My 1.9 FRST - new vid added! (on 2nd page)
17-02-2005, 03:27 PM
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My 1.9 FRST - new vid added! (on 2nd page)
Finally got the Pro Alloy front mounted intercooler fitted to my car.
My old FRST rad had seen better days and a friend of mine was kind enough to donate me a near on brand new XR2i rad so I decided to get it replaced with that instead, it actually helps with fitting due to it's thinner core
I'm going to mesh up the hole in the bottom as it looks a bit crappy being able to see all the bodywork that's been cut away behind it!
The nice thing is if I want to cover it up I just have to reposition the number plate!
What do you guys think?
Cheers,
Andy
My old FRST rad had seen better days and a friend of mine was kind enough to donate me a near on brand new XR2i rad so I decided to get it replaced with that instead, it actually helps with fitting due to it's thinner core
I'm going to mesh up the hole in the bottom as it looks a bit crappy being able to see all the bodywork that's been cut away behind it!
The nice thing is if I want to cover it up I just have to reposition the number plate!
What do you guys think?
Cheers,
Andy
17-02-2005, 04:48 PM
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Thanks - I know it's a bit wonky but it's because I'm running a 2i rad in place of the standard FRST one (the core is thinner) so the valance had to be cut to position it far enough to the driver's side to fit the boost hoses through for the intercooler.
Running a T3 the XR2i rad helped alot as the core of it is thinner but it has a larger frontal surface area, hopefully meaning that it will get more air than the standard FRST rad keeping the coolant temps lower which is always the worry when running a front mounted intercooler
Will get it straightened up - but I'm off to Grove Garage next week or the week after to get it mapped up which is my short term aim as the car has been off the road for the best part of the last year!
Cheers,
Andy
Running a T3 the XR2i rad helped alot as the core of it is thinner but it has a larger frontal surface area, hopefully meaning that it will get more air than the standard FRST rad keeping the coolant temps lower which is always the worry when running a front mounted intercooler
Will get it straightened up - but I'm off to Grove Garage next week or the week after to get it mapped up which is my short term aim as the car has been off the road for the best part of the last year!
Cheers,
Andy
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17-02-2005, 06:35 PM
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Originally Posted by morgan
did you have to do much mods to fit the esc cos rims on???
It wasn't worth it in the end as the car still rubbed when hitting bumps and I compromised my suspension setup for it.
I sold them shortly after trying them out on the car - plenty of archwork had been done too!
I swapped back to my 15s as it runs like a dream on them and is much more fun to drive
Cheers,
Andy
17-02-2005, 07:53 PM
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Originally Posted by mattbibs
nice webcam!! 
).Cheers,
Andy
17-02-2005, 10:44 PM
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Cossie rims look better but agree about the hassle as me and my mate put them on his 8v 2i some time ago and they never really worked!
Do get it straightened up but does look nice and shiney!
What sorta power you looking for once its been mapped?
Do get it straightened up but does look nice and shiney!
What sorta power you looking for once its been mapped?
17-02-2005, 10:48 PM
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Hoping for about 230-240bhp.
SE stage 2 1.9 bottom end, polished head with CVH34 cam, L8 Cossie management conversion running 803 (Green) injectors (courtesy of Gadget), Cossie throttle body, stage 2 T3 with .48 exhaust housing, Alcon 6 paddle clutch and Bernie stage 2 box with Quaife ATB
Should be fun - have to reset the coilovers as well as it's still set up for the Cossie rims (i.e. hard and high!).
Have Cossie brakes up front and RS2000 rear discs on the back - it's a high power go-kart! (when it's running )
Cheers,
Andy
SE stage 2 1.9 bottom end, polished head with CVH34 cam, L8 Cossie management conversion running 803 (Green) injectors (courtesy of Gadget), Cossie throttle body, stage 2 T3 with .48 exhaust housing, Alcon 6 paddle clutch and Bernie stage 2 box with Quaife ATB
Should be fun - have to reset the coilovers as well as it's still set up for the Cossie rims (i.e. hard and high!).
