MK3 Cabriolet Zetec Turbo. SMALL UPDATE 18/03/10

[se mk3 cabbie]

Nice to see another cabbie being saved, good work fella

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[cabrio boy]

top stuff fella!

[ford crazy]

COME IN ON WELL MATE

[snozz2004]

An update at last!
it took me a while to find some steel tubing for the oil return & breather pipes that needed to be fitted to the block, it wasn't really worth doing an update until i had that sorted.
Anyway heres the block stripped down, also made a blanking plate for the standard zetec breather.



Oil feed with standard & aftermarket oil pressure switch.



I drilled & tapped new exhaust stud holes, used an XR2i exhaust gasket as a template.





Camera broke! So theres a few photos missing of me drilling & fitting the oil return/breather pipes to the block & rebuilding the bottom end.

Pistons & crankshaft back in place.



sump, oil & water pumps back on the engine.



I bought a engine mount off Ebay thats been made for zetec engine conversions, the only problem i've had with it so far is the top part of it stops the cylinder head fitting the block properly,



quick chop with the angle grinder, & problem solved.





A peview of the engine, looking good



Next on the list, fit the bottom end & gearbox to the car, get the inlet manifold sorted & fixed to the head, fit 2 litre cams & start on the interior.

[AGAR-COSWORTH]

Thats a great effort so far

Love mk3 cabs. Not many of them around these days.

[Jackass1983]

Hi,

do you use a decompresion plate? or?
What compresion ratio you want to drive?

Cheers Mark ( www.ST2000.de )

[Brian]

Looking good mate


Brian

[Twins]

[snozz2004]

Hi,

do you use a decompresion plate? or?
What compresion ratio you want to drive?

Hi, i'm using a decompresion plate, i think it will bring the comp down to 8:2:1
You can bring the comp down by having the piston crowns machined by 1-2mm, but i've heard that can weaken the pistons. If you have the spare cash, go for forge pistons, it's whats surpose to be used in this sort of conversion.

[snozz2004]

Engine & gearbox have been fitted, the head isn't fitted yet, still got a bit of work to do on the inlet, it's just there for show.






I'm using a CVH oil filter which has plenty of room



Series 1 RS Turbo anti roll bar fitted





I've just started work on the inlet (taken from a rover 420 GSI)



Interior is going back in, had a few problems finding interior parts for a mk3 so i resprayed the panels in satin black.
I found a power hood at the scrap yard, took the lifters & pump & fitted to mine, cost me Ł20!





Fitted the hood & rear window.



Also gave the body a polish.

[749steve]

like this
some good work work done here

[Dutch XR4i Driver]

Hi looks great
hope you wil have lots of fun whit it
here in holland the mk3 is not jet wanted like in England

Cheers Wiebe

[snozz2004]

Thanks for the comments guys

Small update:

I bought a engine mount off ebay near the begining of the build, i was told it was made to fit a zetec engine in a mark 3 & 4 Escort engine bay... But it didn't, so we made one are selfs,
1st. We moved & tig welded the lower bolt hole to the other side of the mount.
2nd. We made the fork section 1" longer (the bit that bolts to the rubber mount on the body)
Here's a few pic's of the mount after modds







Engine & box now fitted properly, all welding was done by a pro using a tig welder.

[stcabby]

Top work fela, its nice to see people savin them from the crusher.

[snozz2004]

Xmas put a grinding halt to my project, the credit crunch didn't help either, but managed to get a few things done.
Put all the engine parts, manifolds & exhaust system together, just to see if eerything fits ok, so far so good.









I've finishing the lower half of the inlet manifold, had to cut some of the alloy away to match the adaptor plate, just need to smooth the ports.





I've decided to to fit a MK4 loom, it comes with EFI management loom installed which i can use FRST OFAC ecu with, i had an OFAB system already, but sold that & got an OFAC one.
I had a few problems with the loom, lots of cut wires, looks like someone removed an alarm system & didn't bother to replace the missing wire.
Took me a while but most of it is fixed



Still have one wire thats a bit of a mystery, brown with black strip that goes from the speedo, its broke & i can't find the other end? if anyone reading this page knows what it does, please let me know.

