djwilma

thanks, dash is made by a man in South Wales he is a small one man outfit and is starting out with the elise dash

It, in theory, can we used on any car. We looked at a mk2 escort for example

djwilma

So finally a year later than expected the engine is in bits!



Block looks in almost new condition, should be as it covered 2000 miles



Nicely built engine, definitely Japanese was the wording by Tech1 but built to last.



Pistons and rods look meaty too



New vs old pistons



Crank again looks solid, apparently the are good for lots of power and 8500rpm. Main think to notice is the gear for the balancer shafts



This photo does not do the weight of this unit justice, it's close to 10kgs (man pick up test). It's not needed so that's good news



Mountune baffled sump and balancer shaft delete kit fitted



Oil blocked for balancer shafts

Crank is off to have the keyway installed and now decision is what cams to fit

Std head flows well, some 550bhp engines in the USA (running meth injection) but with std ports. Spoke with Marshal at speedperformance and he advised the head are twin track as they create "a tornado" effect in the chamber to aid combustion. I can port the head at a cost of Ł900 ($960 but then shipping and import costs) but was advised it's not needed below 600bhp




Hopefully have it built by next week.....

Fudgey

iTrader: (4)

nice one bud, what do the balancer shafts do? make the engine smoother i guess?

when you rebuild can you get a few pics of the cam chain assembly etc please.
mine makes a slight rattle and im not sure if its the chain running over a guide etc as it seems to be from inside the engine, i did think it was a pulley but now not so sure and i have not heard another ST to compare it to.

keep up the good work

djwilma

Yes to the balancer shafts, they spin the opposite way and balance the vibrations out (in theory). But in my case they just add weight and inertia

No problems we took loads of photos of the timing chain. Not heard of another one that rattles, surely its still under warranty

Fudgey

iTrader: (4)

Warranty ran out on xmas eve... i did take it in and they put talc on a pulley. it was exactly the same as when i took it in...

djwilma

So there is good news and not so good news and good news again

Good news is the engine build is on its way, i got very excited and finally thought we'd get things moving and done and i could drive the car. However, we fitted the rods and pistons to the engine and.........see below



Something didnt look right, the pistons were not sitting right in the block. As first we thought possibly that being a GDI engine the pistons sat lower but i called Speedperf6rmanc3 in the USA and turns out that i accidentally ordered the 2.3 Ecoboost rods and not the 2.0 ones.......



Bugger. However the ever helpful Marshall suggested a quicker fix than returning the rods, a 2.3 crank........a stroke of genius (pun intended) and they had just received a set of std 2.3 cranks which are forged and...i stopped him there and ordered one.....as a favour they even keyed and then balanced the crank for me........tops guys

Next issue will be customs clearance and Tech1 finding a slot to build the engine

Problem i have now is the GTX2867 will be on its last legs at 8000rpm, so a GTX3076R would be better, then i can have 550bhp and can tell everyone in the pub. If the wife finds my bills i am dead, although she has a new kitchen we still have the Tartan carpet a year after moving......

djwilma

These just arrived too so I am happy with that

Also the 2.3l crank has arrived, the joyous moment. The last piece (hopefully and may of said that before) of the puzzle


I was so happy when I dropped it off at Tech1, but Paul wasn't as chuffed. He is normally smiling when I drop something off and his body language was terrible. Long of the short is he and his business partner have decided to part ways and he will be closing the work shop
Bollocks
Good news is he will build the engine for me, this I didn't want to take elsewhere and he has a workshop at home and will finish this. When, was the next question and Paul smiled.
So I now have to find someone stupid, sorry enthusiastic, enough to take on a project half done. I may of found someone but if anyone local knows of anyone (I don't) I would appreciate it.
I'd like to do it myself but don't have the time, or the mechanical know how to make the engine mounts and so on.
I think someone is trying to tell me something, and I think its don't give up

Fudgey

iTrader: (4)

Hopefully you will find someone to finish off the job. i dont think Martin at Reyland carries out conversions anymore but it might be worth asking the question.

looking good tho mate, should be pretty brutal when it comes together!

timbhp

Hi just found this project keep up the good work will be nice when done

djwilma

Thanks all, Reyland is a little too far from me. AS with most modded cars they tend to break so i need to find someone who can do the work locally

Some more goodies have arrived courtesy of Speedp3rform6nce, cant praise these guys enough for their support and knowledge

This time its the auxiliary fueling systems, i did want the JM manifold but its taking too long and as i am only going for 450bhp SP advised this kit would be simpler, easier and perfect for what i need. Apparently the std inlet flows pretty well and its also light.

The reasons for this kit are two fold, the GDI engine needs a High Pressure fuel pump(above 200bar) and these run out (depending on who you talk to) at around 350bhp, the injectors run out not far after(depending on who you talk to). Uprated injectors are available but and they need more flow. The 2.3 has 4 lobes, the 2.0 3 lobes, on its cams and a different High Pressure Pump but it was a nightmare to change to this. There are some upgraded pumps, but these cost a fortune and are untested at the RPM i want to go to (saying that the std one is too). This kit has an inlet adpator plate with 4 injector holes, and 4 bottom plugs if i want to run meth/water (which i dont). Injectors are 640cc which are big but they are std FoMoCo for ease. Also combined, ported and direct, i should be able to run about 750bhp (which i wont, yet, maybe, possibly, shouldnt do).

