Phil2002

iTrader: (3)

This project started at the begining of the year as just before xmas my girl friend decided to blow up her escort gti.
Think it was on purpose so she could get a new car which she did we got her a skoda octavia vrs which she loves too bits as it's got a turbo.
so i decided to turn her mk6 escort into a little project i coud get my teeth into.

I decided on a 2.0l zetec turbo engine for it as a mate of mine was breaking a mondeo and gave the engine for free happy days. It was a phase3 zetec with very low milage and am aiming for about 300bhp.

After researching gearboxes and coming to the conclusion that the zetec ib5 box would keep shitting it self i decided to go down the mtx75 route and remembered that i had full mondeo 4x4 runing gear in the back garden so decided to make it 4x4.

The diff hanger is from an escort rs2000 4x4 but i'm having custom rose jointed trailing arms made for it so that i can use the mondeo rear hubs.

The mondeo gear box is hydraulic clutch so i had to modify the clutch pedal to make it hydraulic i used a clutch master cylinder and pedal from an old volvo s40 which my mate was sending to the frag (the same bloke who gave me the engine and who is building my trailing arms really nice guy and bloody good mechanic).

will put some pics up when i get them in some kind of order.

Any comments or advise greatly appreciated.

Thanks,
Phil

Mark V8

iTrader: (2)

300bhp and mt75 transfer box







Treat it with care and make sure to run extra oil as they don't run hardly any as stock.

Mark

Phil2002

iTrader: (3)

The first thing i done was strip the engine and head and adapt the head to take the manifolds i wanted to use which where the erst exhaust and a rover 220 turbo inlet.


I drilled and tapped the head to take the escort exhaust manifold




I made an adaptor plate out of 10mm steel so that the rover inlet would bolt to the zetec head.

Phil2002

iTrader: (3)

Is that an escort or mondeo transfere box?

Minirotty

I take it that heads going to be skimmed now?

Phil2002

iTrader: (3)

why do you say that?

Paul_RS

iTrader: (4)

Probably because the face is on a concrete floor lol

Phil2002

iTrader: (3)

I am having it skimmed but why does it need to skimmed if it has been put on the floor. i have never heard of this and I'm quite curious to no why??

homer j

iTrader: (1)

gets rid of any damage that the uneven surface may have caused. much better to put a head down on a soft surface like thick cardboard.

Phil2002

iTrader: (3)

oh i see i'll bear that in mind when it comes back from the machine shop this week cardboard it is. Thanks for that.

Mark V8

iTrader: (2)

Escort, much the same design though.

Mark

Phil2002

iTrader: (3)

although they are similar in design the mondeo transfer box is much bigger than that escort box and has been used on a focus 4x4 which run 300 bhp

mondeo box

pa_sjo

What else do you intend to do to the head?

crazycage

you should of used ally for your adapter plate then use a rotary bit and a file and mach the ports

Phil2002

iTrader: (3)

nothing major just uprated valve springs and port match the in-let manifold.

Phil2002

iTrader: (3)

Already started to match the ports will probaly make a new adapotor from ally just had that steel kicking about once it's up and running i'll sort it out.

vroooom ptssssh

good stuff, it's all about learning while your building it too which can only be a good thing!

good luck

Phil2002

iTrader: (3)

Thanks for the help on this guys a learning curve it has been indeed.
Theres some more pics and a quick update

Got the front mount intercooler fitted and piped up




made a steel plate to block up the front breather.



Drilled the block and fitted stub for turbo oil return



Removed centre vents too house 3 gauges (boost, oil temp and oil pressure)





More too come.
Thanks for the tips.

EssexMikeSi

iTrader: (3)

Looking good so far and nice to see it being done to a mk6 escort as u dont tend to see many being done.

Phil2002

iTrader: (3)

Ive always had the older fords like mk4 escorts mk2 fiestas but when we bought this for my girl friend i fell in love with it.

My black mk4 escort turbo goes tomorrow to it's new home to fund the mk6 build.
Main reason i done it was cause not many are done.
trying to keep it a standard looking as poss to apart from the wheels and suspension it should look fairly standard.