[snozz2004]

Small update: MK4 dash board fitted with help from Smilers Site



Cylinder head is almost done, valve seated, chambers & ports cleaned up, just needs a skim



Hopefully i'll be building the engine by the weekend

[danny_boy699]

nice work mate, how come u fitted a mk4 dash. also how did u fitted the decomplate

[Smiler]

Impressive stuff! I had originaly planned a turbo conversion for my car too but funds just wouldn't stretch that far. In fact the whole project has laid dormant for goodness knows how long now.

Thanks for the link to my website by the way, good to see it gets used.

Keep at it, it's going to be quite something when it's done.

Smiler.

[snozz2004]

Originally Posted by danny_boy699

nice work mate, how come u fitted a mk4 dash. also how did u fitted the decomplate

Cheers mate, fitted a mk4 dash because 1. i'm using a mk4 efi loom & i didn't want the hassle of rewiring all the switches & plugs 2. the mk3 dash was a bit fucked.

you fit the decomp plate in between 2 head gaskets (gasket, plate, gasket)

Originally Posted by Smiler

Impressive stuff! I had originaly planned a turbo conversion for my car too but funds just wouldn't stretch that far. In fact the whole project has laid dormant for goodness knows how long now.

Thanks for the link to my website by the way, good to see it gets used.

Keep at it, it's going to be quite something when it's done.

Smiler.

The decomp plate lowers the cost a bit, but i'm already planning on building a 2.0 with proper forge pistons, get it on the road first tho.

I've used your site a few time while building the car, very useful info on there, noticed we both got conned into buying a engine mount that doesn't fit properly.

[Smiler]

Actualy, I modified my original mount from the old CVH. Then I managed to lose it during a house move and ended up buying another to modify from an already removed engine in a scrapyard. I modified it accordingly, went to fit it and discovered that it wasn't the correct Escort CVH mount. The wife subsequently found the original modified mount and that fitted a per the website.

As you can see from the website, I have somewhat overstretched myself now. I'm going to finish the Escort with the normaly aspirated 2.0ltr Zetec though I haven't decided on management yet. I started it so long ago that it was intended to use modified CVH EFi as that was all that was cheaply available back then. Of course the correct Zetec management is now cheap as chips and in plentiful supply but I already have the CVH EFi loom fitted. That was kind of why I was looking at going the turbo route with Fiesta RS Turbo management.

[snozz2004]

Is your management loom wired into the main loom or can you disconnect the management loom via a multi plug in the engine bay?

[danny_boy699]

cheers mate if u need some colcks let me know i have a few sets of rev conuter clocks

[snozz2004]

Originally Posted by danny_boy699

cheers mate if u need some colcks let me know i have a few sets of rev conuter clocks

Yeah i'm looking for some clocks, PM me the price m8

[Smiler]

Originally Posted by snozz2004

Is your management loom wired into the main loom or can you disconnect the management loom via a multi plug in the engine bay?

Sadly it's incorperated into the vehicle loom. Otherwise I'd have ditched it by now.

[snozz2004]

Originally Posted by Smiler

Sadly it's incorperated into the vehicle loom. Otherwise I'd have ditched it by now.

Same as mine & the main reason why i switched to OFAC management.
You could use 2i management, have it chipped to suit the engine

[snozz2004]

I got the head skimmed, bought 2 head gaskets & put the engine together



Cleaned out & primed the cam followers & fitted the 2.0 litre cams, then realized i forgot to fit the crank position sensor holder in the block!
So engine back out, gearbox, clutch & flywheel had to removed to fit the holder.



sand blasted the cam cover, dip stick tube, lower section of the inlet manifold, throttle body & coil pack bracket, sprayed the cam cover, manifold & throttle body in silver & coil bracket & dip stick tube in black









Finished all mods to the lower section of the inlet manifold & bought allen bolts to fix it to the head.



