grant_xr

Hi,

pretty sure I had a build thread on the go but I can't find it...... so I'll start another

I've had the car for more years than I can remember, bought it standard then took it off the road to restore some of the bodywork.
I then had the great idea of putting an RS Turbo engine in
After years of patiently building the car up it looked like this






I traveled to Blackpool and had the car custom mapped at MSD with a spec of -
Specialised Engines() Stage 3, 1.9 () tall block, kent cvh 34 cam, bosch 701's, OFAB management, 2wd cosworth t3 and inter cooler, full stainless exhaust, series 2 RST gearbox with AP paddle clutch, 4x4 cosworth calipers and discs with a mondeo master cylinder and servo, spax adjustable suspension and fully polybushed.

The drive home was ace!!! Very impressed
After a few launches I managed to snap a stud on the gearbox
The gearbox was also jumping out of 5th gear when on boost.



The car then began to smoke heavy and the idle became erratic, so I tried a set of stem seals but I wasn't that lucky!
The head came off to reveal badly scored bores, the second hand turbo was shagged too.



After a bit of investigation I found out the second hand 1.9 tall block was infact a 1.8 sierra cvh engine bored out to accept 1.9 cast pistons
So if anyone wants my advice, stay away from Specialised Engines in Essex!
The bores couldn't take another re-bore and I wasn't keen on going down the cvh route as I ideally wanted a bit more than 200hp.
I toyed with the idea of going ZVH then finally decided to go full zetec turbo!

I picked up a second hand fully forged engine from Devil Developments which had came out of Matt Hibberts mk3 Fiesta RS Turbo running around 400hp.
I've since had the engine stripped and checked over by Agra Engineering in Dundee, where they replaced all shells and installed new rings.
I also had the zetec sump baffled to help eliminate any oil starvation when cornering hard!



Pistons and rods



I intend on running an accusump system too.

I spent a bit of time painting up a few bits and re-furbing the calipers with new discs and pads.







I also had my 3dr cossie wheels re-furbed and Pristine! Excellent service, highly recommended!




The old gearbox was stripped of the LSD and I had it installed into a diesel BC box with a fresh re-build.
The car will be run on low boost once mapped until I carry out an MTX 75 gearbox conversion with quaiffe diff

I sent my turbo off to Wilky to have it re-built and a 360 bearing installed



I borrowed my old mans welder and had a go at modifying a mk3 Fiesta RS Turbo Scorpion exhaust to fit the XR2.
The last system I was using was an XR2 magnex mated to an RST downpipe which was really too small a bore, so I decided to upgrade it,




I managed to pick up an uprated rear anti-roll bar set up to stiffen up the rear end even more and some adjustable track control arms and tie-bars.




The New engine






The engine is now in place and I've fitted a bigger front mount intercooler




How the car now sits on the re-furbed wheels and I've fitted RS mudflaps too.



New engine spec is -

2.0 silvertop zetec turbo with 86mm JE forged pistons and Eagle steel conrods.
Standard 2.0 mondeo zetec head bar a skim and Devil Developments uprated valve springs.
Larger front mount intercooler
JR cone filter
2wd Cossie T3 with 360 bearing
Devil Developments tubular stainless manifold
Fiesta RS Turbo Scorpion exhaust - modified to fit the XR2
Cossie fuel pump and external swirl pot
Weber IW 158 injectors (fiat coupe)
and the OFAB management will again be custom mapped by MSD.

Hoping to have the car on the road for the start of next summer.
Really looking forward to taking the car back to MSD now they have their new rolling road set up so I can see what sort of power its putting out!

Hope you enjoy reading!

Grant

little bram

looks nice mate good work

studabear

Looks good, zetec turbo's are the future, I couldn't justify building a forged cvh when a zt was better option.

grant_xr

Thanks guys!

Yeah mate, CVH is old hat these days really, zetec is an all round better unit for a base engine really!

What spec is your engine mate?

gingerturbo

iTrader: (2)

Love this looks tasty on the 3dr rims

studabear

Mines prob a bit lower specced than yours.
Basic run down

St170 bottom end, arp rod bolts, 1.5mm cometic head gasket, brand new head, st170 valve springs, frs inlet, rst exh manifold and adapter, stage 3 ish T3 turbo, megasquirt, 630cc injectors and all the usual bits like fmic stainless exh etc etc

grant_xr

Nice one man. Making good power for not a lot of boost!
Who mapped it?
My limiting factor is my management and injectors. The IW158's flow 385cc which is the largest I can run on OFAB.
It will be plenty enough in the wee fiesta tho. Went like stink with the last engine in so anything more will be entertaining.

studabear

I had it rolling roaded at msd on saturday, I was over the moon when stu said how well it had done.

Rick of this site mapped it, he's done a top job. He runs unicorn motor developments.
http://www.unicornmotordevelopments.com

Have you heard of the ofam ecu? its a megasquirt ecu built into a ofab/c case so it is plug and play into your existing loom, giving you more up to date features and a wider choice of injectors, plus then can be mapped with a laptop and afr/wideband setup.
http://www.boostmonkeys.co.uk/

grant_xr

Yeah I've heard of it, and have considered it.
For me its more cost effective to have it custom mapped again on the OFAB by MSD. I'll get a discount off the mapping as its been done there before, plus I'd have to buy new injectors.
I'll be happy around the 250-275 hp mark. It'll be more than enough in a little fiesta

studabear

You will be in safe hands with msd.

