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Been thinking of starting a new project for a long time, and after much thought i have decided to build a 2.0 Blacktop Zetec turbo and put it into a westfield. Want to run 300bhp. I used to have a share with a guy who had a Westfield with an R1 engine in and that was good fun. but i wanted something i can say ive built myself so going down the car engine route, with more power.
Last weekend i drove to an area around 20 mins drive from my home and secured a brand new 8x8x8ft lockup in a secure compound. Perfect size for building the engine, and can always upgrade to a 20x8x8 or 40x8x8 in the future when the time comes i need the chassis. The bonus of this is the cost of my current lockup is £50 a month.
Since securing it me and my partner laid down 3 layers of carpet we had rolled up in the loft. This is to stop oil spillages and damaging the floor. Build a little workbench out of ply and 2 pallets.
My new engine stand arrived so we popped up yesturday and went and built it and took the other little goodies ive been building up over the last 2 weeks.
Here are a couple pics. The engine is coming tomorrow so will be straight on to stripping that down and getting the block sent off to the machine shop!
I plan to use c20let pistons but am unsure on the rods yet.
More pics tomorrow evening once engine has arrived.
(one thing i am annoyed with!.. i have a paid account with photobucket, why are they still putting watermarks on my photos!?)
Last edited by nickharding; Apr 12, 2020 at 12:23 PM.
Now i have refreshed they have gone, i did have a free account and then upgraded to the paid version, must have taken a little while for it to settle. Thanks for the input.
As promised, one Zetec 2.0 blacktop delivered straight to my container
There is a small collection of cars just outside of the first gate, and the other day whilst i was jumping out to lock the first set of gates i noticed a trailer with 3 engines in, and 2 of them were blacktops! .. Walked over and had a half hour chat with the guy, turns out he has a bigger yard not far away but these were for his own private projects. He said he has 2 blacktops and another coming next month and would be happy to sell one. Cost me £200 and he dropped it straight into my lockup on a forklift! top man.
Sadly i took the wrong bolts with me so couldn't get it mounted to the engine stand but will take the correct ones on the weekend when im back over there.
Have only stripped the loom and flywheel off of it so far. Its done around 100K, and from what i could see through the oil filler cap, the cam lobes look brand new. Should be a good engine.
Heres some snaps....
Cheers Ryan!
Once the loom was removed...
Will be stripping it all down on the weekend once its on the stand.
I am not sure if I would want a Turbo engine in a westfield due to the power delivery...should be quick though.
I had a Tiger 6 with Zetec on Throttle bodies, cams and head work 230 bhp and that really was a quick car.
I quite fancy one with a modern ally V8 of some sort.
Depends on turbo setup and how it is mapped.
Ive seen v8’s in them and they are bloody tight. Wouldn’t fancy driving about with the massive weight on the front and the mad torque they give low down.
Ive seen v8’s in them and they are bloody tight. Wouldn’t fancy driving about with the massive weight on the front and the mad torque they give low down.
I am not sure if I would want a Turbo engine in a westfield due to the power delivery...should be quick though.
I had a Tiger 6 with Zetec on Throttle bodies, cams and head work 230 bhp and that really was a quick car.
I quite fancy one with a modern ally V8 of some sort.
True I may have ruined it but I am working on the same principles of modern hatchbacks. Slightly higher Cr, tiny turbo careful mapping. I am shooting for 250 bhp ish. Biggest issue seems to be cooling with these little turbo cars
Modern v6’s are a better option than a v8 as there Cheaper and easier to get get in the uk. There are a few guys that have got an Aj30 from a jag in there’s. I was part way through a Duratec 30 from an st220 but the the turbo Zetec was already sat in the garage.
I am unsure on pistons and rods, but I know the rods would not be c20let only the pistons themselves. Need to look into it a bit more.
what rods and pistons are you using/planning to use and what c/r does that give you?
Ive built one of these hybrid st170/Zetec engines.
The idea being the weakest link in the Zetec is the rods and then the pistons. The St has better rods with bigger rod bolts and bigger small end. They are sinter-forged with fracture cracked big ends.
They finish up at 9:1
St bottom end. Full rebuild with Arp rod bolts.
new Blacktop head from a crate engine. It’s got the Hd valve springs.
Ford Rs 1.8mm gasket.
Raceline sump
Turbosport Rs flywheel
Subaru Td04L turbo
custom manifolds
running on the Focus Rs engine management.
Mt75 gearbox Ap racing Rs clutch.
And finally the one I am unsure on is the coolex intercooler and rad combo.
Ive built one of these hybrid st170/Zetec engines.
The idea being the weakest link in the Zetec is the rods and then the pistons. The St has better rods with bigger rod bolts and bigger small end. They are sinter-forged with fracture cracked big ends.
They finish up at 9:1
St bottom end. Full rebuild with Arp rod bolts.
new Blacktop head from a crate engine. It’s got the Hd valve springs.
Ford Rs 1.8mm gasket.