Have Cossie brakes up front and RS2000 rear discs on the back - it's a high power go-kart! (when it's running
) Cheers,
Andy
04-08-2005, 12:18 AM
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Major hauling up of an old post here but thought I'd post my progress including the ups and downs since I posted this.
Once I had the intercooler fitted I had the car serviced ready to be sent off to Grove Garage for mapping.
Those pics were taken once I got it back
That very night as I let off from high boost the inlet manifold decided to blast one of the bolts out causing a major air-leak, so I had to wait another few days before driving it again once I'd sorted out machining a new thread and putting a new bolt in.
(the right hand hole in the picture below)
I also purchased a silicon reducer pipe to fit from the standard charge carrier to the modified Cossie throttle body (mounted on it's side)
Shortly after getting the inlet manifold/throttle body leak plugged I then started having major major problems with the ECU on my car.
As I was driving the car back from a test run the car started misfiring and then when driving it about 200 yards from my house the ECU cut out completely meaning I had to push it the final bit home!
Everything was checked over, I went back to Grove Garage with my ECU and ignition amplifier to check and see if it was that but to no avail (I even bought another L8 ECU and swapped the Pectel board across to see if it was that) but still I was having major problems. A friend of mine Andy B from fiestaturbo.com came down and helped me out big time with trying to source the fault but all seemed ok on the ignition side.
As we'd eliminated all of the easy stuff I then had to remove the engine loom completely and check it all over with a multimeter (I even put up a post on here which helped me alot - some really clever people who use this site! ) and check for continuity through all the terminals to each of the sensor plugs.
Strangely this all checked out (apart from a very manky looking cam sensor plug) so I replaced what was broken and put it all back in.
During the investigation throughout the engine wiring we also found that the CPS was completely free-moving and not held in place. The Cossie management conversion I'm using makes use of a 1.8CVH Sierra CPS as this gives the same waveform (Weber Marelli) as the standard Cossie CPS (although my signal comes from an adapter disc on the crank pulley). I then had to get this fixed which took quite some doing due to the lack of space between the bracket and the chassis leg in the Fiesta engine bay.
That was fixed and the car was running again - but I had a persistent problem where the car would start to misfire when the engine got warm. This problem would carry on up until very recently.
I tried various ways of fixing the problem which started with the obvious by making sure the ignition system was as good as possible.
I also got some thermotec heat sleeves for the ignition leads but I'm not really sure if they do much in stopping heat getting to them (they're mounted much more firmly over the spark plug ends now than in this pic).
Having changed all of that it still had this damn misfire!
Then another bad thing decided to happen - my AMAL valve managed to explode! With the way the AMAL valve was mounted it must have caused one of the hoses from the actuator to crack one of the ports on the AMAL valve causing the whole unit to crack into several pieces when passing boost. So I had to wait a week for Ford to special order in another one
Once all of this was sorted I then decided to have a crack at TOTB qualifying in the car - which was to see me encounter more problems on the way home!
I'd never done any quarter mile racing before so was pretty pleased with the times I was getting in - (14.6 or so at 99mph, down to 14.4 and 6.1 0-60 with 100+mph terminals at the end of the day) but I was being dogged by misfire problems after driving the car for a while throughout the day, which is when I met Jano Oddkidd.
He took a look at the setup on my car and pointed out that the cam-sensor would be what is causing all my issues. He then showed me the setup on his car which since fitting hasn't caused him any problems.
