Building a Zetec 16V Turbo
26-11-2005, 08:16 PM
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Building a Zetec 16V Turbo
Hi,
I plan to build a 16V Zetec Turbo for my series 2 just a couple of questions......
im looking for approx 300bhp...i know there are 3 types of zetec engines around which is best for the conversion, ive been advised blacktop is stronger??
I know people use 16 valve vauxhall pistons on ZVH conversions, can you use these and get them machined for the 16V Zetec Turbo??
Who makes the adapter plates for mounting a series 2 exhaust manifold and fiesta turbo inlet manifold??
Ive seen them use mapped fiesta turbo management is this a good route???
Many thanks peeps
Neal
I plan to build a 16V Zetec Turbo for my series 2 just a couple of questions......
im looking for approx 300bhp...i know there are 3 types of zetec engines around which is best for the conversion, ive been advised blacktop is stronger??
I know people use 16 valve vauxhall pistons on ZVH conversions, can you use these and get them machined for the 16V Zetec Turbo??
Who makes the adapter plates for mounting a series 2 exhaust manifold and fiesta turbo inlet manifold??
Ive seen them use mapped fiesta turbo management is this a good route???
Many thanks peeps
Neal
26-11-2005, 08:20 PM
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My quick advice to you:
Use a S2 Zetec - Silver top with 16v ZETEC on the cam cover.
Pistons - Vauxhall Calibra Turbo (C20 LET)
I used to be able to get the adapter plates from my machine shop, not sure about now, I shall enquire, they were about £80 though
Dont use a FRST inlet, use a Rover derived one, M16 type preferably. Thought I believe Area Six (Ian Howell) sells the FRST inlet adapter plates.
FRST management is "OK", but can work out just as expensive as getting a propper aftermarket ECU setup (unless of course its going straight in a Fiesta Turbo). If using a FRST ecu, beware maping will be £500 atleast, injectors will cost a fortune and if using OFAC, youll be capped at 21psi boost.
HTH
Use a S2 Zetec - Silver top with 16v ZETEC on the cam cover.
Pistons - Vauxhall Calibra Turbo (C20 LET)
I used to be able to get the adapter plates from my machine shop, not sure about now, I shall enquire, they were about £80 though
Dont use a FRST inlet, use a Rover derived one, M16 type preferably. Thought I believe Area Six (Ian Howell) sells the FRST inlet adapter plates.
FRST management is "OK", but can work out just as expensive as getting a propper aftermarket ECU setup (unless of course its going straight in a Fiesta Turbo). If using a FRST ecu, beware maping will be £500 atleast, injectors will cost a fortune and if using OFAC, youll be capped at 21psi boost.
HTH
26-11-2005, 08:22 PM
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Bl**dy hell that was a quick reply....
thanks....
ive seen the rover one being used on quite a few engines, are there any mods needed to get it to fit???
thanks....
ive seen the rover one being used on quite a few engines, are there any mods needed to get it to fit???
26-11-2005, 08:54 PM
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my advice to you mate is sit back and soak up all the info you can about the conversion then decide what your going to do reaserch and developement is key my friend and phils advice is good advice, also take into acount everything you,ll need to run this 300 bhp ive been pissing about with rst,s over ten years now and its easy to get overwelmed by bills for this and that apearing unexpectedly because you didnt know this or that, ask all the questions you want mate till your satisfied your clued up enough to seperate the shit from the good then do it 
ive got a silver top like phil mentioned with steel rods ect, for 300 you,ll need steel rods budget a thousand for rods and pistons then the machineing to the block manifolds turbo then management also cooler a std 16v head and cams will give you your 300 so no need to mess thier good luck fella and welcome to pf 
ive got a silver top like phil mentioned with steel rods ect, for 300 you,ll need steel rods budget a thousand for rods and pistons then the machineing to the block manifolds turbo then management also cooler a std 16v head and cams will give you your 300 so no need to mess thier good luck fella and welcome to pf
26-11-2005, 09:07 PM
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thanks again.....
anyone else please post up your specs of your 16v zetec turbos...
Are steel rods def needed, or standard with ARP bolts be enough for 300hp??? ive run 23psi on my CVH for 220BHP for 5 years now and rods have hung in there...(even after meltdown)...ooppsss
cheers
anyone else please post up your specs of your 16v zetec turbos...
Are steel rods def needed, or standard with ARP bolts be enough for 300hp??? ive run 23psi on my CVH for 220BHP for 5 years now and rods have hung in there...(even after meltdown)...ooppsss
cheers
26-11-2005, 09:23 PM
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I use steel rods in mine, but then im looking for closer to 400bhp then 300
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
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26-11-2005, 09:59 PM
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Originally Posted by Sketch
I use steel rods in mine, but then im looking for closer to 400bhp then 300
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
26-11-2005, 11:23 PM
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Originally Posted by Hansenturbo
who can me build a strong zetec turbo i also want to that route and get 350+
Top bloke.