Raceline sump
Turbosport Rs flywheel
Subaru Td04L turbo
custom manifolds
running on the Focus Rs engine management.
Mt75 gearbox Ap racing Rs clutch.
And finally the one I am unsure on is the coolex intercooler and rad combo.
Nice. Where did you find the RS 1.8mm gasket and piston rings for the st170 rebuild ?
Nice. Where did you find the RS 1.8mm gasket and piston rings for the st170 rebuild ?
My local Ford counter found me one of the last gaskets in Germany. And i bought a set of "new" pistons from an engine tuner building a forged engine from a new base engine. Same thing with the new head. The st bottom end has only done 47k
Ive been collecting parts for years. It was going to be a t230 spec track st / Rs rep but the st rotted away faster than I could strip it down.
My local Ford counter found me one of the last gaskets in Germany. And i bought a set of "new" pistons from an engine tuner building a forged engine from a new base engine. Same thing with the new head. The st bottom end has only done 47k
Ive been collecting parts for years. It was going to be a t230 spec track st / Rs rep but the st rotted away faster than I could strip it down.
Update, was meant to post this last night but after a hard days graft and then spending 4 hrs up the unit excluding a hours drive back and forth it was safe to say i was f**ked by the time i had a shower and got into bed!
Started to strip it down, cams look sweet, more on saturday!...
In the last photo the parts on the left are for the breaker who sold it to me (Ryan) if he wants them he is more than welcome to them, more will be added to this pile on Saturday (pistons, rods, oil pump etc)
My mate Jamie turned up for an hour and a half and told me he has a small and large shot blasting machine in work, safe to say i sent him off with a load of bits! Will be back to me on Saturday. After having a long discussion with him his Boss has 2 Westfields all in bits, and would hapily sell any of it, so need to go and meet him ASAP! Might be able to snap up a chassis and bodywork for cheap. Also been given full access to his workshop and tools through Jamie!
Parts unter the workbench are stuff i may potentially need, things like coil pack and htleads are kept as spares for trackdays. Dont fancy buying new as backups.
Cheers for the interest! any hints and tips welcome on pistons and rods as from Saturday afternoon the block will be ready for the machinists!
Head will shortly be off to A.L Developments for fully porting, skimming, and both inlet and exhaust faces machined. Also chemically cleaned. Standard valve springs replaced with piper springs.
Nick.
Last edited by nickharding; Sep 5, 2019 at 08:44 PM.
photos look terrible on phone but look crisp on laptop? looking at the origional taken photos through my phone they look crisp too! alyone else having this issue? dont want to make a project report with shite pics! maybe il upgrade my phone!!?
I wouldn't bin the oil pump unless your dry sump ing it.
I’m looking forward to shot blasting some bits and getting back to the unit tomorrow to get it on the stand finally and strip the rest of it!
When I said bin the oil pump, I’m undecided what I’m going to do with the sump. I need to do something with it as it will be to low to the ground? Was thinking of replacing the oil pump with billet gears?
was looking at this but worried about loosing to much oil capacity?....
Yep ive made two or three of them and you end up at 3~3.5L it’s not enough.
You could make one with more capacity. And they can be a ball ach to get the starter to fit.
For a 7 do it once do it right = Raceline .
Other options.
Neil Dunne does one, they love him on Fb.
Tigger racing, not ideal. Do some research.
Gbs/Kitspares, same sort of thing as Neil Dunes’s but more money..
re the oil pump. Again do your research and make your own mind up but, for 300bhp I would stick with a clean well seasoned Oem pump and over 400 I would go for external pump.
Are you not keeping the cambelt covers ? There getting harder to find if you change your mind.
They can be modified to make them look much cleaner.
Will be keeping the cambelt covers but machining the lower one and not fitting the top one. Quite like the look of the pulleys being on show.
This bracket that sits behing the cam pulleys, is it required? i noticed part of the tensioner sits through the small rectangle hole? Was hoping to do away with it?...
Thanks for the info on the sumps.
Was up the garage yesturday from 4pm till 11 pm. Got the engine finially mounted to the stand, and further stripping was done.
Jamie managed to shotblast a few bits for me so they are ready for painting now. Just need to do a bit more research regarding pistons and rods before i send the block off for engineering!
Engine seemed to be spotless. oil had already been drained so that saved me a job. Only had 2 problem bolts but with a bit of heat from my blowlamp they soon eased up.
Yes a set of open verniers and a Bda cover does look sweet but it's not worth the risk for me.
Having taken the engine out of mine I had to hover, wash, pick a lot of stones and debris out of the engine bay any number of this could destroy your engine if it gets in there.
The zetec is taller than what the little seven was originally designed for. There is less than 10mm between the cover and bonnet on mine. Again to close not to have it for me.
Yes a set of open verniers and a Bda cover does look sweet but it's not worth the risk for me.
Having taken the engine out of mine I had to hover, wash, pick a lot of stones and debris out of the engine bay any number of this could destroy your engine if it gets in there.
