My Ford Ka ZVH Turbo!!!!
31-07-2005, 08:42 AM
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My Ford Ka ZVH Turbo!!!!
hey guys
jus though i would share some pictures of my new enigne i will be fitting to my ka!
i picked the enigne up from caerphilly and managed to shoe horn it into my boot of my car not great but has some comedy value
picked up the engine and loom ecu , box etc etc for £350 which i thouht was good!
these are wip pics of me stripping the engine excuse the mess first time i ve done this and i am a bit un organised tools every where lol
thought i have come across one problem and thought i 'd ask before i broke anything, there is an oil return pip from the turbo coming ino tthe sump its bolted to the main bearing casing, i removed the bolt, then tried to move it and it wont budge any ideas or hoe to move it so i can changed the main bearing shells?
pistons out
pistons a bit more organised awaiting new big end bearings and piston rings
i have sinmce fittednew rigns and big ends, currently gotta fit mains, then get my sump gasket kit from fords been waiting a week for it. as they said they didnt have a kit any where in ford uk
so its been delayed a bit
but so far i have bought
a recon t2 turbo
new high tensile head bolts
new water pump and gasket
new oil pump
new head gasket
new big end bearings
new main bearings
headgasket set
mild head work and head skim
new piston rings
new cam belt
new alternator
new alternator belt
and a few more thigns i forgotten!
i bought 90% of the stuff from fords there prices were
very high considering the motro factors equivalent but i was advised to get all ford bits when rebuilding it as it would pay off in the long term.... i hope so 
i am on the hunt for either a non pas rack and colum from an early ka or maybe looking at an elctric pump from a car to run the pas not shore which to do , the non pas option would be easier ut the pas option would be good! we'll see if i can find out what parts i need first then see if i am capable of fitting them!
i will keep this post updated as i progress slowly but shorely!
i have contacted a few people on here bout a 2wd saph intercooler jus waiting on replys that should keep the charge temps down sufficently! also been in contact with radtec about a possible radiator same size as the ka item but increase the thickness!
thanks for looking and what ya all think?
jus though i would share some pictures of my new enigne i will be fitting to my ka!
i picked the enigne up from caerphilly and managed to shoe horn it into my boot of my car not great but has some comedy value
picked up the engine and loom ecu , box etc etc for £350 which i thouht was good!
these are wip pics of me stripping the engine excuse the mess first time i ve done this and i am a bit un organised tools every where lol
thought i have come across one problem and thought i 'd ask before i broke anything, there is an oil return pip from the turbo coming ino tthe sump its bolted to the main bearing casing, i removed the bolt, then tried to move it and it wont budge any ideas or hoe to move it so i can changed the main bearing shells?
pistons out
pistons a bit more organised awaiting new big end bearings and piston rings
i have sinmce fittednew rigns and big ends, currently gotta fit mains, then get my sump gasket kit from fords been waiting a week for it. as they said they didnt have a kit any where in ford uk
so its been delayed a bit
but so far i have bought
a recon t2 turbo
new high tensile head bolts
new water pump and gasket
new oil pump
new head gasket
new big end bearings
new main bearings
headgasket set
mild head work and head skim
new piston rings
new cam belt
new alternator
new alternator belt
and a few more thigns i forgotten!
i bought 90% of the stuff from fords there prices were
very high considering the motro factors equivalent but i was advised to get all ford bits when rebuilding it as it would pay off in the long term.... i hope so i am on the hunt for either a non pas rack and colum from an early ka or maybe looking at an elctric pump from a car to run the pas not shore which to do , the non pas option would be easier ut the pas option would be good! we'll see if i can find out what parts i need first then see if i am capable of fitting them!
i will keep this post updated as i progress slowly but shorely!
i have contacted a few people on here bout a 2wd saph intercooler jus waiting on replys that should keep the charge temps down sufficently! also been in contact with radtec about a possible radiator same size as the ka item but increase the thickness!
thanks for looking and what ya all think?
