Hi,
pretty sure I had a build thread on the go but I can't find it...... so I'll start another
I've had the car for more years than I can remember, bought it standard then took it off the road to restore some of the bodywork.
I then had the great idea of putting an RS Turbo engine in
After years of patiently building the car up it looked like this
I traveled to Blackpool and had the car custom mapped at MSD with a spec of -
Specialised Engines(
) Stage 3, 1.9 (
) tall block, kent cvh 34 cam, bosch 701's, OFAB management, 2wd cosworth t3 and inter cooler, full stainless exhaust, series 2 RST gearbox with AP paddle clutch, 4x4 cosworth calipers and discs with a mondeo master cylinder and servo, spax adjustable suspension and fully polybushed.
The drive home was ace!!! Very impressed
After a few launches I managed to snap a stud on the gearbox
The gearbox was also jumping out of 5th gear when on boost.
The car then began to smoke heavy and the idle became erratic, so I tried a set of stem seals but I wasn't that lucky!
The head came off to reveal badly scored bores, the second hand turbo was shagged too.
After a bit of investigation I found out the second hand 1.9 tall block was infact a 1.8 sierra cvh engine bored out to accept 1.9 cast pistons
So if anyone wants my advice, stay away from Specialised Engines in Essex!
The bores couldn't take another re-bore and I wasn't keen on going down the cvh route as I ideally wanted a bit more than 200hp.
I toyed with the idea of going ZVH then finally decided to go full zetec turbo!
I picked up a second hand fully forged engine from Devil Developments which had came out of Matt Hibberts mk3 Fiesta RS Turbo running around 400hp.
I've since had the engine stripped and checked over by Agra Engineering in Dundee, where they replaced all shells and installed new rings.
I also had the zetec sump baffled to help eliminate any oil starvation when cornering hard!
Pistons and rods
I intend on running an accusump system too.
I spent a bit of time painting up a few bits and re-furbing the calipers with new discs and pads.
I also had my 3dr cossie wheels re-furbed and Pristine! Excellent service, highly recommended!
The old gearbox was stripped of the LSD and I had it installed into a diesel BC box with a fresh re-build.
The car will be run on low boost once mapped until I carry out an MTX 75 gearbox conversion with quaiffe diff
I sent my turbo off to Wilky to have it re-built and a 360 bearing installed
I borrowed my old mans welder and had a go at modifying a mk3 Fiesta RS Turbo Scorpion exhaust to fit the XR2.
The last system I was using was an XR2 magnex mated to an RST downpipe which was really too small a bore, so I decided to upgrade it,
I managed to pick up an uprated rear anti-roll bar set up to stiffen up the rear end even more and some adjustable track control arms and tie-bars.
The New engine
The engine is now in place and I've fitted a bigger front mount intercooler
How the car now sits on the re-furbed wheels and I've fitted RS mudflaps too.
New engine spec is -
2.0 silvertop zetec turbo with 86mm JE forged pistons and Eagle steel conrods.
Standard 2.0 mondeo zetec head bar a skim and Devil Developments uprated valve springs.
Larger front mount intercooler
JR cone filter
2wd Cossie T3 with 360 bearing
Devil Developments tubular stainless manifold
Fiesta RS Turbo Scorpion exhaust - modified to fit the XR2
Cossie fuel pump and external swirl pot
Weber IW 158 injectors (fiat coupe)
and the OFAB management will again be custom mapped by MSD.
Hoping to have the car on the road for the start of next summer.
Really looking forward to taking the car back to MSD now they have their new rolling road set up so I can see what sort of power its putting out!
Hope you enjoy reading!
Grant