26-11-2005, 11:32 PM
#11
As philm said that the best way in terms of budget. Ive looked into it a LOT to decide a spec suitable for me, as iam only looking for a reliable 250 bhp (its in a XR2 for hell's sake 
) ive decided on:
Silver Top Zetec
LET (calibra turbo pistons)
Drill and tap the block for a RST exhaust manifold
Make my own spacer for 1.8 inlet as i BELIEVE they flow better than a standard RST item.
The Rover inlet does flow a lot better but needs a fair bit of modification to make it fit and wasnt suitable for me as i have a reverse charge carrier for my intercooler so dont fancy running the pipes back on them selves! Also didnt fancy going through the extra hassle of the fitting but as i say depends what spec you are after.
I learnt all this through a few silly posts (Thanks phil/ginge etc...) and MAINLY using the search in this forum and reading EVERY post that included 'Zetec', 'ZVH', '16 valve' and 'LET pistons'. that will soon lead you to many guys on here projects that have been soooo helpful (Red16/Rudey etc...)
) ive decided on:Silver Top Zetec
LET (calibra turbo pistons)
Drill and tap the block for a RST exhaust manifold
Make my own spacer for 1.8 inlet as i BELIEVE they flow better than a standard RST item.
The Rover inlet does flow a lot better but needs a fair bit of modification to make it fit and wasnt suitable for me as i have a reverse charge carrier for my intercooler so dont fancy running the pipes back on them selves! Also didnt fancy going through the extra hassle of the fitting but as i say depends what spec you are after.
I learnt all this through a few silly posts (Thanks phil/ginge etc...) and MAINLY using the search in this forum and reading EVERY post that included 'Zetec', 'ZVH', '16 valve' and 'LET pistons'. that will soon lead you to many guys on here projects that have been soooo helpful (Red16/Rudey etc...)
27-11-2005, 01:57 AM
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My engine is a bit of a cross bread, iam using a silver top bottom end, with a late (black top) top end, has been a mission to get them together as the tensioners are in a different place, will hopefully be the best of both.....if it works! lol
27-11-2005, 06:23 AM
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Originally Posted by Brasso
Originally Posted by Hansenturbo
who can me build a strong zetec turbo i also want to that route and get 350+
Top bloke.
27-11-2005, 12:24 PM
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Originally Posted by Rossco
My engine is a bit of a cross bread, iam using a silver top bottom end, with a late (black top) top end, has been a mission to get them together as the tensioners are in a different place, will hopefully be the best of both.....if it works! lol
27-11-2005, 12:44 PM
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Originally Posted by * Rudey *
Originally Posted by Sketch
I use steel rods in mine, but then im looking for closer to 400bhp then 300
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
Perhaps i didnt make it quite as clear as i meant to 
What i meant / mean by that is that with the standard head and cams, you are power limited to around 300bhp (ish).... i havent seen many graphs (any?) of a 2.0 16v zetec on a standard head and cams (yours aside), making 300bhp, and even then i guess it'd have to have a T34 and be running a lot of boost!So if running with standard head and cams, the standard rods with ARP bolts can probably live with the maximum power you can achieve on that engine.
All in my own opinion of course
27-11-2005, 04:19 PM
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So can anyone say they have sucsessfully used the Vauxhall 16v Turbo piston, i believe earlier ones are forged in a zetec 16V Turbo???
Any oher pistons advice for compression ratio for what boost you are running...
hope this makes sense after a few sunday beers things go down hill around now!!!
Cheers
Any oher pistons advice for compression ratio for what boost you are running...
hope this makes sense after a few sunday beers things go down hill around now!!!
Cheers
27-11-2005, 05:12 PM
#19
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Originally Posted by Sketch
Originally Posted by * Rudey *
Originally Posted by Sketch
I use steel rods in mine, but then im looking for closer to 400bhp then 300
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
IMO, if using a standard head and cams, then i'd say that standard rods with ARP bolts will be just about ok....
300bhp in a S2 is plenty fast believe me
Perhaps i didnt make it quite as clear as i meant to What i meant / mean by that is that with the standard head and cams, you are power limited to around 300bhp (ish).... i havent seen many graphs (any?) of a 2.0 16v zetec on a standard head and cams (yours aside), making 300bhp, and even then i guess it'd have to have a T34 and be running a lot of boost!So if running with standard head and cams, the standard rods with ARP bolts can probably live with the maximum power you can achieve on that engine.
All in my own opinion of course
aha youve seen my graph? im gonna have to come and get you now say goodbye to your loved ones and tell them youve gotta go away the price of r+d
lovein the look of yours mate
27-11-2005, 05:15 PM
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Originally Posted by neal1980
So can anyone say they have sucsessfully used the Vauxhall 16v Turbo piston, i believe earlier ones are forged in a zetec 16V Turbo???
Any oher pistons advice for compression ratio for what boost you are running...
hope this makes sense after a few sunday beers things go down hill around now!!!
Cheers
Any oher pistons advice for compression ratio for what boost you are running...
hope this makes sense after a few sunday beers things go down hill around now!!!