31-07-2005, 10:04 AM
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you'd be better off running a non pas rack, from what i've heard its a bitch to try and get pas in. best person to speak to is blakey, i dont know if he still fabricates stuff for the ka turbo conversions
16-11-2005, 08:53 PM
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16/11/05 (56k put the kettle on)
havent updated this thread for a while so , i thought it was worth an update seeing as my ka is making very good progress now!
first off once my engine was rebuilt, i had to wire in the ofab management, keeping the ka ecu as it controls the imboiliser! basiaclly i am jus using the engine loom from the fiesta and the ecu the rest will stay ka!
here are a few pictures!
had to locate the ka ecu drill out the supporting rivet s and get to the wiring!
then once i had access to all the wires it was time to start cutting and splicing!
then once i had soldered what i needed it was time to try and find a plac for the new ecu! not easy
then i needed to find a feed for the fuel pump, a permenant 12v when the starter was cranked over, a good look throught ther haynes and i had found my wire
jus to prove my loom works, powered up ecu and had a 12v on the boot controller so it seems to be all ok!
onc the wiring was ll in place , i then had the fun task of ripping the old engine out and making way for the new engine!
getting ready to lift
and the compulsary lad in the engine bay pic
also while i ripped the k apart also been shopping, had a special clutch made up specially for the ka cvh conversion, (thanks tecnhclutch), jus a fast roaD RS CLUTCH WITH STRONGER PRESSURE PLATE AND COMPETITION RELEASE BEARING!
also sent my gearboz to the welders to have the cvh starter motor hosuing cut out and welded in on the ka box!
ka box/cvh ib5
when it cam time to put cvh into the ka the weather was shit, but i knew with a make shift tent i could do it
jus fitted the clutch and securing the sump on trying to stop the gasket from kinking
soon after i stopped raining and i was able to mount the engine went it really easily very happy!
this is the mount i needed
my lovely turbo
its starting to take shape... you make recognise the charge carrier from sy's old ka turbo, there are only 2 in the uk floating round so i knkew when he was breaking it that i had to have it.
once the engine was in i then had to wire up the oil pressure light on my dash as i wanted everythign working. bit of a pain in the arse but, it now works lovely
once that was all done i needed and exhaus system made, to the rescue came charlie from pro speed in cardiff gave me 2.5" bore all the way through sounds and looks the tits.
then i needed something to stop with. so alex dando ( thanks bud) asked me if i wanted his few hundred miles escort cossie brakes, i snapped his hadn off and trotted of to bristol to collect them, must say pal escort looking mnit
old fiesta rs turbo brakes
then ended up like this
just to show the comparision
dont need the wear indicators
jus finally bleeding them, i'll do them again once i ve driven it but jus to getsome feel on the pedal
the engine now runs, and revs like a champ, had a slight problem with my loom being shit, but its all sortednow hoefully fingerscrossed, once i get new actuator and oil feed pipe for turbo i can take her for a spin!
i have an escort cossie intercooler as well whihc i havent got a picutre off but sits in the front, should do the trick lovely!
thanks for looking
gary
first off once my engine was rebuilt, i had to wire in the ofab management, keeping the ka ecu as it controls the imboiliser! basiaclly i am jus using the engine loom from the fiesta and the ecu the rest will stay ka!
here are a few pictures!
had to locate the ka ecu drill out the supporting rivet s and get to the wiring!
then once i had access to all the wires it was time to start cutting and splicing!
then once i had soldered what i needed it was time to try and find a plac for the new ecu! not easy
then i needed to find a feed for the fuel pump, a permenant 12v when the starter was cranked over, a good look throught ther haynes and i had found my wire
jus to prove my loom works, powered up ecu and had a 12v on the boot controller so it seems to be all ok!
onc the wiring was ll in place , i then had the fun task of ripping the old engine out and making way for the new engine!
