Versus_Creations

iTrader: (1)

After Bill having so much trouble with his first engine that was built for him, which let go with 450miles on it... He decided to get a decent engine, so thought id show a few pics now its running.




This is a comparison between the Cosworth Racing pistons and the WRC Mahle items, you can just see the rods in the background which show the difference between the FRSmk1 rod and the forged steel version.










He hopes to get it out on the road just in time for the winter months so he can get some miles on it ready for next year.

Rogeyboy

iTrader: (2)

Looks good, what spec etc?

Does the FRST inlet prove restrictive?

essexRSTSouthend

Looking sweet. Exhaust manifold been heat treated?

Versus_Creations

iTrader: (1)

The engine has some very nice parts inside, which include some rare 22mm pin WRC pistons from 1999 as pictured above with index bored clyinders. Custom mahle piston rings for the unique design on the piston. These will only work on a std size bore due to the regulations on the engine for race use, which is hard to find on a used 2l engine from a mondeo. The crank is also std size with mahle race bearings all round. Forged rods with ARP bolts stretched correctly. ARP head studs with multilayer gasket.

Top end has been stripped, then the front face has been welded up also a small alloy block has been added for one of the exhaust manifold studs then skimmed flat. Obviously then new threads for the CVH manifold with Zetec studs. Thermostat side has been modified to use a CVH thermostat housing and components like switch and sender etc. Headwork wise valve seats angled 5 degree, uprated springs. Solid lifters very mild work to ports. Std cams while engine runs in, to be honest its unlikely that Bill will want more power than it will be able to produce with the current turbo and injectors anyway so changing cam/s probly wont be needed for a while at least.

The inlet manifold is far from std and will have no issues providing more power than the current injectors will be able to flow maybe even the turbo. In the past the same manifold has been used on similar engines with much bigger turbo and injectors and made over 400bhp. The bottom half of the manifold has been made longer by aprox 3in, then the whole manifold has been ported inside to match the gaskets and the custom conversion plate to allow the use of the EFi manifold. The angles which the manifolds when combined have been changed to fit the engine bay and pipework etc.

As for the colour of the exhaust manifold... I have no idea?? Bill supplied it with the Turbo. I just bolted it on. I dont think its any kind of heat treatment more like paint. Its been used before and didnt burn like paint etc?

creator

Another epic build jano love this engine real credit to you mate bill will be so pleased when hes got it back,was good to have a look round it the other day

project rs

if you ever have engine out again jano be worth tipping the engine to the correct angle it was designed to sit at most people over look this or don't even realise it sits at an angle in the donor car which aids a touch in oil distribution i believe and hope theres a nice box in there and not an rst or ib5 one as could soon be out anyway again but all considered it looks at home in there and should make for a lively drive well done

darrenb16two

Who built Bill's first ZVH engine jan? Very jelous of this new engine! Should make nice power!

creator

Unfortinatly the gearbox is the only downside to the build,bill knows this but its all money as you know mate so bills just going to have to take it easy on the ib5 box,

Rob_DOHC

iTrader: (4)

Looks like its been ceramic coated.

Don't understand why you just don't get a traders account Jano, you would pick up so much business and actually be aloud to call the above an advert.

Rob,

Versus_Creations

iTrader: (1)

Rob to be able to handle more work i would have to take on someone else to help out, i cant trust anyone to do the job right, so i wont put my good company name into any jeperdy.
As for advert it clearly is not, there is no suggestion that i am offering any of these parts for sale. Some of the parts cant be sourced again, even if i wanted to sell them.
Purely showing what and how is no different to any other person who is building or built a car. If thats classed as trading in your opinion, then the likes of passion ford would have no members very quickly as everyone would have to have a trade account to show what they do.

Anyway its not about that, so lets keep it out of the thread.

Rob_DOHC

iTrader: (4)

It was light hearted Jano more of a query, and a fair comment about finding someone you trust to hire. Be nice to see what power it runs

Canada1

Keep up the good work Jano,

It is fantastic to see someone who knows what they are doing - and shows us a few
pictures of quality builds.