Just need to get the top half of the inlet manifold modified now.

[danny_boy699]

nice mate what throttle body u useingand what u modding on the inlet

[snozz2004]

Originally Posted by danny_boy699

nice mate what throttle body u useingand what u modding on the inlet

I'm using a fiesta rs turbo throttle body, had to match the ports of the lower section to the plate, also had to cut some of the casing because there wasn't enough room to get a bolt through.

See the 2 bolts to the left of the sensor in this pic, that part of the manifold is normally rounded, so i cut a straight edge & used allen bolts to solve the clearance issue

Originally Posted by snozz2004

[Smiler]

I'm getting jealouse!

[POHelbert]

fuck off spammer

[snozz2004]

It's been a while, mainly dew to my dad restoring a triumph spitfire, picture of the finished product below.



So while that was going on i spent my time cleaning a few things up, sandblasted the intercooler, gearbox mounts & top half of the inlet.







Wire brush attachment for the angle grinder help alot with the driveshafts



Managed to track down a Series 1 body kit not to far from my location.



S2 RST brake disc's & calipers, another ebay bargin, these will get a good clean up before fitting.



MK4 dash painted satin black & fitted, many thanks to danny_boy699 for the speedo



Found MK4 RST black carpet on ebay, looks better than the old grey & faded carpet



Mocked up the alternator, everything is good here, just got to finish the bottom radiator hose.



Figuring out where & how to position the throttle body.



Driveshafts painted & fitted, should have took a picture of them before fitting, but got carried away.

[Smiler]

Looking good, those mk4 dashboards look so much better in black don't they. What paint did you use? Used some specialist paint particularly made for painting items such as dash boards and it's rubbish, it's started lifting and peeling and I'm not happy about it. I would redo the whole thing but in some places it's stuck really well so I'd end up with lumps and patches.

Nice to see the alternator has gone on no problem, I have finally restarted work on mine and the alternator is almost next on the list.

Spifire looks nice by the way, I quite like old Triumphs. I'd quite like to lift the 2.5ltr 24 valve straight six out of my track day Beemer and drop it into an old Triumph 2000 saloon car.

[snozz2004]

Originally Posted by Smiler

Looking good, those mk4 dashboards look so much better in black don't they. What paint did you use? Used some specialist paint particularly made for painting items such as dash boards and it's rubbish, it's started lifting and peeling and I'm not happy about it. I would redo the whole thing but in some places it's stuck really well so I'd end up with lumps and patches.

Nice to see the alternator has gone on no problem, I have finally restarted work on mine and the alternator is almost next on the list.

Spifire looks nice by the way, I quite like old Triumphs. I'd quite like to lift the 2.5ltr 24 valve straight six out of my track day Beemer and drop it into an old Triumph 2000 saloon car.

Went to a car paint shop & asked what i should use, the gave me some plastic primer & standard satin black cellulose paint, i also wiped it down with thinners & used some pre paint liquid on it before priming.

I used a KA alternator, but had to modify it slightly with an angle grinder

Sounds like a plan, you should do it, plenty of room under the bonnet.
If you want to see more pictures of the triumph i have them hosted on photobucket click

[steve st220]

your doing well there mate, i'm in the middle of restoring a mk3 se cabby

[snozz2004]

Originally Posted by steve st220

your doing well there mate, i'm in the middle of restoring a mk3 se cabby

Cool, you going to post pictures of your rebuild m8?

[steve st220]

heres a few pics of mine for you











just waiting on paint now

[gagzyboy]

loving the update mate, nice work very inspiring ;0)

[dingla rs]

look like my old turbo clocks if they ofa danny

[Smiler]

Just re-discovered this thread and taken a look at those pics of the Spitfire. Looks like a very good proper job, nice work.

[danny_boy699]

Originally Posted by dingla rs

look like my old turbo clocks if they ofa danny

they could be mate, i had 2 sets that i sold at the same time, i know yours where lockwood 1's

nice work mate keep it up