Zetec turbo escort. Nearly there...
16-04-2013, 10:43 PM
#1
Kapow!!
Thread Starter
Zetec turbo escort. Nearly there...
Well... I bought an Escort RS Turbo when i was 19. It had been stripped out with a cage, buckets and harnesses, gauges ect..
It had willwood 4 pot cossie size front brakes and a 2wd saph cos rear disc conversion, and in-car brake pipes with a bias controller.
Suspension wise it just had koni shocks and lowering springs.
It had a zetec turbo conversion. It was a fully rebuilt standard 2.0 silvertop zetec, with skimmed pistons to lower compression.
Also had a stage 2 T3 turbo with .63 housing (used cvh manifold with adapter plate), full stainless exhaust, rover turbo inlet manifold with adapter home made adapter plate, onex 600 ecu, oil cooler, ally rad, pace intercooler ect... Had a printout for 254bhp at 14psi of boost, but i ran it with 11psi.
also had a diesel gearbox with an rst lsd.
Kept the thing for about a year, had some fun with it then sold it.
However... 9 or 10 months later, i txt the bloke i sold it too and bought it back. In about 100 bits.
I ran it again for a couple of months, untill one night i raced an Audi S5 on the motorway. We were side by side. He hit the limiter. I polluted Southampton with lots of smoke.
So then i decided to build a proper engine instead of a lump of budget bollocks.
I bought a set of forged rods and pistons and rebuilt the bottom end. And could see what caused the smoke issue too.
Had the blocked bored out for the oversized pistons...
New oil and water pumps ect, and the bottom end was done.
As for the head... I wanted to keep the rover inlet manifold. My friend races a rover turbo in a saloon championship, he has over 550bhp with the same manifold so cant be that bad!
Anyway... I had a proper good quality adaptor plate made, bolted it to the head, then i had the zetec injector cutouts filled with ally weld as these wernt needed any more, then got my die grinder out and flowed it all as one thing
Then gave it a little port and polish. Then had 3 angle valve seats cut, valves refaced and had the head skimmed.
Then i decided i didnt want a cvh manifold with an adaptor plate, so i bought a standard focus rs manifold, turbo and downpipe.
Then i thought... I need a gearbox thats strong.
I bought a focus rs gearbox with starter motor and gear cables, but then found out what needed modifying to fit the thing! Making the clutch hydraulic wasnt too bad. Just needed a master cylinder on the pedal.
Then we needed to make a top mount (thanks to crazycage)and rear mount. That took sone time but got there in the end.
So now the engine was built, box was fitted, we were ready to roll...
But no. 300bhp clearly wasnt going to be enough. The engine and box could handle double that so i bought a big T4 turbo, had a tubular manifold made by crazycage with external wastegate, 710cc injectors, the biggest intercooler that would fit in the front withough major modifications, and big shock when i looked at my bank balance afterwards.
Then i thought i'd better not use a standard focus rs clutch, so i got a 6 paddle item
So then i thought, i'd better make thing stop and handle too... So i bought a set of decent coilovers and focus rs front brakes
And then i thought, i want it to look half decent. So i totally stripped the thing.
Then i flatted it all back, ready for primer.
But then got put on hold for 6 months
But then one day, it actually got primed!
Then painted in Ferrari Silverstone Grey
I had my dash flocked, then refitted that...
Then refitted the engine bay and made some new brake pipes ect
Then the thing was ready to go in...
And today, i fitted the doors, boot, bonnet and bumper.
Would like to say a massive thanks to Crazycage and Twins so far for their help, and also s2rst for flocking my dash and the turbo, and weaksy for the coilovers.
Anyway, thats how far i am so far. More updates soon!
It had willwood 4 pot cossie size front brakes and a 2wd saph cos rear disc conversion, and in-car brake pipes with a bias controller.
Suspension wise it just had koni shocks and lowering springs.
It had a zetec turbo conversion. It was a fully rebuilt standard 2.0 silvertop zetec, with skimmed pistons to lower compression.
