HaggisTurbo

Hey, Been on PF a while now and decided it was about time I start one of these these posts to share what is going on!! Apologies for the one post after another, I am copying it over from another forum onto this one and going to update this one instead!

Had a few fords over the years and had an Fiesta RS Turbo until i staved it into the back of a taxi on the motorway never had the money to fix it up so just decided to break it for spares.

So after a few years of owning some normal everyday cars I had the itch to get another Turbo Ford and decided to build a Zetec Turbo on a budget!! I just needed to find a car to put it in.

After buying a Escort Mk4 5 Door, Then a Black Orion RS Kit, I finally settled for a Matisse Blue Mk2 Orion in very good nick! that and I was running out of space!!





Managed to secure this 52k Mile example for £750, It's in great condition, Not Mint but not far off it but most importantly it is solid and has been waxoiled underneath so most of the hard bit is done! Was garaged for years as it's elderly owner used it less and less, so ideal starting point!

Here is some pics of when I got it:







You don't see many mk2 Orion's up here so decided this would be the ideal car to put the Zetec Turbo in and start the project!

The plan is to leave the car looking as standard as possible and have some subtle mods done but without any bodykits etc, a semi sleeper is the plan!

HaggisTurbo

First thing to sort was to lower it a little so managed to get myself a set of Koni Adjustables with springs for £100 a steal! only thing was that the springs had seen better days so decided to DIY some paint stripping from it and a respray with some Hammerite shame about the washing line

Not bad I thought for a first attempt but certainly made them look a lot healthier!



Next up was to sort the wheels, I was never really a fan of pepperpots on the Orion, thought they were more suited to the Fiesta XR2 so swapped them out for the S2 RS Turbo wheels from my other Orion and this made it look a lot better although I think the drop is more 50mm+!

Apologies about the poor picture quality I took it was taken at night after dealing with a very stuborn bolt taking off the front suspension!

HaggisTurbo

So to update further, My mate has asked if he can take the Orion to the Scottish Car Show for their stand and seeing as they both detail cars I thought it would be a good chance to let them loose on the car to see how well it would come up after a detail and polish, In my opinion it came up stunning even in the indoor light of the car show:



Some outdoor shots:








so now that the car was looking as I wanted it was time to get some engine work done

HaggisTurbo

A few months ago I managed to source myself an engine and the spec and price was good so I bought it from DavySaff from PF. Did mean a fair drive from Glasgow to Wirral and back in the not so trusty Fiat Brava I use as a daily!

The spec is based on the tried and tested Zetec Turbo conversion thread that Karlos put up, this suited me perfect and so bought the engine!

Spec is

- 2.0 Litre Blacktop Zetec Head
- ST170 Focus Zetec bottom End
- 106 GTI valve springs with Shims fitted
- Genuine Ford Focus RS Head Gasket
- ARP bolts
- Turbo Oil Feed
- Turbo Oil Return

The amount of other things I got in the deal from Davy was mental, also got:

- Recon CVH Alternator
- Cosworth Fuel Regulator
- Zetec Cam Locking Tool
- Spare Aux belts and Pulleys
- Cone Filter
- Water Pump Idler Bracket
- Gen Ford Exhaust & Inlet Gaskets

and a bag of other stuff that will come in handy for the conversion! Some guy Davy

Planning to strap a T3 / T34 to the above to hopefully see 300 to 320 bhp that is the goal!

HaggisTurbo

Got the engine up the road and assembled it on the engine stand to take a better look:







First thing I needed to do was have an extra breather added to the sump, I was wanting to keep things simple so was planning on using the Escort RS Turbo Manifold with an adaptor rather than a custom one that would need an exhaust made up for it also means I only need to source a ERST Stainless exhaust system instead, much easier!

So Sump, Pan and Pickup pipe removed I am happy to see the ARP bolts in there:




The amount of slimey sealant on this oil pan was crazy!! Not sure if it is a better or worse design of the cork gaskets on the CVH!



Was being quoted around £50 for having the barb for the breather welded to the sump but one of the guys from the local car clubs in here is an alumminium welder to trade and done it for some beers, Top Guy and the finish was pretty good too!

HaggisTurbo

Bit of an amusing update to say that I managed to source a full Stainless Scorpion Exhaust System in great condition

for the bargain price of £50!! Only problem was it was 100 miles away so off for another road trip in the Fiat

Turns out that wasn't the only downside, The exhaust was not in parts it was in one complete system with the joins

welded and Downpipe attached!! This made for a very interesting and comical drive back home to Glasgow and I

couldn't help myself but get a picture of how ridiculous it looked!! I also have no idea how we never got pulled over

either haha!

HaggisTurbo

With the engine beginning to take shape it was time to address the issue of selecting a decent turbo, Turbochargers arent't my strong point knowledge wise so after some help from the very patient people of PF I decided to opt for a T3.