Cheers

Ad4m RST

For me in Fords there's nothing better than an immaculately built S1 packing power the right way.... perfect Jano

project rs

depending on what if any of the parts you used you are having trouble re sourcing then the wrc ones are available but are designed of another makers engine and are readily available as we picked a set of pistons up last month to go on our wrc rods we wiped out at ford fair for Ł180 a set

Versus_Creations

iTrader: (1)

project rs

Are they the same pistons as pictured above.
Im not saying you cant get them as clearly i did at one point. However they are very rare and not easy to find, or find parts for.
There is no rings off the shelf that will fit either.
If the same as ones i used above, did they come with rings?
If they did what make and part numbers.

Versus_Creations

iTrader: (1)

Thanks Perry, i could say the same thing about you as you have given people on here and my site lots of useful info and help. Its people like us that give others answers without them even knowing.

Versus_Creations

iTrader: (1)

If i had done an MTX75 box conversion like the other ZT's then i would of lowered the engine in the bay and could, like you say tilt the engine for better geometry and workings. .

However after Bill having no joy with his first engine that was built for him (no names mentioned) then having a decent one built, has sadly left him with an inferior box and eaten up the funds that would of been able to get the good box done.
Maybe in the future he will who knows.

project rs

yes came with rings too the problem if i remember right is pin diameter is bigger in the wrc stuff 22mm instead of the 20mm but as we know lots of stuff that is custom is simply borrowed from someone elses parts bin to through you out and i'd love to tell you were there from but as a well known tuner is still offering them for sale at the rrp then i think it would be unfair till they've exhausted there stock first for me to put it out there just as if you were selling something to make a living i'd respect your interests too, but on a side note the sets you sell are just as good and next time round will probably use one of your kits for nice responsive 350bhp zt

Versus_Creations

iTrader: (1)

The 22mm issue is easy to sort as the FRSmk1 uses this size. Its the rings which are the issue.

project rs

i'll have to look at the ones in garage then when we come to rebuild it then for that info

b11lkw

that'll be my engine then jano, nice 1 for posting up on here, thought id take a look.
gotta say Jano has done an excellent job with this engine, pretty much no expense spared on the build and altho im only running her in at the mo she is a dream to drive!
you can feel the potential power lurking under the bonnet, looking forward to getting her run in and mapped so i can use it properly.

also i noticed there was a question about the manifold, it is just a standard RST manifold that i painted with zinc galvanising spray, mainly just to tidy it up but seems to have held up[ better than i expected.

crazycage

i'd like to see some pic's of the inlet runners .

Versus_Creations

iTrader: (1)

Here you go.

bomsch

iTrader: (1)

Why not to use zetec inlet manifold and why cvh termostate housing?
Is there some advantage or just easyer to fit?
I`m step away to build zetec turbo with MTX75. So its good to know problems before they apear. Like what will be the best engine angle in mark4 shell.

muz

The CVH thermostat hosuing is metal and has an internal swirl pot so is better than the plastic Zetec job.

I'm guessing using the CVH inlet would have something to do with injectors, as the Zetec uses side fed injectors, not end fed like the CVH/Cossie ones so wouldn't mate up with the fuel rail etc.

crazycage

it was the head flange/runners i wanted to see.

Versus_Creations

iTrader: (1)

This pic wont show much but the only one i have to hand.

Versus_Creations

iTrader: (1)

The EFi inlet is a very good design with central throttle body. In std form its good enough for most typical engines we would have in our cars. Every now and then an engine which can flow alot of air quite easily, requires the manifold to have some work done. In this form there would be other restrictions before this would need to be reworked again. There are some good threads that cover inlet design in depth, have a search of my previous posts.

As for the thermostat housing it has many reasons for its use.
Firstly its metal allowing the other sensors required for the management system to be drilled and tapped. Then if you use a 1.4cvh housing the water pipe for the heater matrix has a 90degree less of a turn which aids flow. Also the thermostat housing for a 1.4cvh has no water swirl pot design in the casting, so when fitting an external water swirl pot this is the perfect one to use. The casting also has perfect areas to fit the extra sensors which is not as easy with the swirl pot type. Last the pipework setup is as std needing no extra bodged up bits of pipe and connections getting in the way.

The CVH thermostat housing ends up with.

Water temp sensor
Water temp Sender
No swirl pot
90degree less
metal
thermostat
fan switch

As for angles of the engine and heigth etc. That has also been covered in a recent post. Again have a search and see what you come back with.

Regards
Jano