Unfortunately on the way home from the qualifying event I had another problem with the car, as I was giving it a bit of stick on a dual carriageway close to home I saw a plume of grey smoke coming out from the exhaust in my rear view
I pulled over, opened the bonnet and the oil breather was sending out smoke vapour and the oil cap had popped off! Thinking that my piston rings had probably let go or similar I put the cap back on and nursed the car home leaving smoke signals behind me 'Ford owner on the go-slow'
I decided as the cam-sensor arrangement needed to be changed and I had another near EFI head sitting at home that I better check whether any damage had been done to the engine. Off came the head and it was apparent that the valve-train had been getting really hot with the valves being a quite strong reddy colour! Putting this down to the misfire and the car jumping into limp home mode when the cam-sensor moves off it's phase (flimsy bracket it was mounted on) I had the head rebuilt and a new headgasket put on along with the cam sensor bracket, laser cut phase disc and machined vernier pulley that I had sorted out for me in very quick time by Jano Oddkidd. All I needed to complete the change over of cam-sensor system was a standard Cossie CPS which I ordered from Motorsport Developments as they kept them in stock (it's a special order part from Ford - that's if they can even find it on their system!). That arrived in quick time so a big thanks to MSD as well
Anyway - here's my new cam sensor arrangement and the bits that are now done.
Having put all that effort into getting sorted we have now discovered that the turbo oil seals are knackered!
So I'm going to have to send off my turbo for a rebuild - all that misfiring meant that unburnt fuel was passing through the turbo and it had been getting extra hot, thinning the oil out and doing some damage obviously Hopefully I can get it sent to Turbo Technics or someone and get it back good as new 
For that reason I'm not going to be on track at Ford Fair like I had planned, but I will hopefully be there with the car on the FordSport stand (if I make it!) so come over and say hello!
Cheers,
Andy
Once I had the intercooler fitted I had the car serviced ready to be sent off to Grove Garage for mapping.
Those pics were taken once I got it back
That very night as I let off from high boost the inlet manifold decided to blast one of the bolts out causing a major air-leak, so I had to wait another few days before driving it again once I'd sorted out machining a new thread and putting a new bolt in.
(the right hand hole in the picture below)
I also purchased a silicon reducer pipe to fit from the standard charge carrier to the modified Cossie throttle body (mounted on it's side)
Shortly after getting the inlet manifold/throttle body leak plugged I then started having major major problems with the ECU on my car.
As I was driving the car back from a test run the car started misfiring and then when driving it about 200 yards from my house the ECU cut out completely meaning I had to push it the final bit home!
Everything was checked over, I went back to Grove Garage with my ECU and ignition amplifier to check and see if it was that but to no avail (I even bought another L8 ECU and swapped the Pectel board across to see if it was that) but still I was having major problems. A friend of mine Andy B from fiestaturbo.com came down and helped me out big time with trying to source the fault but all seemed ok on the ignition side.
As we'd eliminated all of the easy stuff I then had to remove the engine loom completely and check it all over with a multimeter (I even put up a post on here which helped me alot - some really clever people who use this site!
) and check for continuity through all the terminals to each of the sensor plugs.Strangely this all checked out (apart from a very manky looking cam sensor plug) so I replaced what was broken and put it all back in.
During the investigation throughout the engine wiring we also found that the CPS was completely free-moving and not held in place. The Cossie management conversion I'm using makes use of a 1.8CVH Sierra CPS as this gives the same waveform (Weber Marelli) as the standard Cossie CPS (although my signal comes from an adapter disc on the crank pulley). I then had to get this fixed which took quite some doing due to the lack of space between the bracket and the chassis leg in the Fiesta engine bay.
That was fixed and the car was running again - but I had a persistent problem where the car would start to misfire when the engine got warm. This problem would carry on up until very recently.
I tried various ways of fixing the problem which started with the obvious by making sure the ignition system was as good as possible.
I also got some thermotec heat sleeves for the ignition leads but I'm not really sure if they do much in stopping heat getting to them (they're mounted much more firmly over the spark plug ends now than in this pic).
Having changed all of that it still had this damn misfire!
Then another bad thing decided to happen - my AMAL valve managed to explode! With the way the AMAL valve was mounted it must have caused one of the hoses from the actuator to crack one of the ports on the AMAL valve causing the whole unit to crack into several pieces when passing boost. So I had to wait a week for Ford to special order in another one
Once all of this was sorted I then decided to have a crack at TOTB qualifying in the car - which was to see me encounter more problems on the way home!