getting ready to lift
and the compulsary lad in the engine bay pic
also while i ripped the k apart also been shopping, had a special clutch made up specially for the ka cvh conversion, (thanks tecnhclutch), jus a fast roaD RS CLUTCH WITH STRONGER PRESSURE PLATE AND COMPETITION RELEASE BEARING!
also sent my gearboz to the welders to have the cvh starter motor hosuing cut out and welded in on the ka box!
ka box/cvh ib5
when it cam time to put cvh into the ka the weather was shit, but i knew with a make shift tent i could do it
jus fitted the clutch and securing the sump on trying to stop the gasket from kinking
soon after i stopped raining and i was able to mount the engine went it really easily very happy!
this is the mount i needed
my lovely turbo
its starting to take shape... you make recognise the charge carrier from sy's old ka turbo, there are only 2 in the uk floating round so i knkew when he was breaking it that i had to have it.
once the engine was in i then had to wire up the oil pressure light on my dash as i wanted everythign working. bit of a pain in the arse but, it now works lovely
once that was all done i needed and exhaus system made, to the rescue came charlie from pro speed in cardiff gave me 2.5" bore all the way through sounds and looks the tits.
then i needed something to stop with. so alex dando ( thanks bud) asked me if i wanted his few hundred miles escort cossie brakes, i snapped his hadn off and trotted of to bristol to collect them, must say pal escort looking mnit
old fiesta rs turbo brakes
then ended up like this
just to show the comparision
dont need the wear indicators
jus finally bleeding them, i'll do them again once i ve driven it but jus to getsome feel on the pedal
the engine now runs, and revs like a champ, had a slight problem with my loom being shit, but its all sortednow hoefully fingerscrossed, once i get new actuator and oil feed pipe for turbo i can take her for a spin!
i have an escort cossie intercooler as well whihc i havent got a picutre off but sits in the front, should do the trick lovely!
thanks for looking
gary
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16-11-2005, 11:45 PM
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dude !! how big are them alloys? they look mahoooosive !! class job tho mate, nice one, i haven't seen a fully working rs Ford Ka yet, apparently they are prone to all kinds of problems????
good work mate , rims look 18" /19" 
18-11-2005, 07:19 AM
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Originally Posted by BillyCabrio
I actually quite like the bodykit, PHAT!!!
Keep up the good work fella, don't let the shite weather bear you down
Keep up the good work fella, don't let the shite weather bear you down
25-11-2005, 05:43 PM
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a little update today !
i removed the loom today from the ka, to replace some dodgy repairs that were done previously, i also had to extend some plugs as they were a bit tight!
loom out on the floor
me hard at work heat shrinking and insulating
gary
i removed the loom today from the ka, to replace some dodgy repairs that were done previously, i also had to extend some plugs as they were a bit tight!
loom out on the floor
me hard at work heat shrinking and insulating
gary
05-12-2005, 03:37 PM
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little update!
hopefully the ka will have its first road test on the weekend! had it running most of the weekend, found a few leaks whihc i will need to sort out!
it needs the silicones for boost system, new actuator! and it can be driven!
i ve also soucred a escort cossie fuel pump to uprate the ka item, s2 gear box with lsd ( i am robbing some the internals for my ka ib5) and t3 turbo and manifold as i plan to uprate to a t3 later on next year!
hopefully the ka will have its first road test on the weekend! had it running most of the weekend, found a few leaks whihc i will need to sort out!
it needs the silicones for boost system, new actuator! and it can be driven!
i ve also soucred a escort cossie fuel pump to uprate the ka item, s2 gear box with lsd ( i am robbing some the internals for my ka ib5) and t3 turbo and manifold as i plan to uprate to a t3 later on next year!