Reid

awesome project fella.

NATH-RSZT

Keep us updated. the engine in my sig is in a mk6 . fwd mind

Phil2002

iTrader: (3)

and its white and in kent blimey thought i was gonna be one of a kind lol.

Phil2002

iTrader: (3)

Just a quick update.
The engine bay is now empty and ready for a clean before the new engine goes in. waiting on a delivery for my main and big end shells from the states then i can build the bloody thing been waiting nearly 3 weeks.
i'll get some more pics up soon.

NATH-RSZT

dont worry it ended up going to manchester so your one will be on of a kind. were about in kent are you i'm down in dover. just started turbo'ing my focus theres a thread in this section if you wanna take a look. I got the same stick about my inlet plate to.

Nath.

Chip

iTrader: (3)

Good enthusiasm, hope it all goes to plan.

MENIS

good ideas you have there mate keep up the good work

Phil2002

iTrader: (3)

I live in Chatham. what sort of power you hoping for from the focus

Phil2002

iTrader: (3)

Hear is a few more pics for you to look at

The rose joints that will eventually hold the rear end together



The a piller pod i made to house air to fuel gauge and volt meter



I moddified the tape holder under the stereo to take my fan controller and air intake temp gauge.


T3/T4 turbo external wastegate on an est manifold and pipercross cossie filter.


Thanks for looking.

rst in breaking

iTrader: (2)

looking great mate, are you chopping andmodding the rover inlet? as i had toinme mk3 and bloke with mk6 above has had to to clear reservoir?

Hobomassiv

Nice project!

Its rare to see a decent modified motor around chatham as well

Get yourself down to the industrial estate when its done and smoke some saxos etc

pa_sjo

Where do you intend to put your radiator?

Jay,

iTrader: (4)

good project shall watch this with interest

crazycage

how did you chop yours mate all the ones ive seen just cut the end off and weld a plate on the end for the fiesta rs throttle body,ive got the same inlet but i cut it up and made the whole plenum that way you it looks a bit better and you can put the throttle body anywhere you like.

rst in breaking

iTrader: (2)

i cut it after the vacuum pipes with a hack saw, filed it up a prepped it, then had a flange made by ian howell to accept the cossie throttle body then made a bracket to hold the transit throttle cable , hows yours getting on mate?

NATH-RSZT

I cut my rover inlet before the vacum pipes then had a plate ally welded to it.

That spacer from the manfold and turbo is abit big by the looks of it. i think thats why the guy asked were your radiators gunna go. When i used a t4 i just cut a copy of the thin gasket out in 6mm steel.

Phil2002

iTrader: (3)

Thats not there as a spacer that is a T3 adaptor to take an external waste gate. All i had to do was shift the rad forward about 2" and the rad cleared the turbo.
The engine is not quite in properly in this pics the engine is leaning forward so there is a bigger gap between the turbo and the rad.



just sorting out some photos and i'll show you what i done with my inlet and TB.
Thanks for all the comments.

woolford

good work love what im seeiing

Phil2002

iTrader: (3)

I decided to use a 76mm throttle body off an old jag as i got it for peanuts off ebay and it come with the tps.



Due to the size of it i could not make it fit the rover inlet easily and decided it would be easier to make a new plenum to suit the TB and to clear the master cylinder.





I used weber 45 trumpets in side it to help the last cylinder from running lean (if i were to make it again i would have sloped the plenum down towards the last cylinder too).



I ade these two plates one is for the iscv and the other is vacum hoses etc.



Here is a pic of it finished on my hall way floor.
(please don't tell anyone but that is a vauxhall fuel rail on it from a old shite calibra that i found in the breakers!!!!!!)The iscv is from a fiesta turbo.



Here is what it should look like when it's in the bay.



The only thing that i'm going to change on it is i'm going to cut down the face that the TB sits on to get rid of that corner towards the back.

all comments welcome.
thanks,
Phil

NATH-RSZT

That inlet is foooking sweet. if you had spare time you could make a few of them up and make a fair few pennies on ebay. i see a complete shite one badley made from steel go for over 100 quid .

Nath