I'd never done any quarter mile racing before so was pretty pleased with the times I was getting in - (14.6 or so at 99mph, down to 14.4 and 6.1 0-60 with 100+mph terminals at the end of the day) but I was being dogged by misfire problems after driving the car for a while throughout the day, which is when I met Jano Oddkidd.
He took a look at the setup on my car and pointed out that the cam-sensor would be what is causing all my issues. He then showed me the setup on his car which since fitting hasn't caused him any problems.
Unfortunately on the way home from the qualifying event I had another problem with the car, as I was giving it a bit of stick on a dual carriageway close to home I saw a plume of grey smoke coming out from the exhaust in my rear view
I pulled over, opened the bonnet and the oil breather was sending out smoke vapour and the oil cap had popped off! Thinking that my piston rings had probably let go or similar I put the cap back on and nursed the car home leaving smoke signals behind me 'Ford owner on the go-slow' I decided as the cam-sensor arrangement needed to be changed and I had another near EFI head sitting at home that I better check whether any damage had been done to the engine. Off came the head and it was apparent that the valve-train had been getting really hot with the valves being a quite strong reddy colour! Putting this down to the misfire and the car jumping into limp home mode when the cam-sensor moves off it's phase (flimsy bracket it was mounted on) I had the head rebuilt and a new headgasket put on along with the cam sensor bracket, laser cut phase disc and machined vernier pulley that I had sorted out for me in very quick time by Jano Oddkidd. All I needed to complete the change over of cam-sensor system was a standard Cossie CPS which I ordered from Motorsport Developments as they kept them in stock (it's a special order part from Ford - that's if they can even find it on their system!). That arrived in quick time so a big thanks to MSD as well
Anyway - here's my new cam sensor arrangement and the bits that are now done.
Having put all that effort into getting sorted we have now discovered that the turbo oil seals are knackered!
So I'm going to have to send off my turbo for a rebuild - all that misfiring meant that unburnt fuel was passing through the turbo and it had been getting extra hot, thinning the oil out and doing some damage obviously
Hopefully I can get it sent to Turbo Technics or someone and get it back good as new For that reason I'm not going to be on track at Ford Fair like I had planned, but I will hopefully be there with the car on the FordSport stand (if I make it!) so come over and say hello!
Cheers,
Andy
04-08-2005, 12:26 AM
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Oh yeah - forgot to do my thank you's as well (prepares Oscar acceptance speech):
My mate Simon for doing the majority of the mechanical work on the car to get it done for silly deadlines for various reasons!
Grove Garage and Ahmed Bayjoo - for helping me out with finding the cause of the faults with the wiring and ECU, lending me of parts to test out etc. Also for mapping the car in the first place!
Gadget - for helping me out with what wires go where when checking over the wiring loom!
Ryan from here for helping me sort out the wiring loom and understand what it is that was causing me grief! (I now know alot more about how my engine management works than I ever thought I would! )
Motorsport Developments for providing me parts in quick-time along the way!
Jano Oddkidd for letting me use his Pectel monitor around Bruntingthorpe which immediately pinpointed my problems to the cam-sensor on my first run round with it! Also for supplying me with the last few parts I've needed to 'complete' the engine management conversion
Burton Power et al and all those on fiestaturbo.com, fordsport.org.uk and passionford.com that have helped me along the way!
Having spent so much money on this car I can't imagine ever selling this damn thing! Luckily I have access to suitable storage space for the car so even if I didn't use it that much I should still be able to have room for new toys (my next one being a mk2 Escort with YB power ).
Thanks for reading!
Cheers,
Andy
My mate Simon for doing the majority of the mechanical work on the car to get it done for silly deadlines for various reasons!
Grove Garage and Ahmed Bayjoo - for helping me out with finding the cause of the faults with the wiring and ECU, lending me of parts to test out etc. Also for mapping the car in the first place!
Gadget - for helping me out with what wires go where when checking over the wiring loom!
Ryan from here for helping me sort out the wiring loom and understand what it is that was causing me grief! (I now know alot more about how my engine management works than I ever thought I would!
)Motorsport Developments for providing me parts in quick-time along the way!