I managed to source a T3 Turbo from a 4x4 Saff that had not long been rebuilt with a 360 degree baring so had pretty much the same spec and internals as a stage 3 RST T3 so I figured it was a good starting point and keeps things simple.

The Stage 3 T3 with -31 Actuator :







Should suit what I need perfectly!

HaggisTurbo

So a week has passed since my last update and I can't believe it myself but I just bought another bloody turbo! I was happy with the 4x4 T3 until Gadget put his freshly rebuilt T34 with .48 Housing up for sale! Snapped it up literally minutes after it was advertised for sale, I thought it was too good a deal to pass up even if my bank card did take a bit of a doing for it

T34 Turbo:




You don't really appreciate how big this turbo is until you sit it next to a T3 (bearing in mind this is the 4x4 T3 so is bigger than an RST T3 already!!)





Managed to sell the T3 too for what I paid for it so at least I never made a loss selling the T3 on.

T34 is definitely the turbo for me and should flow well enough for the 300bhp that I am looking for with a fair punch too

Glenn_

iTrader: (1)

Cool project matey. This will be a quick car when its done.

jason_nike

Excellent mate.
Look forward to updates

HaggisTurbo

So started to collect some other parts for the build and managed to bag myself a full Megasquirt setup with all sensors and the ECU from another Zetec Turbo that was being broken, They even marked all the wires so that I have a lot less hassle when fitting it. Got the lot for £200 bargain!!

The guy I bout it off left all the sensors and labelled it all with Masking tape! Ace







The MS2 Ecu



Question is though does anyone know what the fuel pump live feed is on an EFI car? had a look and can't figure it out! Any Ideas?

Malfis

You did not mention anything about pistons and rods. Are they forged!?

HaggisTurbo

The Pistons and Rods on a ST170 bottom end are uprated and easily hold up to 350bhp without any bottom end work, The standard blacktop head bolts straight onto it too. Ideal

HaggisTurbo

One thing I had to address was the fabrication of a downpipe adaptor, The one problem with the T34 is that it only comes with the option of a cossie exhaust housing (The RST One I found was restrictive anyway so was easier to get a bracket made up. Whilst on the hunt for finding someone to make up an elbow for me I found someone selling on on PF for £35 so couldn't pass up the chance.

The main thing about this is that it allowed me to bolt it up straight to the stainless Scorpion RS Tuebo exhaust I have.

Not got any pics of this of my own but I have the ones from the sale page

HaggisTurbo

So I went on a family holiday to Florida for a few weeks and couldn't resist buying some parts for the build, Really good savings to be had, I bought a set of Siemens Deka IV 630cc Injectors for £90 rather than the £200+ they are here, Also managed to get an AEM Wideband Lambda with sensor and gauge for £100 again half the price of the UK. Couldn't believe how cheap it was, just had to worry about US customs thinking that I had bullets in my bag lol

The Siemens 630cc injectors will easily flow enough with some headroom to the desired 300bhp so I thought they were the perfect choice:



The wideband will be more of an extra bit of insurance for me so I keep an eye on the AFR and don't end up melting all my hard work



Does anyone know the best place to mount this lambda sensor as I imagine the manifold and downpipe on a turbo car to be a lot hotter than a standard one, Would I be ok putting it where the cat would be on a modern car? and do I need to angle it or can it go in straight?

HaggisTurbo

Not updated for a while so here is an update of what is next on the list and that is the gearbox.

I decided on a ib5 gearbox first to keep the costs down and will be mating this with an AP Racing CP2000-35 clutch kit (Unless anyone can recommend anything else that can take that power?).


I would have opted for the MTX75 conversion but the costs including the shafts and brackets etc was just out of my price range for what I am looking to spend so I opted to go for the Ka 1.3 gearbox as it was a later IB5 so a lot stronger than the BC box and it also has very similar ratios making it an ideal choice I thought, this gearbox is hydraulic though so will need to do a conversion on the car to hydraulic which in my opinion is well worth is as the pedal would be extremely heavy on the AP Clutch without it. For this I am going to be following Karlos's guide again but can't do this until the engine has been lifted out.

One question I do have though is that the gearbox I have doesnt seem to line up with te sump bolt holes is this normal or is it only attached from the top? Just want to make sure I have the right gearbox, Here are some pics to show you what I mean

Gearbox:


Sump:


Does anyone know if this is the correct gearbox I should be using?


Whilst on the topic of gearboxes I managed to pick up an LSD from Ebay and because it was on a mispelt auction I managed to get is for £20 so another bargain! Ideal for keeping the costs of the build down!

I know nothing about gearboxes but there is a man that can in the next town to me who will fit it and uprate the main shaft bearing in the gearbox for around £100 so sounds like a plan!!