I may have to look at a mtx gearbox conversion in the future, as the gearbox and clutch are my limiting factors, besides traction lol.

I will keep a eye on your thread.

grant_xr

Not updated this in a while

The XR2 is now on the road Ended up biting the bullet studabear an bought OFAM Best move I made imo!

Got it running around 13psi at the mo and its a bit of a handful through the twisties

Torque steers like a bitch so I've come to the conclusion the standard ERST diff is shit But better that an open diff I suppose!

The gearbox I bought which I thought was a diesel box, has a very short fifth gear so top speed isn't very high and is achieved quite quickly. Plan is to fit an MTX of some variety with a quaife diff probably next year.
Just plan on having some fun in it this summer!

Intercooler painted and black hoses

bagginsRSturbo

iTrader: (1)

Very nice mate looks good on the 3dr wheels bet it goes well

studabear

Nice to see it on the rd, who's mapped it for you?

grant_xr

Cheers guys! Mapped it myself so far

Do plan on taking it to MSD when the time is right for a power run and some final tweeks by the pro's!

Grant

studabear

Great stuff, I wouldn't have dared try to map mine,

(infact I collect it tomorrow after its little holiday for cold start and iscv tweaks)

grant_xr

Tbh I was very wary about attempting mapping it myself but I read up a lot on it and I was given a pretty good basemap so I decided to give it a go. Obviously only making small adjustments at a time and taking it slowly but starting to get the hand of it now!

Brian

iTrader: (2)

Looks very nice mate


Brian

grant_xr

Cheers Brian!
Have you been on xrtwo lately? Can't seem to post on there, don't think anyone can as there aren't any new posts?

Grant

Glenn_

iTrader: (1)

Wow what a cool car. I like it a lot.

slammedorion

Looks lovely...

eddie_od

iTrader: (1)

Class wee motor, absolutely love turbo'd mk2 XR2's.

Had turbo technics and RS turbo'd ones, great fun.

grant_xr

Cheers guys!

Gearbox let go this afternoon

Mtx75 time I think!

Grant

Brian

iTrader: (2)

Opps

I'm thinking of going with a MTX gearbox


Brian

grant_xr

Well I've bit the bullet and bought a mk1 Focus RS box and a second hand but brand new and unused AP organic clutch kit & Focus RS flywheel! Also got a set of Siemens Deka 630cc injectors thrown in on the deal with the gearbox 8)

Now that the drive train will be able to handle some abuse I'll be upping the boost to 21psi with the bigger injectors fitted! :cool!:

Should have the bits end of this week/next week so will start the conversion asap!

Will be selling my frst flywheel and AP paddle clutch kit once the car is stripped. The clutch has only covered 5k (if that) and the flywheel had been skimmed before fitting.
I'll also be selling my vibratechnics gearbox mounts (again covered 5k) and the gearbox bearer/brackets with late spec linkage.

Will keep the thread updated with pics of progress

Grant

studabear

I need a mtx conversion, what else you needing now then?

Shafts
Mounts
Hydraulic clutch conversion

grant_xr

I've bought the gearbox with all mounts, shafts, gearstick/cables and clutch master cylinder.
Need to source/make up the pipework to the slave cylinder and fab the mounts.
Will be cutting an sleeving shafts so most of what I need is bought and will be cracking on with it once it arrives!
Hows your boc coping with the power? I was either unlucky or my driving style must be more abusive than yours

studabear

Fully rebuilt box lasted 450 miles or thereabouts, on another rst box at the minute.

grant_xr

Thats about as long as mine lasted.
Didn't help it was my mate driving at the time He wasn't even driving hard as it was his first shot, I'd been caining it before he got in tho!

Brian

iTrader: (2)

Good news on the FRS gearbox mate

Make sure you keep your thread up dated as i'm hoping to go the same route


Brian

studabear

What you opting for regarding the speedo Grant?

grant_xr

I'll be speedo less for this year
Speedo wasn't working with last box anyway, required a new cable.
I'll look into it winter time/next year. Prob upgrade the speedo and rev counter.

slammedorion

Will be keeping a eye on the updates...
Once I've moved I need to pull my finger out and get my RS set up in...
Need to get back in contact with Crazycage... Get it stripped and trailered up to him I think...

RS16iDale

Going to be a really good spec once its done.
Im thinking about getting megasquirt for mine whats your thoughts on it so far?

studabear

Megasquirt is great if built well, avoid extraefi

RS16iDale

O really why avoid them?

grant_xr

I can only speak for boost monkeys and I can't recommended ofam enough. I'd consider the gen 8 ECU they do if looking to change loom etc.
I think the extra efi build quality isn't meant to be as good but I have no experience of their kit.

Grant

studabear

I had a bad experience with them.

0150carmac

you done a cracking job with this
i look forward to reading the updates

grant_xr

Cheers folks!



Received my new clutch & flywheel today!
Just need the rest of the kit to arrive and I can crack on with it.

Grant

grant_xr

Took delivery of the MK1 FRS gearbox etc today
The rear gearbox mount hasn't been sent tho but will sort that out!

Plan is to start the conversion tomorrow night/all day sat with my old man, will keep thread updated with pics!

Cable shift feels ace even outside the car

XR2 is looking sorry for itself!