This is my first post,

I have been slowly attempting to build a quality S1 RST
Back in 1999, I bought an S1, I think the reg was C659 CAS,
This had a zvh conversion but was belching smoke everywhere, the piston were found to cracked round the rings
So I sourced and built a block with forged rods + pistons ect,
Whilst the engine was out I gave the shell a good once over and soon realised it was in a state -
There was holes and corrosion everywhere - real bad
So C659 CAS was stripped off all good parts and search was on for a fresh shell,

Sourced B680 BSU,
Car had new pannels had been fitted and was resprayed,
Was non-runner when bought but changed the metering head and it run fine
but engine was soon ripped out to make way for high spec ZVH,
All undersealer was removed to check for corrosion - shell was solid
Think that was back in 2003/4

Since then it had slowly recieved the following -

Spec as follows -
Zetec Block + Crank - Bored to 86mm,
Tufrided / Nitrided Crankshaft
Steel Conrods - Arrows + ARP's
Forged Pistons - Arrias 86mm Dia with 20cc Bowls, giving 2047cc
All balanced bottom assembly (crank, flywheel, clutch + pulleys) -
Stage 3 1.6 cvh head - (power engineering)
Piper T258-2 High Boost Cam Kit
Stage 3 T03 Garrett Turbo
GRS Evo Intercooler + 2 Kenlow 10" fans
AP 4 Paddle Clutch + 220mm fly-wheel
CTS Stage 2 gearbox with Quaff ATB LSD
B&M Short Shifter
Mocal Oil Cooler + Thermostat
Scorpian 4" stainless zost
Modified Metering Head - AVA
Uprated fuel pump
Mappable 5th + 6th Cosworth green injectors
MF2 Control Unit + 3Bar map senson for injectors
(not yet connected - engine needs run in first)
Autometer cooling Fan controler
Webber Alpha Air / Fuel ratio monitor - 15 led
Cosworth Brakes - front + back
Koni Adjustables
All fuel Lines now stainless braided - not in foto's
All running gear shotblasted + painted
Powerflex bushes all round + Vibra-technics gearbox mounts
Custom made front tiebars, solid 1" bar with oversise thread,
(standard tiebars bend to easy)

After all these years being off road, it's almost ready to run
The compression ratio worked out at 7.4-1 meaning it will handle serious boost,
I assembled the engine and done all work myself,
Apart from Agra Eng that bored the block to perfection to suit the pistons, hardened the crankshaft + balanced the bottom assembly
They says the bottom end is good for 450-BHP,
and the steel rods will let it rev to 8800.
Wont be going that far, but with the 5th + 6th cossy injectors
i should be getting close to 300Bhp - more that enough for FWD.

Foto's are about 2 year old

Notice layer of "protective" dust, not had was for years..since being garaged

A few shot from rear - wish I had cleaned it before taking pics

Black crossover pipe with cossy 5th + 6 th injector kit has since been fitted, - Also all fuel lines are now braided..

Not into chrome - hence no chrome...

Now some underside shots

Tie Bars are solid 1" steel, bigger M16 thread, standard ones are no good

Forgot to say blackdiamond disks all round

Modified + baffled sump - to clear exhaust..

All brakes now have stainless braide hoses

Trial fitting rear cossy's, had to make up 10mm spacers,
Fitted new seal + slide kits fo all calapers -



Braided fuel lines- last thing I want is fuel leakin onto hot exhaust

Air / Fuel ratio meter - will indicate detonation.. ect..

B&M Shortshift - these are getting hard to source

Pics taken when the Bottom End was waiting anxiously in the hall way to be assembled,


Comparing to the standard internals - Huge difference in strength!

 

great progress, not to keen on the grill though

 

m8 nice car

i would dump the head and cam you wont get the full potential out of the engine, peak power would come too early in the rev range,even with loads of boost you might struggle to hit 300hp, and another thing 300 fwd with proper suspension components 300hp would be a walk in the park..

sean

 

nice mate very nice. shame to use them shinney parts in the engine lol

 

Sweet mate! I look forward to hearing what it can do!!

 

Looks great mate! nice to see them comin out of the woodwork!!