NobbyClark

Cool Orion. Love the colour and the Escort turbo wheels look brilliant!

studabear

Your exhaust front pipe might need extending to get the system to line up properly.

Water pump pulley bolts need cutting/grinding to about half their original depth.

You doing well. I would consider having the block decked if you haven't built it all up properly yet, I recently killed mine and its looking like it could be down to me not having the block decked.

Wideband I would suggest put it in the front pipe inbetween the bulkhead and driveshaft pointing straight upwards.

Your doing well, I will get the pic of the sump where I cut mine asap.

studabear

I'm pretty sure I didn't take anymore of the sump i will have a better look when i'm in the garage next.

HaggisTurbo

Hi Stu, Cheers for the pics ! Really appreciate it, I was following the other thread when you said that your engine was burning coolant, What head gasket were you using? Unfortunately mine is all built up but it is a genuine Ford Focus RS one 1.8mm

Was yours a scorpion system too mate?

Thanks

studabear

Mine was a cometic head gasket as the 1.8mm ford wasn't available at the time.

My exhaust is a mongoose, crazycage extended the front pipe and added the flexi for me.

HaggisTurbo

Hi Stu, I wonder if it was the difference in compression due to the gasket differences? Either way not good to hear

My exhaust is going to need some work anyway as the orion is a good 10-20cm longer anyway at the back, at the moment my exhaust is at the spare wheel well lol,

Anyway off to cut the sump today and hopefully not my fingers lol

studabear

Whatever the comp It can just have the map tweaked.

HaggisTurbo

So decided to start preparing to take the CVH out the Orion, this seemed like quite a simple idea in my mind but every bolt we came to didnt want to come off and required the WD40 and the hacksaw to come out!

Was dreading taking the bumper off the front of the car as I was not wanting to see what was behind it, I was pleasantly surprised and I think this panel has survived pretty well! Also the first bumper I have removed with all 4 bolts in place which made removal well... interesting!







There was also no need for the standard radiator and fan so they both came out as well, This thing was a bitch to pull out and i really should have done it after the manifold came off!



The next thing that decided it was not leaving was the downpipe as the bolts on the manifold were rounded, Not to worry let me mate loose with a hacksaw and this was the end result bye bye downpipe!



I really should be a lot tidier when doing these things then I would know where my tools are half the time

HaggisTurbo

A rare thing happened in Scotland today and that was that the sun made an appearance so decided today was the day to get the engine out the orion so that I can start preparing for the conversion, So roped in two of my mates at his place and got to work!

First thing I noticed is that there is no heat shield on the starter motor, i wonder if this is what was causing the starting problems when the car was warm, least once converted the car will have a rear starter and this will no longer be a problem!



After looking at the inner wing on the drivers side I think that the crank sump gasket has failed on this car or something big has let go as the whole wing and chassis legs are caked in about 3mm think of what I can only describe as sludge this will be fun to clean up later!





The other side looks a lot healthier and I am surprised at how well it has survived 20+ years almost rust free!





Found this push on wire hanging around next to the CPS and the starter, Anyone know what it is for?

HaggisTurbo

Disconnecting the last few wires and connectors ready for the engine being lifted out





Did all EFI cars come with adjustable fuel regulators or is this one that is not suitable for turbo use?



Got the ropes tied up to the crane and started to lift the engine out





I had forgotten how tight it was lifting everything out at once, and this is the smaller CVH lol. brought back memories of doing the Turbo engine in my Fiesta years ago lol



The last bit needed a bit of "gentle" persuasion to move



And finally its out!!!





Time for beer!

HaggisTurbo

Just a quick update with some more parts I have acquired in the last few days. Was at a relatives in Grimsby so on the way back made a quick detour to buy an Airtec Alloy RS turbo rad and a Kenlowe fan, Should I keep the one fan or look to do twin kenlowe fans? What is the general opinion? got both for £90 which I thought was good!





Also got myself a cossie fuel regulator to fit onto the zetec rail - Just hope it fits!! Otherwise I will need to source a FRST one

HaggisTurbo

Well tonight started out with a visit to Halfords to stock up on some bits, I used the trade card and thought the discounts were pretty poor, Only got a £5 off this lot which I thought wasn't that great but hey it was £5 less than I would have had to buy I suppose!



First task tonight was to remove the layers of sludge on the front panel and on the inner wing, I used Astonish engine degreaser and gave up with it as it was terrible!! Does anyone have a recommendations to something that will cut straight through all the oil and sludge without damaging the paint?

The bits I did do are beginning to look like normal again!