Cheers
27-11-2005, 06:15 PM
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Originally Posted by essexrsturbo
Originally Posted by Rossco
My engine is a bit of a cross bread, iam using a silver top bottom end, with a late (black top) top end, has been a mission to get them together as the tensioners are in a different place, will hopefully be the best of both.....if it works! lol
The black top also has lightly bigger valves i belive too
27-11-2005, 07:26 PM
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All LET (Turbo Calibra etc.) pistons are forged, fully skirted Mahles.
XE (Norm. Aspirated) pistons vary - some are cast some are forged Mahle. You can tell by the looks as well as the Mahle stamp on the underside. These are only good for ZVH so uninteresting to this post.
Zetec block needs boring out for these pistons - 86mm. Makes 2.05l (most people claim 2.1)
There are American 'off the shelf' pistons and rods suitable for Zetec Turbo - however you need to strip and check your block as they are standard bore, so will not fit a block that needs a rebore. these piston/rod combos may work out only marginally more expensive than the price of second hand pistons + boring/honing + little end work + new rings...so it's deffo worth considering.
There loads of stuff to consider - most of which only become apparent as the problem arises...an oil cooler would be a good idea as well for example!
XE (Norm. Aspirated) pistons vary - some are cast some are forged Mahle. You can tell by the looks as well as the Mahle stamp on the underside. These are only good for ZVH so uninteresting to this post.
Zetec block needs boring out for these pistons - 86mm. Makes 2.05l (most people claim 2.1)
There are American 'off the shelf' pistons and rods suitable for Zetec Turbo - however you need to strip and check your block as they are standard bore, so will not fit a block that needs a rebore. these piston/rod combos may work out only marginally more expensive than the price of second hand pistons + boring/honing + little end work + new rings...so it's deffo worth considering.
There loads of stuff to consider - most of which only become apparent as the problem arises...an oil cooler would be a good idea as well for example!
27-11-2005, 11:16 PM
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Originally Posted by * Rudey *
aha youve seen my graph? im gonna have to come and get you now say goodbye to your loved ones and tell them youve gotta go away the price of r+d lovein the look of yours mate
lovein the look of yours mate
28-11-2005, 10:51 AM
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anyone know of any prices then for a set of low comp forged pistons for standard bore 2.0 for use wth the 16V head....
I know i asked earlier but is anyone using standard zetec rods and running around 300bhp???
I know i asked earlier but is anyone using standard zetec rods and running around 300bhp???
28-11-2005, 11:15 AM
#25
philM got about 300 on std rods and xe pistons mate.
im building one too, im getting proppa pistons made that will be a direct fit to std zetec rods
my spec
2.0l Silvertop, 0.5mm over bore
wiseco pistons (about £500)
steel rods (£ dunno yet )
ported head
standard cams
primary designs exhaust manifold
T34 with .63 housing
special 1 off inlet manifold
SECS S8 management
all this should easily see past 350bhp
im building one too, im getting proppa pistons made that will be a direct fit to std zetec rods
my spec
2.0l Silvertop, 0.5mm over bore
wiseco pistons (about £500)
steel rods (£ dunno yet
)ported head
standard cams
primary designs exhaust manifold
T34 with .63 housing
special 1 off inlet manifold
SECS S8 management
all this should easily see past 350bhp
28-11-2005, 11:42 AM
#29
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Originally Posted by Sketch
Originally Posted by * Rudey *
aha youve seen my graph? im gonna have to come and get you now say goodbye to your loved ones and tell them youve gotta go away the price of r+d lovein the look of yours mate
lovein the look of yours mate
i dont really know about figures and stuff heres the graph the head cracked so run was aborted as you see at 5500 little more to come brand new head on now slightly lower cr
28-11-2005, 11:48 AM
#31
Lookin good Rudey!!
im getting the rods from the same place as the pistons, dunno price yet but will be about £6/700
the ones im getting done tho are gonna DIRECT fit to a silvertop zetec as there are NO direct fit ones on the market at the mo!
of course you can get Eagle rods/pistons fromt he states but they are for black tops and you cant have lower than 8.2:1CR iirc
Originally Posted by neal1980
your considering going steel rods as well then???
What prices you found so far?
Loads of boost is good!!!!!!
What prices you found so far?
Loads of boost is good!!!!!!
the ones im getting done tho are gonna DIRECT fit to a silvertop zetec as there are NO direct fit ones on the market at the mo!
of course you can get Eagle rods/pistons fromt he states but they are for black tops and you cant have lower than 8.2:1CR iirc
28-11-2005, 12:13 PM
#35
Originally Posted by fudgeass
YOU RECKON
CTS stage 2+
sunnys is fine and his motor was a bit special
CTS stage 2+
sunnys is fine and his motor was a bit special
It's just that I have a Stage 2+ Box from Bernie and am going for around 400bhp. I'm just wondering how long it's going to last
28-11-2005, 12:54 PM
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Originally Posted by Cliff S1
Originally Posted by fudgeass
YOU RECKON
CTS stage 2+
sunnys is fine and his motor was a bit special
CTS stage 2+
sunnys is fine and his motor was a bit special
It's just that I have a Stage 2+ Box from Bernie and am going for around 400bhp. I'm just wondering how long it's going to last
i'm running a cts stage two plus after breaking fifth gear on my stage two