There's no way in hell you are going to be able to achieve this with the 1.8's chocolate pistons, shitty clutch and fragile gearbox.

Either start a build with a 2.0 litre blacktop engine which has Mahle pistons as standard and under piston oil squirters (just be aware the rods and rod bolts are the weak link) or drop in a Focus RS engine (buy a written off one and swap everything over).

Now that that bit's out of the way.


My questions are:
- is it worth doing using the ERST manifold/turbo? Focus RS exhaust manifold will be a much better yet still fairly cheap option
- will i need aftermarket management or can i just map my std ecu? You will need an aftermarket ECU - you CANNOT convert to forced induction with just a remap
- is std inlet manifold ok? Will i need uprated injectors? Uprated injectors for definite. Pass on the standard inlet manifold (though bear in mind it's plastic!)
- any other parts need uprating? (iv currently got full exhaust/induction/cam mods) Throw out the cams you have, if they are aftermarket jobbies for an NA engine then they will be no good for a turbo engine
- will my gearbox be ok running that power? if not wot other options are there? Already made my point on that one. You'll blow it apart without much effort, assuming you can stop the clutch slipping
- what sort of costs would the parts cost and rough idea on fittin costs/time? A decent, reliable turbo conversion starts at around 5k using decent spec parts, aftermarket parts and a decent mapping session

There's no such thing as a 'cheap' turbo conversion - you either pay for it upfront to be done properly or you do it on the cheap to begin with then spend a fortune over the long run fixing all the things that break.