markobcars

Hello!

I would like to show a project that I started for this winter.I wanted to do this long time ago but never found the time...

I have a small workshop in which I make custom parts for race cars called MBC Custom Parts.

The car is going to be daily driven with a power goal of 230-250bhp out of a 2.0 zetec.

The conversion will first be done with cosworth engine and after it is fully functional zetec is going in until money and time allow me to drive it with cossie inside...

A lot of components will have to be modified to make this a functional daily driver.

This is done so far...

markobcars

I appologise for the poor picture size,this is my first thread on this forum.I'll find a way to post full size pictures.

markobcars

markobcars

markobcars

Cosworth engine spec will be:

Custom rods C/C 133.5mm
PA1086 (90.82) short Cosworth pistons
Custom steel flywheel
Custom multiplate clutch
Standard doweled pinto crank
Cooper head gasket with block Orings
Valves will be 7mm stem intake and exhaust Cosworth items
ported head
standard cams
Custom MBC ECU ( I have my own stand alone engine management system based on PIC microcontrollers)
custom intake and exhaust manifolds
T3/T4 turbo

dojj

iTrader: (3)

it may be worth investigating the focus v8 conversion from america

this allowed the installation of a v8 into a mk1 focus with bolt in parts

the parts were around $4,000 american so not cheap, but it may save a lot of fabricating if they can be simply bolted in

markobcars

I know and thank You for the advice!!I have been thinking about which way to go with this and decided that I will try to modify only the subframes and leave the body original as much as I can.Gearbox tunnel will have to be modified and few beams around the firewall. It is not a problem for me to fabricate parts for the drivetrain and the goal is to do everything I can so I don't have to buy expensive parts...

markobcars

Small update...
I have spot welded the sierra sub frame to mondeo sub frame and for the first time I have fitted the engine

The engine will have to sit lower by 40mm so new engine mounts will be made and a modified sump will be needed...

I still haven't decided on the steering rack... I can use the sierra rack but it will need to be modified to sit lower under the engine and if possible i will shorten it by 100mm...

Second option is to use a mondeo steering rack which is shorter and sits lower in the sierra sub frame when mounting holes are modified.It travels on the opposite side(from sierra rack) when turning the steering but I am planning to use a gear steering quickener which will change the direction of rotation...

markobcars

This is a short shift modification of mt75 box... Tried and tested,it shifts perfect with zero play! Every joint is modified to plastic/steel joints and the shift knob is positioned high so it is in the peripheral eye sight...

Mk4 Rick

Nice work mate I will be watching this

Carlos-Titx

Welcome to PF!

That engine sits very close to the bulk head? Would it not hit it and rattle constantly?

markobcars

Thank You!

Yes,but this is only a first trial fit... I mentioned in the post that engine will be sitting lower by 40mm and the firewall will be modified so everything fits nicely

BRAM

iTrader: (1)

Nice project, no hanging around either engine mounted already

Carlos-Titx

Ah got you.

What's the colour options?

Do it citrine yellow

markobcars

matte black is the only option

This is painted just to see how will it fit mondeo body... After i finish the conversion everything will be sandblasted and painted




This is my current brake setup:
Front: 300mm Focus st front disc with 4x44mm piston calipers
Rear: 260mm mondeo front vented disc and calipers with twin piston hydraulic H brake calipers

Carlos-Titx

Any body kit or as is?

Like the wheels.

markobcars

I would really like to get my hands on RS body kit(bumpers,skirts...) but here in Croatia nobody can get it and it costs too much to order from ebay
Ford parts dealer wants too much for the bumpers...

Carlos-Titx

That is a very nice looking kit.

Had one on my old mondeo.

Scrap yards maybe? That's where I found a replacement when I needed one.

Mister G

Awesome project, although matt-black isn't for me, I'd like to see a few more Mondy's saved and turned into propper sleepers!

markobcars

Scrap yards will be my only option...