05-12-2005, 07:55 PM
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thanks for the positve comments!
i am fittign some gauges this weekend so i'll take some interior pictures!
and its not having the big bumpers on any more, its being put standard looking on 15-16"!
i ve built the car to be driven now, and dont want the fiberglass slowing it donwn, so the kit and 18" will be up for sale at some point!
keep looking!
glad ya like it
i am fittign some gauges this weekend so i'll take some interior pictures!
and its not having the big bumpers on any more, its being put standard looking on 15-16"!
i ve built the car to be driven now, and dont want the fiberglass slowing it donwn, so the kit and 18" will be up for sale at some point!
keep looking!
glad ya like it
13-12-2005, 08:25 PM
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jus a little update, hadf a few leaks sunday , had to take the water pump off and get a new gasket fitted as i tore the other one when fitting it first off!
i had also found a dodgy and rather nosiey lifter which was making the ka sound like a bag of shit! went to local factors and for £4.68 the engine now sounds alot quieter!
once that was done, i had spoken to stuart at msd, and ordered a new actuator as the one on my turbo was damaged and had a dodgy spring!
fitted it and its works a treat, thats anohter item of my ever shortening list onyl need 2-3 thigns now!
i ve also bougth a 80mm rev counter from etb, it should be with me friday! then i can see what the engine is doing!
a few gauges have been bougth as well, boost, oil pressure and oil temp, water temp!
, my silicones will be here tomorrow, so i'll get some more pictures of the ka tomorrow!
i had also found a dodgy and rather nosiey lifter which was making the ka sound like a bag of shit! went to local factors and for £4.68 the engine now sounds alot quieter!
once that was done, i had spoken to stuart at msd, and ordered a new actuator as the one on my turbo was damaged and had a dodgy spring!
fitted it and its works a treat, thats anohter item of my ever shortening list onyl need 2-3 thigns now!
i ve also bougth a 80mm rev counter from etb, it should be with me friday! then i can see what the engine is doing!
a few gauges have been bougth as well, boost, oil pressure and oil temp, water temp!
, my silicones will be here tomorrow, so i'll get some more pictures of the ka tomorrow!
24-12-2005, 07:08 PM
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little update!
any one who has seen a ka will notice the rather comical air vents in the dash! while i was sat in ti the toher day i noticed i hadnt fitted a tacho yet, so i measured up the size of the air vents and realised if i could get a 80mm tacho i could get it to fit inside the vent!
http://public.fotki.com/garyhurn/rev...ing/rev_2.html
got the item from etb lloks great as well!
http://public.fotki.com/garyhurn/rev...ing/rev_1.html
then i measured it up for size and had to modify it slightly to fit
http://public.fotki.com/garyhurn/rev...ing/rev_4.html
this is it after triming it and it sits flush well pleased
this is it all in wired up, will get some bulb paint so it lights green to match btu i think it loks cool as fuck !
http://public.fotki.com/garyhurn/rev...ing/rev_6.html
also i got the ka on the ramp to fix a sligthy leak from the oil return, i noticed how small and shitty the exhaust system wass, currently i have a 2.5" down pipe with 2.5" flexi gogint o middle of car then mated to my old ka system 1.5"! obviously this was gogin to restrict it! so i got some 2.5" pipe and set about making my own rear system
its not perfect by any means but i thougth i would save my self the 300 quaoted for the rest of the system!
http://public.fotki.com/garyhurn/rev...ting/size.html
this shows the old pipe and new pipe!
http://public.fotki.com/garyhurn/rev...e_matters.html
i basically jus tried to make a copy of my old system so i could keep the twin exit etc!
jus shows the ka on the ramps!
http://public.fotki.com/garyhurn/rev...ting/lift.html
it'll be mot'd next week hopefully everything will be ok!
any one who has seen a ka will notice the rather comical air vents in the dash! while i was sat in ti the toher day i noticed i hadnt fitted a tacho yet, so i measured up the size of the air vents and realised if i could get a 80mm tacho i could get it to fit inside the vent!
http://public.fotki.com/garyhurn/rev...ing/rev_2.html
got the item from etb lloks great as well!
http://public.fotki.com/garyhurn/rev...ing/rev_1.html
then i measured it up for size and had to modify it slightly to fit
http://public.fotki.com/garyhurn/rev...ing/rev_4.html
this is it after triming it and it sits flush well pleased
this is it all in wired up, will get some bulb paint so it lights green to match btu i think it loks cool as fuck !
