Had my s1 rs rollin roaded today
engine runnin well and had some new parts fitted etc
everything is as it should be now
only problem i have now is most times when comein off boost
the cuts out on me if it dose not cut out the revs drop right down and almost cuts out.
The tuning company said it could be the dump vale sticking

however i have removed it and blanked it off.


But its still doing the same.

There are no air leaks on the engine all the sensors are fine and working well.

The fuelin is set now and car drives and boosts well.

What could this be down to ???????????

 

cris4rst
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After 8 years my S1 RST will boost again - 2.1 ZVH - forged
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!
Last edited by cris4rst; 03-12-2009 at 06:09 AM. Reason: required editing -

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16-09-2008, 02:05 AM #2 Dan16v
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great progress, not to keen on the grill though
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16-09-2008, 05:48 AM #3 turboboss
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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
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16-09-2008, 11:52 AM #4 NATH-RSZT
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nice mate very nice. shame to use them shinney parts in the engine lol
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16-09-2008, 01:26 PM #5 Karlos G
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Sweet mate! I look forward to hearing what it can do!!
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16-09-2008, 08:22 PM #6 vroooom ptssssh
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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?
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17-09-2008, 12:28 AM #7 cris4rst
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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...????

 

Could be over boosting, The ecu cuts power to stop you blowing the engine up with too much boost wrong fueling.

 

check the fuel pump mine caused my s2 to run lean due to it bieng knckered and it scrapped my bottom end it also causes it 2 run hot