, 05:52 PM
#31
not concerned about it to be honest, will just get a bigger one if needs be later only money :blub:
still need to change map sensor from the 2.5BAR one and get sequential injection/ignition/coil on plug sorted, or find someone willing to mod ecu as i'm not ready for doing it myself yet
23-05-2011, 06:17 PM
#32
PassionFord Post Whore!!
really? should be good for just over 450bhp on the 0.63 housing, upto 550bhp on the 1.04 (?) housing. it has a ball bearing cartridge in it.
not concerned about it to be honest, will just get a bigger one if needs be later only money :blub:
still need to change map sensor from the 2.5BAR one and get sequential injection/ignition/coil on plug sorted, or find someone willing to mod ecu as i'm not ready for doing it myself yet
not concerned about it to be honest, will just get a bigger one if needs be later only money :blub:
still need to change map sensor from the 2.5BAR one and get sequential injection/ignition/coil on plug sorted, or find someone willing to mod ecu as i'm not ready for doing it myself yet
diy autotune for the map sensor about 50 quid .
heres a pic of the COP kit i do
23-05-2011, 07:19 PM
#34
Too many posts.. I need a life!!
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23-05-2011, 10:16 PM
#36
gary i ditched the 4wd cossie turbo and got a T04B super v trim 0.63 ceramic ball bearing turbo.
custom drive shafts, man in a shed, so to speak, made from 42 rockwell steel, so very hard, could be hardened further if i wanted, but he made some for a 950bhp cossie once and still going strong.
cost me £160 for work and materials, then cv's and boots on top and fuel, so around £260 all in all.
he won't be getting 42 rockwell any more, but will have 30 rockwell due to inconsistancy in strength as he tests every rod since he has the kit to do so.
flywheel is a brand new 2.0 zetec flywheel.
custom drive shafts, man in a shed, so to speak, made from 42 rockwell steel, so very hard, could be hardened further if i wanted, but he made some for a 950bhp cossie once and still going strong.
cost me £160 for work and materials, then cv's and boots on top and fuel, so around £260 all in all.
he won't be getting 42 rockwell any more, but will have 30 rockwell due to inconsistancy in strength as he tests every rod since he has the kit to do so.
flywheel is a brand new 2.0 zetec flywheel.
24-05-2011, 05:01 PM
#38
PassionFord Post Whore!!
25-05-2011, 10:17 PM
#40
I've had a productive day after collecting more bits and pieces this morning
i've made new wiring for alternator, main power feed from battery to starter, battery to engine earth. rewired the reversing switch, water temp sender for cluster. wired in oil temp sender in sump, oil pressure sender and relocated the ACT sensor. also piped in boost controller and relocated the solenoid (changed layout due to external wastegate). finished off the oil return from turbo to sump, piped in ISCV, refitted the header tank and strut brace.
i realised i needed another take off from boost pipes for boost controller and act sensor so added a boss for that.
as far as i can tell i need to just mount oil cooler and attach hoses, finish off piping coolant pipes from stat housing to heater matrix (tiny job), fit breather pot (somewhere lol!) and make an extra brace for front of gearbox to crossmember.
that's all the big jobs done then in the bay, just leaves wiring in new dash, speed sensor from gearbox and changing ecu loom over to the zetec one i made a while back.
when all that is done i'll work over the centre console and remount roof clocks, then turn the key once fluids are in
yet another pic of bay with more stuff planted in it
i've made new wiring for alternator, main power feed from battery to starter, battery to engine earth. rewired the reversing switch, water temp sender for cluster. wired in oil temp sender in sump, oil pressure sender and relocated the ACT sensor. also piped in boost controller and relocated the solenoid (changed layout due to external wastegate). finished off the oil return from turbo to sump, piped in ISCV, refitted the header tank and strut brace.
i realised i needed another take off from boost pipes for boost controller and act sensor so added a boss for that.
as far as i can tell i need to just mount oil cooler and attach hoses, finish off piping coolant pipes from stat housing to heater matrix (tiny job), fit breather pot (somewhere lol!) and make an extra brace for front of gearbox to crossmember.
that's all the big jobs done then in the bay, just leaves wiring in new dash, speed sensor from gearbox and changing ecu loom over to the zetec one i made a while back.
when all that is done i'll work over the centre console and remount roof clocks, then turn the key once fluids are in
yet another pic of bay with more stuff planted in it