http://public.fotki.com/garyhurn/rev...ing/rev_6.html
also i got the ka on the ramp to fix a sligthy leak from the oil return, i noticed how small and shitty the exhaust system wass, currently i have a 2.5" down pipe with 2.5" flexi gogint o middle of car then mated to my old ka system 1.5"! obviously this was gogin to restrict it! so i got some 2.5" pipe and set about making my own rear system
its not perfect by any means but i thougth i would save my self the 300 quaoted for the rest of the system!
http://public.fotki.com/garyhurn/rev...ting/size.html
this shows the old pipe and new pipe!
http://public.fotki.com/garyhurn/rev...e_matters.html
i basically jus tried to make a copy of my old system so i could keep the twin exit etc!
jus shows the ka on the ramps!
http://public.fotki.com/garyhurn/rev...ting/lift.html
it'll be mot'd next week hopefully everything will be ok!
09-09-2007, 01:38 PM
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thought i should better up date this project
the car was finished back in december 2006, the bodywork was converted back to std!
and resprayed here are a few pictures of how it looked
here is how the engine looked once completed!
having an estimated 200+bhp from the engine i was in the hunt for more power, so in early january i removed the 1600 having only covered 200-300 miles and deiced to build a BIG power zvh engine!
Gordon @ streetracers have built the engine
rough spec is
2.1 zvh
custom streetracers spec pistons
farndon rods
oil spray jets
focus rs head gasket
burton power stage 3 big valve head
kent cam kit
anti pump lifters
tommy field custom inlet manifold and cosworth throttle body(tom scarlets old one)
t3/t4 turbo from precision in usa
omex 600 ecu
vernier pulley
lightened and balnced bottom end
area six spec helix 4 paddle clutch
550cc injectors
i am hoping for power in the region of 330-350bhp when fully mapped hopefully
also converted the ka to run rear discs from a focus 2.0 and also upgraded to focus st170 300mm up front!
this is how ka stands awaiting new engine
also removed std pedal box and servo and master cylinder and opted for a custom set of willwoods pedals built by danny b at adrenaline race&performance
changed the rear lights for smoked units
i have a few other pictures to post when i get home to download them
but i will be running a range rover rad in the rear of the car as fitting it in the front maybe an issue with the turbo being so big!
i will be collecting the engine from streetracers middle of next week and i cant wait as i can get the car back on the road and see what 350bhp feels like!
cheers for looking
the car was finished back in december 2006, the bodywork was converted back to std!
and resprayed here are a few pictures of how it looked
here is how the engine looked once completed!
having an estimated 200+bhp from the engine i was in the hunt for more power, so in early january i removed the 1600 having only covered 200-300 miles and deiced to build a BIG power zvh engine!
Gordon @ streetracers have built the engine
rough spec is
2.1 zvh
custom streetracers spec pistons
farndon rods
oil spray jets
focus rs head gasket
burton power stage 3 big valve head
kent cam kit
anti pump lifters
tommy field custom inlet manifold and cosworth throttle body(tom scarlets old one)
t3/t4 turbo from precision in usa
omex 600 ecu
vernier pulley
lightened and balnced bottom end
area six spec helix 4 paddle clutch
550cc injectors
i am hoping for power in the region of 330-350bhp when fully mapped hopefully
also converted the ka to run rear discs from a focus 2.0 and also upgraded to focus st170 300mm up front!
this is how ka stands awaiting new engine
also removed std pedal box and servo and master cylinder and opted for a custom set of willwoods pedals built by danny b at adrenaline race&performance
changed the rear lights for smoked units
i have a few other pictures to post when i get home to download them
but i will be running a range rover rad in the rear of the car as fitting it in the front maybe an issue with the turbo being so big!
i will be collecting the engine from streetracers middle of next week and i cant wait as i can get the car back on the road and see what 350bhp feels like!
cheers for looking
