Ive been thinking of doing it for ages, after getting a puncture I decided now was the time to do it.

This is how the car looked b4 :



Full spec so far :

1.6 CVH
Lightend and balanced bottom end
Low comp Mahle pistons.
ARP bolts througout
Piper 285T2 cam and vernier pulley
Stage 1 ported, polished and gas flowed head.
Felpro group a gaskets throughout
Turbotechnics stage 1 turbo with 360 degree thrust bearing
-31 actuator
turbosystems unlimited boost chip.
GRS full width intercooler
Aquamist water injection
Samco hoses
ms developments dumpvalve
K&N induction kit
Full 3" Scorpion exhaust with 4" rolled out tailpipe.
Fusion fabrication chromed header tank / chrome rocker cover, heat shield, wiper motor cover etc etc.
2 x kenlow slimline fans
ap 4 paddle clutch
ABS removed
cossie 283mm
Poly bushes

Suspension :

Top adjustable koni shocks
40mm koni springs with 2 1/2 coils removed.
adjustable front tca's

Exterior / interior :

Storm single wiper conversion
17" white momo sport alloys
Seat ibiza front splitter
clear front indicators and side repeaters
smoked rear lights
white rear roll cage
White Dials
3 Spoke RS Steering wheel.

Performance :

Proven 217bhp @ 14psi boost with 230lbft torque.

Now for the work to begin. (theres a few pics missing as i didnt have my camera here)

I let the pics do the talking



















So what you think soi far? i'll try and get as many photos as pos as i carry on with it.

 

Sounds cool mate but the pics dont work.

 

pics fixed. u just got there 2 quick, they were still uploading.

 

I like the way you've blocked the holes up on the block. Good idea.

 

Thats going to be cool mate.

 

HAVE JUST FITTED SAME PISTONS TO MY ZVH DNT FORGET TO GET THE SKIRTS MACHINED THERE A BIT BIG AND THEY HIT THE OIL SPRAY BARS

 

More pics please ,you got any more plans for the body work

 

my mate has just found this out the hard way. as all 4 of them have broke off and wrote the whole engine off. even took a lobe of a brand new piper cam.

 

DID THE SME TO ME STARTED CAR UP AND IT RAN FINE THEN STARTED RATTLING SO TOOK SUMP OF AND 3 SPRAY BARS FEL OUT. SO HAD TO TAKE BACK OUT AND HAVE EM MACHINED AND REBUILD FULL BOTTOM END AGAIN ITS A SHAME BURTON POWER DNT TEL U THIS WHEN YA BUY EM GUD LUCK WITH YA BUILD

 

 

i thought it would be better as i can always re-use the block for a full 2.1 zetec turbo using the 16v head at a later date.

the last hole needed drilling out first :

 

other than what you have seen so far i am going to smooth the back bumper out, remove and smooth - lock on tailgate, rear wiper, handles, locks, where the second wiper used to be, fuel filler hole (as im having a racing fuel cell in the boot.

i am going to extend the home made roll cage into the front. ive only had it in there about a month or so, took me ageeeees to build that. i'll post some pics of it, all the welds are smoothed out on it.

 

hi,

what size are you tapping the holes and where did you get the bolts, that is a good idea. I am building a NA ZVH mysealf and want to do a simular thing

 

I cant remember what size it was off the top of my head, i'll have a look tommorrow. the blanking nuts are sump nuts from fiat. there a few quid each.

i can also get them from a trade supplier i have. pm me if you want some.

 

cars gonna look sweet mate when its done, keep the pics commin mate

 

keep up the good work!

 

Looks real nice
What spec are you going fo on the engine?

 

lookin good mate should look well nice when done is there a resion for making the ZVH and not just makin a ZT ?

 

great work mate also like the idea of blocking the oil ways with removable grub screws in the block

what paint did yuo use on the block?

not keen on the splitter on the front bumper tho

 

Fully lightend and balanced bottom end, crank, pistons, rods, flywheel
accralite pistons
**steel rods** cant really afford them yet but i may be able to get Saenz steel rods at a good trade price.
arp bolts though out
piper cam
gonna get the head done, bigger valves, 3 angled valve seats, cossie management.

i will be using the turb, intercooler, water injection etc i have already got.

im trying to get the engine work done asap, so i can start stripping the old engine out and get the engine bay sorted out.

 

i first sprayed it with a high temp paint, if you look on the pics you can see light blue patches, where the core plugs go. then i painted over that with a a high temprature high gloss caliper paint.

 

theres a few reasons really. first one is i want to build a variety of different engines. ive built a 1.6 cvh over 200bhp. i now want to do a zvh, then im doing a 1.9cvh then a zetec turbo.

also alot of power can be produced by a zetec turbo, but in fwd car its hard to put the power down, i think 300bhp is the limit. especially when on a budget.

i will however be going down the route in the future. i love my fords and im going to probobly have some sort till im 50. im only 22 now so ive got plenty of time to experiment.

 

jesus that's nice!

 

fair enough, good luck with the rest of the project should be mad when its done

 

 

did a bit more today, thought i would show how im doing my badboy bonnet.

i first cut out a peice of metal to the right shape:



the start of me bending over the lip :



half bent :



bent :



In place :



Me armed with a welder :



welded :



weld ground down :



View from inside :



Im off now to wack some filler on it.

 

Looking good mate



Brian

 

Keep the pics coming mate

 

 

a few more :

fibre glass filler :



Sanded down :



Skim of filler :

 

awesome sized workshop you got there mate

car will look good once finished

& go well

 

I really do think you should go for a stage 3 T3 or a T34 with that spec engine the turbo will probably not last long

 

I will do eventually mate. i'll just run it in on that turbo for a few months. It will give me some time to save up some money.

 

Ive done a bit more today :

bad boy bonnet finished.



the inside of the bonnet



Skim of filler on the inside




Some one had waxoiled the inside of the bonnet, eventualy got rid of it, using shit loads of thinners and a scraper. and got it flatted ready to be primed.



a bit more filler on the bumper :




striped the door card off :



and lock & handles :



handle resses welded in :



welds ground down :



skim of fibre glass filler :



Im going to have a kfc now and crack on with it for the rest of the afternoon.

 

Brian

 

Interesting project

 

Nice.. Get more pics up

 

 

Keep them piccys coming

 

doing a great job