I've saw CR's allot lower but should be able to take a fair amount of boost! i'd of been inclined to go for a T34 turbo with prolly a .63 dependin on where you want the power in the rev range!

looks great tho!

p.s. meant to ask, the tow eye on the rear? has it had a mk4 boot floor fitted or is it a mk4 shell?

 

Yea, I should have went for the T34 turbo, this is going to bug me....
The T3 turbo on at the moment was bought brand new,
I'll see what happens with the T3 when on the rollers,
It is a Stage 3 job, but if it runs out off puff, I'll have to invest in a T34
How far up the rev range do you think the T3 will go before running out of puff..???

About the rear toe eye,
Bought the car as a standard non runner from a lad who works at a local bodyshop,
It was newly painted + fitted new floor pan, pannels and tyre well,
That's a MK4 tyre well welded on,
I will have to post a pic of the tyre well showing the weld,
Last thing I want is folk thinking its a MK4.....

Am also thinking bout putting standard grill back on,
But the grill in the foto will allow for better air flow to the coolers........
Nae sure what you think folks...????

 

Cool car, let us know the progress.

 

definatly put the standard grill back on.

 

Stick the standard grill back on deffo! It wont have any noticeable effect on airflow, cant see it being much worse at all!

As for when the T3 will run out of puff, I dont know maybe wont pull as hard from 6K onwards, total guess tho sure someone will know!

I've possibly got a T34.63 for sale in the next 4-6 months depending on what I do turbo wise, but if your interested then give me a PM.

I've stuck your car on the Series1 pic/regi database hope you dont mind!

https://passionford.com/forum/ford-escort-rs-turbo/76469-series-one-picture-database.html

I notice AVA modded your metering head, has it been there in the past?

 

Stud conversion on front hubs

Work on the underside now complete


Interior work in progress

Finally - back on wheels





the engine runs real smooth + and rumble from exhaust sounds awesome - it pops and backfires when revved -
landa sensor display shows it to be running on the rich side - next job is to get it tunned and run it easy for 1000 mile,
After that the cozzy 5th + 6th injectors will get hooked up and then on the dyno to see what it can do.

 

just interested mate, im looking at doing a very similar conversion! how much has it roughly set you back to do everything? doing all the work yourself etc!

you dont have to answer if you dont want to

 

lovely post mate and love the modding, not keen on that front grille though!

 

Definitely needs a stage 3 T34, the grill reverting back to the original one.

I really don't think those brakes will be up to much with the power you will see. You can pick up a Focus ST170 front conversion for around Ł300. So much better than the cossie seup that people sometimes use.

 

tidy as fuk, good to see a big power rsturbo in aberdeen not much goin about these days, gives me some thing to play with when im out in my 3 door! is this the boy from peterheads old car who worked at auto spray in bridge of don?

 

Progress update since last post -
not much really, took it for a test drive last month to check brakes, steering ect - It felt real solid, As the engine wasn't yet run in or tunned I drove easy but soon after couldn't resist and gave it some boost, the turbo wound up real fast and both wheels spun at around 4000rpm in 3rd - in the dry - didnt have the road to try 4th,
But problem with one of the front wheels scuffing the arch, so back to the shed to investigate, Suspect it is the TCA as compared it looked slightly different to the other one, so going to buy a set of adjustable ones from
Compbrake http://compbrake.co.uk/shop/product_info.php?cPath=9&products_id=267
Once these are fitted it will get full geometry / alignment set-up
Also been thinking about getting a set of front MEF motorsport Adjustable Bilstein Coilovers with spherical bearing top mounts
http://www.909sport.co.uk/mef/downloads/mefmotorsport_1.pdf
Have uploaded a vid of the engine running -
http://www.youtube.com/watch?v=YZcl6o2xV6c

Standard grill is going back on, but need to modify it as the lower lugs wont clear the 2 x kenlowie cooling fans on the intercooler,
Had to cut some of the front pannel off to fit the 2 fans, the bits where the standard grill would have slotted into,
Rest assured the standard grill will be going back on!

 

nice work! would bin that standard breather set up imo

 

Good work mate

 

Hope you have a bias valve fitted with them rear discs matey, Top work, loving the attention to detail