Jano Oddkidd for letting me use his Pectel monitor around Bruntingthorpe which immediately pinpointed my problems to the cam-sensor on my first run round with it! Also for supplying me with the last few parts I've needed to 'complete' the engine management conversion
Burton Power et al and all those on fiestaturbo.com, fordsport.org.uk and passionford.com that have helped me along the way!
Having spent so much money on this car I can't imagine ever selling this damn thing! Luckily I have access to suitable storage space for the car so even if I didn't use it that much I should still be able to have room for new toys (my next one being a mk2 Escort with YB power
).Thanks for reading!
Cheers,
Andy
04-08-2005, 12:43 AM
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Originally Posted by digita1dragon
fookin ell mate! sounds worse than mine
hope you get to enjoy it properly when its all sorted!
hope you get to enjoy it properly when its all sorted!
Thanks alot dude - hopefully the turbo refurb will be the last thing needed to finally say the engine is 'done'
I can start work on straightening the intercooler and getting the bumper fibreglassed up to the core properly this time - the winter's project for the car is stripping the stereo and interior out and converting it into a track car. One of my more urgent requirements is an oil cooler though - I think this could help save my engine and turbo from further problems oil related (opens up Burtons catalogue again
).Cheers,
Andy
04-08-2005, 01:36 AM
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Originally Posted by digita1dragon
hehe is that a pectel monitor in there? What oil temps are you getting up to?
The screen showing in the interior pic before Brunters is the touchscreen for my in-car computer system (GPS, MP3, bumper-cam etc.)
I'm going to fit my new motorised in-dash version of the same screen tomorrow!
No idea on oil temperature as I haven't got a gauge for it - that's high on my 'things to buy' list now though as I want to keep an eye on everything so that I can try to find faults before they really become a problem! Might get one of those dual oil temp/pressure gauges.
Cheers,
Andy
04-08-2005, 01:09 PM
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Thanks guys!
I wish I was made of money Matt - I would be if I hadn't started plunging it all into the bloody car!
Unfortunately my car hasn't passed it's MOT but I've now got a small list of things that need to be fixed including the Turbo!
The car's tax ran out last month so I'm going to have to declare it SORN
No Ford Fair for the Turbo this year, I'll be on the FordSport stand for a bit with a rather shonky looking Escort Cabriolet.
Oh well - yet more money to burn on the dustbin!
Cheers,
Andy
I wish I was made of money Matt - I would be if I hadn't started plunging it all into the bloody car!
Unfortunately my car hasn't passed it's MOT but I've now got a small list of things that need to be fixed including the Turbo!
The car's tax ran out last month so I'm going to have to declare it SORN
No Ford Fair for the Turbo this year, I'll be on the FordSport stand for a bit with a rather shonky looking Escort Cabriolet.
Oh well - yet more money to burn on the dustbin!
Cheers,
Andy
04-08-2005, 01:19 PM
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Ive got one of the oil temp/pressure guages from our favourite: Burton Power
Deffo a necessary item on a tuner car IMO
Pop over to the XRTwo.com stand if you have time on Sunday Andy, would be good to have a chat!
Deffo a necessary item on a tuner car IMO
Pop over to the XRTwo.com stand if you have time on Sunday Andy, would be good to have a chat!
04-08-2005, 06:28 PM
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Got the car stickered up this morning before the MOT - thought I'd post the pics up
I think it looks pretty good - the car could do with a real good clean though (will save that until it's all back together and ready).
Cheers,
Andy
I think it looks pretty good - the car could do with a real good clean though (will save that until it's all back together and ready).
Cheers,
Andy
04-08-2005, 06:50 PM
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Sorry Brycey - forgot to thank you for helping out with the choice of logo.I think it looks stunning!
Thanks dude - you going to Ford Fair?
Cheers,
Andy
07-08-2005, 10:31 PM
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Picked up the latest Redline magazine today and noticed that there was a feature on the TOTB qualifying so I thought I'd buy it and have a look
Waddya know - the gormless moron that is me got a little write up in there!