Glenn_

iTrader: (1)

Cool project matey.I will defo be keeping an eye on it.

adam151082

Cool car, love the wheels.

markobcars

Thanks everybody!!

Today I started cutting the body for the gearbox and I fitted the gearbox to Cosworth and also to Zetec engine...

I hate to say it but Zetec is much easier to fit inside the mondeo body...There is much more space around the engine...

The hardest modification of all will be to fit a steering rack because mondeo front subframe i soooo much in the way and i want both engines to sit low in the body...

packman

As the Mondeo is heavy id say u are going to need a min of 300 hp with similar torque ....
nice project thou will be keeping tabs on this also loving the rear disc setup ....

markobcars

It would be a nice car to drive with 300Hp and much better weight distribution vs FF setup and 130Hp standard.
My biggest limitation for big HP numbers is fuel consumption... I think that 300hp is the upper limit for a daily driver with fuel prices of 1.5eur per 1L and a pay check of 600eur per month:/

That is the only reason for fitting a zetec engine...

Cossie Sean

keep it Cosworth!!

https://www.google.co.uk/search?q=re...w=1272&bih=649

markobcars

yeah...

I won't be able to sleep at night if I leave that cossie engine laying on the shelf

Vedran

Svaka cast covjece,si opet poceo s proizvodnjom dijelova?
I ove felge mu u biti jako dobro stoje
Sad nek se englezi pitaju kaj sam napisal

dojj

iTrader: (3)

won't the steering rack and geometry be based on what suspension you will be using as one is front and the other is on the rear?

markobcars

The only possible place for the steering rack(fwd or rwd) is under the sump,just like the sierra setup but I have a problem because I will keep the original mondeo subframe and suspension A arms...
Sierra rack aluminium body and gear shaft is longer than mondeo rack body and also the shaft,so mondeo rack is more suitable for me to use because it causes less interference with mondeo subframe.
I have the solution for rack fitment and I will post the pictures on monday or tuesday when I get the parts from water jet cutting...

chris cdti

How about a sierra type of steering setup along with a sierra subframe?

markobcars

One of the best things about the Mondeo is its front subframe and beams around the firewall and gearbox tunnel! It makes the chassis stiff and I don't want to lose that!!
So I will cut out the piece of the mondeo subframe that is in the way of the steering shaft but I'll strengthen the subframe with a bridge above the steering rack.... It is a little complicated for me to explain in english...
The steering geometry will stay the same like on a sierra... I will only change mondeo knuckles from from left to right so steering arms are faced forward...
I'll post the pictures soon

Mondi-DZK

iTrader: (1)

Hmm Mondeo Cosworth

Looking good allready, keep it up.
Really love this. I hope you will find an RS kit mate.

Mk4 Rick

Defo mondeo Cosworth

markobcars

This looks good...

Mk4 Rick

The bad boy bonnet ruins it in my opinion.Is that a ford mustang badge I spy as well lol if it is I would rip that off as well lol.rest of the car looks well I do like the idea of the vent in the wing

Mk4 Rick

Go Cosworth with it though you have gone this far with it.What gearbox are you using

Mk4 Rick

Miss read the thread its a mt75 box lol

Maxwell

Needs to be painted "Citrine" and have an RS kit and it will be the Mondeo that Ford should have made!

markobcars

At first it will be a Cosworth but my biggest problem is that I have parts for some 400bhp and it would be a shame to run it at lower power levels... It will be a problem to drive it every day... We don't have race tracks here where we can enjoy every weekend in our cars... There is one big race per year and it is a King of Europe Drift and drag festival held i Osijek,Croatia...

I have another engine option... 2.9 24v BOB cosworth biturbo!! I have custom rods made for it and KKK16 turbines with identical serial number and in perfect condition!
I would weld v6 automatic gearbox flange to an MT75 box (we don't have v6 MT75 boxes here)...

For the colour I will decide when the time comes soon I hope