The zetec is taller than what the little seven was originally designed for. There is less than 10mm between the cover and bonnet on mine. Again to close not to have it for me.
I wonder if I could get my hands on a Perspex pulley over or if I could get one made for me. That would be awesome. Full protection but still get to see what’s going on!
Havent had a lot of time reciently as been flat out in work, most days 8-9, moneys good but as for time including travel to the lockup finding it hard to accomodate the project!
Did manage to get over there for a hour and a half saturday morning. Removed the valves, springs, collets and valve sem oil seals. Not gonna send the head off to a company, doing the work myself and not porting. Not esssential due to being forced induction.
Head has now gone off with other parts to jamie for chemical cleaning. will then go off for skimming, and will then be rebuilt with relapped valves with uprated piper valve springs, and then skimmed, once skimmed i will be priming and painting using high temp sprays.
Apparently with the uprated piper springs i need to change the tophats or the collets? can anyone enlighten me?
no more ideas on pistons or rods yet, need to gain time to do research! haha.
Also done a bit of grinding regarding the origional block breather as wanted to include the origional seporator. couple pics below. 2 gaskets and will be sweet. still unsure if im going to thread the plate for the brass fitting or get an ali elbow welded to it. will soon see!...
Ordered more bits earlier..... More soon!
Last edited by nickharding; Sep 17, 2019 at 08:57 PM.
The crankcase breather blank off plate which was made of stainless, i drilled a 18mm hole in it and tapped it to a 3'4 thread so my brass elbow would fit, i then silver soldered it into place so it faces directly up to the head. Then whilst i was visiting Liam my mechanic he kindle cut some slots in the other side of the brass allowing it to mate up to the air seperator. this will require a double gasket but will work perectly....
Once that was done, i got him to cut off the origional water pump impellor and press on my new IKEngineering one, allowing opposite direction water flow (same direction as engine roration...)
After that i decided to spray some parts. Using VHT primer and spraypaint, temp resistant up to 1000 degrees so ideal for engines, blocks, heads, etc, decided im gonna spray all my parts with it. 1 coat primer 3 coats paint. then fitted my water pump. lovely paint....
Big shout out to Liam Poll today for his help. It was Laim who lent me his Valve Spring Compressor, luckily mines arrived now, but have a feeling will need more help from him during the build!
Bring on pay day. Had a short month this month as i had 21 days off following up from 16 days in the south of france and 4 day bank holiday weekend, need funds! next month will be better!
Was in the same situation a couple of years ago, all excited about doing a turbo build. After the initial building of the engine sorting out all the other bits required dragged on and then there was the spec changes and new ideas. Anyway have some motivation for a new push so this thread caught my attention, will be keeping an eye on progress
The Black Count - Thanks for your reply, its amazing how much research you can do when you havent got the time or money to spend with your project. Thankfully ive got lots of ideas gained due to my research, all will be revealed soon.
Turbo Zetec - Thanks for your private messages and input to the thread. Liam pressed it on a little bit further (so a tighter tighter fit) than the standard position, not because of this issue as i didn't know about it, but it will allow a little more clearance in the housing and now knowing what you said above, allows it to be on there a bit more snug! fingers crossed no issues!
Might have some piston/rod updates soon!
Sent the head and a few other engine bits off to Jamie to be chemical cleaned at his work. Once back the other bits can be sprayed and the head can be send off to be skimmed.
More soon ...
Last edited by nickharding; Sep 25, 2019 at 07:39 PM.
With the pump it’s not a good idea to just push it on a bit more. You need a tolerance between the impeller and housing. By increasing the gap you will reduce the pumps efficiency.
So do you get a new drive pulley to go with that water pump impeller?
I will have to yes. The standard pulley is smooth as it runs off the back of the belt. In my new config I will need a ribbed pulley. It’s on my to get list but is quite expensive. So ordering things that are priority atm so can keep the build moving.
big_wasa...
We looked at the gap and I’m not to concerned. The new impeller is 25% more efficient than the standard item. To the point people fit a larger pulley to slow it down. So not to concerned that it’s pressed on slightly further than an original item. I think it will be fine. Will have to keep an eye on it when it’s finally running.
Thanks for the link. Will see how money goes. got my girlfriends birthday on the 7th, which just so happens to be my monthly invoice date. Hopefully i can get the IKE one, also been enquiring about the bearings. really want to get the crank back in. Pistons are in my watch list but not wiling to order them untul i can find a set of williams rods with a 22mm pin, Theres someone on ebay doing blacktop and silver top rods with a 21 and a 20mm pin option. apparently Williams do a 22mm pin version which will suit the pistons of my choice, just hard work finding a set!
I was watching them on eBay last year or the year before but the pistons dried up so I lost interest. I would also be interested in a set.
Burton power have the pistons at £300 but I haven’t checked if that’s plus vat.
pec offer the Rs spec rods but nearly twice the price and you may as well get forged pistons while your at it. Back to the Rs pistons. They are NOT forged.
2.0 Blacktop Turbo Westfield Build