Has finished off a top day I had at Ford Fair!
Cheers,
Andy
Waddya know - the gormless moron that is me got a little write up in there!
Has finished off a top day I had at Ford Fair!
Cheers,
Andy
08-08-2005, 03:49 PM
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Thanks Jano - have you picked a copy up yet? You're in there as well
It's a shame they didn't get the times in the magazine that I put in at the end of the day, got my 0-60 down to 6.1 and the quarter mile down to 14.43 @ 101mph.
I am certain the car is capable of sub 14 second quarters and a sub 6 second 0-60 - maybe on a cooler day with better chassis setup and tyres
Cheers,
Andy
It's a shame they didn't get the times in the magazine that I put in at the end of the day, got my 0-60 down to 6.1 and the quarter mile down to 14.43 @ 101mph.
I am certain the car is capable of sub 14 second quarters and a sub 6 second 0-60 - maybe on a cooler day with better chassis setup and tyres
Cheers,
Andy
09-08-2005, 12:54 AM
#38
Got a copy of the mag today, the cars all look good
The fezzy is mental
Your car should be able to get sub 14's no problem! Now you have a decent reading from the cam sensor
Shame i couldnt use full boost on the day due to mapping session that was only two days after this event ... Would of been great to see what the new setup would of changed. Last time my 0-60 was 5.6 running 18psi now its the same 0-6 but with only 12psi. The change on the figures should be the same for the 0-100 and 1/4 mile hopefully, but the next chance we will get to test this with the same sort of flash GPS stuff that redline mag had is ages away
Lets hope we get another chance soon hey?
The fezzy is mental
Your car should be able to get sub 14's no problem! Now you have a decent reading from the cam sensor
Shame i couldnt use full boost on the day due to mapping session that was only two days after this event ... Would of been great to see what the new setup would of changed. Last time my 0-60 was 5.6 running 18psi now its the same 0-6 but with only 12psi. The change on the figures should be the same for the 0-100 and 1/4 mile hopefully, but the next chance we will get to test this with the same sort of flash GPS stuff that redline mag had is ages away Lets hope we get another chance soon hey?
09-08-2005, 12:56 AM
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Yeah - definitely, I think someone on here was organising a group thrash for RST owners.
I'm sure one of the mags was interested so perhaps another chance to use the Datron timing gear again?
Thanks for the vote of confidence - cam sensor should help me alot (as will having the turbo refurbished!) - can't wait to get a 13second pass!
Cheers,
Andy
I'm sure one of the mags was interested so perhaps another chance to use the Datron timing gear again?
Thanks for the vote of confidence - cam sensor should help me alot (as will having the turbo refurbished!) - can't wait to get a 13second pass!
Cheers,
Andy
10-08-2005, 09:38 PM
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Went to Rally Design in Faversham today to pick up some bits to help keep everything together when thrashing the car in future
That lot includes a 13 row MOCAL oil cooler, sandwich plate with thermostat, all required connectors, oil pressure and temperature gauges and pressure gauge sender unit and a dash-top triple pod gauge mount.
Pretty bloody good price too!
I've already got a boost gauge and an ACT gauge (from Mike Rainbird) but I'm wondering what gauge to fill up the third slot now - Rally Design didn't have any EGT gauges available (do you know of who stocks them?).
Can't wait to get it all fitted - the turbo's being sent off to Turbo Technics next week so I'll get it all fitted up in the mean time
Cheers,
Andy
That lot includes a 13 row MOCAL oil cooler, sandwich plate with thermostat, all required connectors, oil pressure and temperature gauges and pressure gauge sender unit and a dash-top triple pod gauge mount.
Pretty bloody good price too!
I've already got a boost gauge and an ACT gauge (from Mike Rainbird) but I'm wondering what gauge to fill up the third slot now - Rally Design didn't have any EGT gauges available (do you know of who stocks them?).
Can't wait to get it all fitted - the turbo's being sent off to Turbo Technics next week so I'll get it all fitted up in the mean time
Cheers,
Andy