Sounds complicated but Specialist Components already have the software to run both port and direct injection already (so i wont need the additional controller), and most High Power GDI engines, like the Mercs, run both port and direct.

Issue will be with the mapping but i will send the engine back to Specialist Components as they have probably the most experience on these engines in the UK, so need to get an exhaust manifold making and hoping Maniflo in Salisbury can help.

I have also found someone stupid enough to take on the engine mounts, and they are local ish, so having a ready mapped engine will make their and my life easier.

The Complete Kit


The Inlet adaptor


FoMoCo Injector, which is a bosch item


Additional Controller that i dont need

djwilma

Engine is being built, all parts fit......so far

Fudgey

iTrader: (4)

Good progress!

djwilma

thanks just forgot to buy the Main Bearing ARP bolts so these are on order !

djwilma

So progress at last, Engine builder got a new job (after needing a break) and engine was in one place and tools in another

Anyway a month later the three of them got re-united and the engine is being built (again)

Issue i had was the Main Bearing studs, the OEM items are stretch bolts and once used you need to measure the stretch and then change the torque accordingly, so i rang Speedperf6manc3 and asked what this should be. The ever helpful, if busy, Pablo explained that i needed to fit ARP bolts.

Next problem was searching for the correct bolts, ARP catalogue number came up at Ł270 and no one in the UK had any, and they were 6 weeks delivery. Rang Pablo again, and asked him to ship some. Turns out the ARP bolts for the 2.3MPS DISI engine are the same as the ECOBOOST, and Ł175 ! Luckily i found a supplier in the UK, who also sent sweets with the delivery.....





Pauls managed to fit them this week and cams are next



Cams are on lifters as per the Duratec but they are not shimmable, instead the buckets come pre-sized. Great idea but Paul needs to fit the cams check the gaps and then order some buckets.......more delays ffs

Good news on the cams, i decided to fit the full blown 12mm lift cams capable of 650bhp and 8000rpm........just need a bigger turbo, chargecooler, radiator, bigger tyres, more cooling and the head porting.........hmmmmm

Fudgey

iTrader: (4)

Thats going to be a bit of a weapon when its done!
Have you found anyone to fit the engine when its complete?

NEEDFORSPEED

awsome project!

djwilma

Thanks all, yes to engine fitter......if i can get the engine finished

Well its Christmas soon.......

Engine progress is slow, the last (please for the love of god) challenge is the cam followers. Ford in their wisdom made the ecoboost (like the duratec) with mechanical followers. They then made cam followers "un-shimmable" so you have to buy the correct followers shimmed accordingly.

Luckily i only need three, and these have been ordered direct with Ford

Then the engine needs building and dressing, flywheel, clutch and gearbox then ship it off to get a manifold made then off to get dyno'd




#nevergiveup

It's Czech Mate

Nice build

djwilma

Thanks much appreciated

Wish I could update quicker but once the engine is built we can speed things up and get it on the road for the summer

djwilma

Well New Year, New Engine !

Its finally been built, well almost the flywheel, clutch and box need to go on and the gearbox.

Engine with the external oil filter bracket and PCV delete and breather



Without the inlet fitted



With the new auxillary fuel manifold, basically a spacer with ports for 630cc injectors and ports for meth injection




Engine Fully built




I then need to make an exhaust manifold adapter (engine has on internal exhaust manifold) which needs to have an external wastegate something like this



If anyone can make one for me let me know as the USA is the only place to get them and they only sell them as kits with upgraded turbos ffs

Worst still Garrett have released a GEN II GTX2867R which would be perfect for this engine, the current GTX2867 will run out of puff above 7500rpm.........and the internals are not interchangeable

However good and bad news, the tartan carpet has gone and we now have Brimstone

djwilma

Had a mad thought today as i realised i havent fitted the custom flywheel, helix clutch (Rover T series) and gearbox (PG1 but C4 u spec) all together

Good news is it all fits, gearbox input shaft meshes with the clutch friction plate and everything seems to be ok

Obviously wont know its all perfect until its in and i have pressure on the clutch. But the signs are good

Good news is the engine is now pencilled in for the dyno with specialist components, and i have found a nice man to make the turbo adaptor. Plan is to have one made in stainless steel, to the best guess, get the engine dyno'd and hope it fits when the engine goes in. Then make one out of inconel for the long term.

Rowe

good read this!