HaggisTurbo

The next task for the night was on Stu's recommendation and that was to grind down the waterpump pulley bolts to half their size, Unfortunatley I do not own a vice so I had to use mole grips which were far from safe but hey ho it worked lol

Before:



During



After:



Attached to pump again (Engine still on stand though):



Are these short enough now Stu?? Couldn't really get them shorter as I still had to get a socket on them!

HaggisTurbo

The next task was at Stu's reccomendation from the main Zetec Turbo how to page and that was that a notch had to be cut out of the engine mounting point, so with my new found confidence of using a grinder I decided to lop off the notch to stop it fouling the zetec engine when it was fitted.

Now here is the pic I had to work with but was enough for me to figure out what I needed to remove



And here is my attempt at the same ( I did smooth the rough edges after the pics btw!)





This enough do you reckon Stu, I didn't really want to risk cutting any more as it was weaken the ledge i thought, I will get some hammerite on it too stop it rusting up.

HaggisTurbo

Decided to give the ERST Manifold a good rub down and a spray in some VHT Silver paint, Made it look 10 x better I thought!!



And on to the final task of the evening and that was to cut / trim / grind all the excess parts of the sump, I did this task last as I wanted to get a bit more confident with the grinder first!!

Using Stuart's reference from above I had a go and was quite impressed with the results,

Here is a before shot:



And After:

studabear

Water pump pulley bolts look fine mate, I had to trim mine with the engine, felt like my arm was gonna drop off with the hacksaw.

The engine mount ledge looks something like, give it a bit of a tidy up before you paint it.

Sump should be about right too, worst case might need a bit whizzing off, if you put the engine and box together before putting it all in the bay you will soon see if its sorted.

HaggisTurbo

So the other day I decided I would make an attempt at spinning the housings round on the T34 as they were still set to the Cossie positions, Read up on it and was told it was easy, was it heck haha! Took around 3 hours to get the alignmet correct and just when I thought I had it the bloomin actuator would never line up

Then the bloomin thing lined up and The housing was fouling the manifold,

Finally managed to get it working but in the process i found the Rubber Seal was broken on the compressor housing, Quick email to CR Turbos and they are sending a new seal up Free of Charge! Nice

Mission Acomplished lol:



Sheer size of this thing I am not looking forward trying to fit this between the block and radiator lol!



This is how close it is to fouling the manifold you are lucky if there is 2mm gap left! I assume that it wont suffer from heat transfer then?



A close up with how close the gap is



Looks like it means business now





Just waiting for the seal to arrive and I can finally get it mounted to the engine,

The other problem I have found with buying things months in advance that bits go missing, I have lost the bolts and nuts for the exhaust manifold adaptor, So had to order them again too !

Ahh well getting there!

HaggisTurbo

Today is not a good day, O ring turned up for the compressor housing and as I went to pull off the compressor housing the fucker slipped and broke two blades!1!

Absolutely gutted





Phoned a few places and it's going to be abour £80 to £120 to fix with a new wheel.

I am in turmoil because the Turbo centre in Glasgow are quoting me £80 all in for a supply fit and balance

Dan from Turborebuild is £105 but I need to post it and CR Turbos are wanting £125 + VAT collected and returned

The Glasgow option is a lot cheaper but how do I know they are any good? are they cheaper for a reason? Any opinions folks?

studabear

Pm wilky on here or bernies blowers on facebook.

HaggisTurbo

Are they the same person or two different people?

studabear

The same person.

HaggisTurbo

Decided eventually on Dan from Turbo Rebuild who offered me the best deal so got it wrapped up and sent via UPS to him on Tuesday there, In the mean time I thought I would do a bit of sprucing up of the engine a bit to give it a bit of colour

First up was to finish and fit the Escort RS Turbo Exhaust Manifold, used some Ultra Very High Temperature Paint on it and thought it came up pretty well so fitted it along with the exhaust manifold adaptor





Also fitted the gasket for my T34 to the manifold, bit controversial really as lots of people say you don't need one but it was £4 so where it the harm!

HaggisTurbo

Turbo has been away for 24 hours and it's fixed and ready to come home, Top Guys at Turbo Rebuild! but whilst I was waiting on it coming back to me I thought that the rest of the other bits attached to the block could do with a spruce up too,

Before:




Painted the dipstick tube first with the same Silver Hammerite Spray Paint




Then did the main support bracket that attaches to the engine block:

(Even if I did have to do it twice as I dropped it on the floor - Jump lead slipped lol )



Rubbed down and sprayed the idler pulley bracket for the waterpump to spin the other way:



I then fitted everything up once it had dried inccluding some overspray onto the rocker cover (Which is getting replaced anyway)

HaggisTurbo

Bought a new rocker cover from a silvertop which I am told will bolt up nicely, but most importantly it has the secondary breather output on it so that I can use the RS Turbo breather set up with it.

Not sure about the colour but i think the white is growing on me!!