Also had a stage 2 T3 turbo with .63 housing (used cvh manifold with adapter plate), full stainless exhaust, rover turbo inlet manifold with adapter home made adapter plate, onex 600 ecu, oil cooler, ally rad, pace intercooler ect... Had a printout for 254bhp at 14psi of boost, but i ran it with 11psi.
also had a diesel gearbox with an rst lsd.
Kept the thing for about a year, had some fun with it then sold it.
However... 9 or 10 months later, i txt the bloke i sold it too and bought it back. In about 100 bits.
I ran it again for a couple of months, untill one night i raced an Audi S5 on the motorway. We were side by side. He hit the limiter. I polluted Southampton with lots of smoke.
So then i decided to build a proper engine instead of a lump of budget bollocks.
I bought a set of forged rods and pistons and rebuilt the bottom end. And could see what caused the smoke issue too.
Had the blocked bored out for the oversized pistons...
New oil and water pumps ect, and the bottom end was done.
As for the head... I wanted to keep the rover inlet manifold. My friend races a rover turbo in a saloon championship, he has over 550bhp with the same manifold so cant be that bad!
Anyway... I had a proper good quality adaptor plate made, bolted it to the head, then i had the zetec injector cutouts filled with ally weld as these wernt needed any more, then got my die grinder out and flowed it all as one thing
Then gave it a little port and polish. Then had 3 angle valve seats cut, valves refaced and had the head skimmed.
Then i decided i didnt want a cvh manifold with an adaptor plate, so i bought a standard focus rs manifold, turbo and downpipe.
Then i thought... I need a gearbox thats strong.
I bought a focus rs gearbox with starter motor and gear cables, but then found out what needed modifying to fit the thing! Making the clutch hydraulic wasnt too bad. Just needed a master cylinder on the pedal.
Then we needed to make a top mount (thanks to crazycage)and rear mount. That took sone time but got there in the end.
So now the engine was built, box was fitted, we were ready to roll...
But no. 300bhp clearly wasnt going to be enough. The engine and box could handle double that so i bought a big T4 turbo, had a tubular manifold made by crazycage with external wastegate, 710cc injectors, the biggest intercooler that would fit in the front withough major modifications, and big shock when i looked at my bank balance afterwards.
Then i thought i'd better not use a standard focus rs clutch, so i got a 6 paddle item
So then i thought, i'd better make thing stop and handle too... So i bought a set of decent coilovers and focus rs front brakes
And then i thought, i want it to look half decent. So i totally stripped the thing.
Then i flatted it all back, ready for primer.
But then got put on hold for 6 months
But then one day, it actually got primed!
Then painted in Ferrari Silverstone Grey
I had my dash flocked, then refitted that...
Then refitted the engine bay and made some new brake pipes ect
Then the thing was ready to go in...
And today, i fitted the doors, boot, bonnet and bumper.
Would like to say a massive thanks to Crazycage and Twins so far for their help, and also s2rst for flocking my dash and the turbo, and weaksy for the coilovers.
Anyway, thats how far i am so far. More updates soon!
Like the colour
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17-04-2013, 06:01 PM
#11
Kapow!!
Thread Starter
19-04-2013, 07:08 PM
#28
Advanced PassionFord User
Wow this looks great 
well done.
well done.
21-07-2013, 10:50 AM
#32
Advanced PassionFord User
Looks lovely mate,
Really liking that colour too!
Cheers Paul
Really liking that colour too!
Cheers Paul
10-08-2013, 11:43 AM
#40
Kapow!!
Thread Starter
Didn't really get much further with it, and unforchunatly is now for sale as an unfinished project. if it doesn't sell il break it for parts. Simply don't have the time to finish it, I have too many 'toys' and this one has to go. PM me if anyone is interested. recently fitted the focus RS front brakes and fitted the new wheels. All that's left to do is a few bits of wiring, down pipe, screamer pipe and boost pipe set, and then to get it mapped. the roll cage needs painting, then the new seats (that are still in packaging) can be fitted. Theres not much to do at all really.