Fudgey

iTrader: (4)

Nice.
one thing tho, stainless steel or Inconel, you will need a brace for the turbo to take the weight or it will crack.

visa_broke

just had a read all the way through. So close to having it in the car

fury556

That's bonkers, can't wait to see it done!

djwilma

All in hand my man, will have two braces bolted to the block to take the weight off

Today is a good day

Custom dash is nearly ready and i was asked if i wanted a custom screen so i got a pen and a fag packet and drew, like a 5 year old, what i'd like on the back.

a few weeks later and this is what has been done, at startup the 111ST logo is shown on boot up (not for long but if first boot it takes a few moments longer i am told), at the redline the welsh dragon appears in the middle (something the designer and I share heritage from so seemed apt and its a dragon !!) and the third and last screen is as per my request. 1st is copy of std dash, for road use but all the parameters shown on 3rd screen (track screen) can be show also on the 1st screen.

Oil pressure gauge is duplicated a few times but will be replaced with air temp, battery voltage and something else.

Its all plug and play with the analogue inputs, fuel etc and plugs directly to my ECU and will show all parameters it does.

Could not be happier, and i cant thank Alex enough for doing this

Here is the video, no idea how to embed it or if you can on here

https://youtu.be/rBSeaTqIS0U

jonfoc

That dash is the icing on the cake. Great work

djwilma

So today i have the, first production dash fitted to the car and wow....just wow....i mean like wow

First off was the box


Then the contents, the dash on the top and the wiring below




I've spoken to Alec about how to control, and whilst you can use the trip reset and indicators he asked if i would like a small joystick for moving around the dash, i said yes a small discreet one with a push button so he supplied this. Idea is to have it mounted on the dash or just use it when you need it and plug it in



Next was fitting it to the standard mount


The original dash was taken out a few months ago and sent to Alec so fitting the new dash took about 30 mins




Fit and finish are pretty damn good and the graphics are awesome, the dash can take up to 6 screen designs (one of which i designed myself and Alec made for me), and then the 7th is the data logger


Took some photos, from afar, sun light was straight ahead but not direct sunlight but the dash was more than bright enough






Overall very very happy and it has more features that you can shake a stick at, everything was plug and play and worked

However i dont have an engine in the car, so couldnt test drive it

Fudgey

iTrader: (4)

I must say, that is pretty sweet!

Mark V8

iTrader: (2)

That is cool !


How do you calibrate it to all the sensors ?

djwilma

Its plug and play for my car, but mainly as Garw (company who makes them) started off with the Elise

But for each input, be it digital or analogue you can scale to suit each sensor

Or if you have an 11bit CANBUS you can take if from the ECU direct and it will show what the ECU sees

djwilma

Finally getting the manifold made, this was the first attempt. I didnt like how much it stuck out and how the turbo was rotated



So second attempt looks a lot better

NEIL A

iTrader: (6)

Stunning build and good to see someone pushing the iceboats engine further than the normal bolt ons.

Love the dash I will be ordering one for my S2 as soon as they become available

djwilma

I now have the engine at home, I need to add in some oil and water pipes to the turbo and tidy up the breathers



JEK Fabrications made the exhaust manifold, oil return and also the brace which is rose jointed to allow movement due to heat.





I have also looked at the PCV breather and added in an oil pressure sensor (only comes with temp as std) and I need to seal all the joints



Then I need a TMAP sensor, Lambda sensor and stuck whether I ship it back to Specialist Components for mapping (where their normal dyno has a long waiting list) or book it in to make the engine mounts, get the engine running (2 month waiting list) on the std map and then drive to SC to have it mapped.

Ideally I ship it to SC and they get it back in 2 months and I get the engine installed but I don't think the way the project has run its that easy

youngben

iTrader: (2)

Are you using the Focus Throttle pedal on this setup for the FBW? And if so is the wiring and connection for the pedal included within the loom from SCS?

And how did you get such a good deal from SCS on the ECU? Have myself an engine now so will be looking to do this conversion in a few months 👍🏼

Keep up up the good work. Love seeing the updates on this thread.

djwilma

I am not using the std Ford dbw, I have a gm one that somehow fits the Elise pedal

But the SCS uses a std focus St loom, modded to fit the ecu and needs just 14 inputs to work, so would be plug and play for the std dbw pedal and easy as to use for an engine conversion. I have a 1600 sport on my drive that's my brothers and I keep wanting to fit the ecoboost to it as it would be so simple

Actually Simon from SCS saw my car and sent me an email and explained how easy it would be to fit to the Elise (he is ex Lotus)

djwilma

Wow, you go away for holiday and leave the car with a man and shit gets done.......why didnt i do this before

Anyways, engine mounts are now made and engine is in the car. Turbo hasnt been fitted but i see no reason why it wont fit

Drive shafts fitted all ok, no rubbing (unlike duratecs so i am told)












No idea what this lug is but seems to be ok



Wiring next

Fudgey

iTrader: (4)

Nice one! Another step closer bud.

djwilma

Yep, will plumb in the water and oil lines and see where i can fit the charge cooler

Then have the wiring done, engine should be good to fire on the std map

Need a better fuel pump now, and one is available so i dont need to have a swirl pot and so on

djwilma

Got the inlet and the turbo on today

Looks like it was meant to be in there, lot of room for the turbo and inlet was fitted in 30 mins as it went through the inspection hole

Wiring is now being sorted and I'll plumb in the water and oil hoses when home