Its about time i started a build thread i spose so here we go...

I bought the car about 2 years ago. it had a rebuilt standard 2 litre silvertop zetec apart from 1mm skimmed pistons (to lower compression), stage 2 T3 on cvh manifold, rover turbo inlet manifold, alloy rad, bigger intercooler, omex 600, oil cooler, deisel box with rst lsd

Prinout for 254bhp at 14psi. But i turned it down to 11psi.

willwood saph front brakes
saph rear brakes
inline brake pipes with bias controller
uprated shocks and lowering springs
front strut brace
full cage
sparco bucket seats and harnesses
various gauges















The engine had been build on a low budget, so like most zetec turbo on standard internals, it died! Well, it started to smoke and had a loss of power.

I sold the car as it was to P33PRK from on here (i think)

However... about a year later i wanted it back so after a few txts it was on its way back as he was on about selling it anyway.

He replaced the turbo to hopefully cure the problems but it was still the same. When i got it back i thought i may aswell start again and build it properly. First i took the head off just to see what was going on inside, and this is what happened.



Commonly know as... Blown to the bone.

So i took that engine out and binned it, and started again with a doner engine from an automatic mondeo.

First i bought some 1mm oversized forged low comp turbo Wossner pistons and PEC rods.





Then i had the block bored



Then built the bottom end.









Then bought new oil and water pumps



Then i started the head, which was very time consuming! I still wanted to use the Rover Turbo inlet so i had an adaptor plate made. Then i filled the zetec injector cut-outs with ally weld, then bolted the plate to the head and matched the head to the plate, and ported and polished the inlet side





Then i had 3 angle valve seats cut (and valves re-faced)



So now the engine is pretty much done. Ive also decided to use a Focus RS gearbox. Luckily i found a package on ebay- which consisted of the gearbox, driveshafts made to fit a mk4 escort, clutch, flywheel, starter motor, gear selector cables and electric speedo.

Then i had a go at mounting it...

First i mounted the engine and box together and dropped it in the engine bay where i wanted it. I mounted the engine side, then made a bracket on the inner wing for the top gearbox mount.











And thats as far as ive got really. The clutch and flywheel are on the enine and the engine is bolted to the box.

Next job is to modify my clutch peddle for the clutch master cylinder then drop the engine in, then put everything back on.

I also got fed up of the cvh manifold adaptor plate blowing so i bought a 2nd hand Focus RS Exhaust manifold, turbo and down pipe.

Il use this for now, then mabey upgrade to a hybrid GT28 and Ford Motorsport Manifold next year.

My aim is to get it built, run in and mapped for RS Central day next month but cant see it realisticly happening at the moment!

Since i got the car back i also painted the wheels and vents black for when its done.