Mk2 XR2 Turbo,Mapping done (beast) 2/8/07
24-02-2004, 09:34 PM
#1
Mk2 XR2 Turbo,Mapping done (beast) 2/8/07
Right then, thought it was about time to put some info on here about how the project is going so far.
Well it's taking longer than i first expected but thats probably because i'm being a bit fussy, working to much over time (but need to so that i can buy stuff)and want to replace everything on the car (well almost). This a list of what i've done and things to do, things i've bought and things that i need to get.
I got the engine running on Saturday with only 1 wiring problem which was the fuel pump relay that i had to bridge to get it started the first time.
Engine
Block bored to +1mm.
+1mm Accralite forged 7.8-1 pistons.
New Ford rods.
ARP con rod bolts.
Crank reground and all light and balanced.
AP Paddle clucth, complete kit.
Felpro head gasket.
Heavy duty head bolts
New oil pump with high presure spring.
RS1600 rocker cover and modified intake pipe.
Full Samco water set & custom 60mm intercooler pipe work.
Kent CVH35 cam kit.
Adjustable pulley wheel.
Magnecor 10mm leads.
K&N filter.
Bailey oil breather and swirl pot.
Vibra-tec mountings.
Mocal oil cooler & termostat plate.
S2 LSD box.
Full stainless ERST exhaust cut to fit.
Custom Intercooler.
ESRT fuel pump and tank fitted with swirl pot.
Swaped the small return fuel line for one the same as the larger so both are the same size.
Suspension and chassis
Spax front and rear.
Front & rear strut brace.
Poly bushes.
All tie rods, axle and all removeable underside parts sand blasted and hammerited black.
New front & rear bearings.
New bottom ball joints.
Wilwood 4pots, and 285mm drilled disc's.
Rear disc conversion with drilled 2WD cossie discs & Wilwood ajustable bias valve.
Sheel
Well the shell took a bit of time due to there being a bit of minor rust that needed repairing including the rear arches.
I've seam welded the engine bay and the front chassis rails, plus i've fitted a new front panel and wings, also cut FRST bonnet vents into my new bonnet.
I've already painted the engine bay and the underneath in the new colour, Magenta.
I've managed to fit the bonnet so that it opens towards the back of the car to make it easier to work on but i'm not sure if im gonna have it on hinges yet.
Battery fitted in boot.
The preping will be done by my mate but the shell is in good condition.
Electrics & interior
Well the fitting of the RST loom was a bit of a pain, but i had 2 looms so i could trace all the wires back if i got stuck which made it a bit easier.
I've got electric windows that i made myself from Mk3 Granarda rear motors, I'm also using an ESRT central locking and electric window loom which is just 2 positive's, 1 ignition and 1 constant live oh and 2 earths.
I'm fitting the central locking from my old S2 ESRT along with the alarm.
I've got a Fiesta Festival console to fit the stereo as i'm fitting a boost and oil temp & pressure guage's were the original one goes.
I've got Leather Recaros that i trimmed myself for my old ERST, but have'nt yet finished the rears.
Well that's about it for know, Just a case of putting all together and collecting the few bit that i need.
Some pics to follow.
Well it's taking longer than i first expected but thats probably because i'm being a bit fussy, working to much over time (but need to so that i can buy stuff)and want to replace everything on the car (well almost). This a list of what i've done and things to do, things i've bought and things that i need to get.
I got the engine running on Saturday with only 1 wiring problem which was the fuel pump relay that i had to bridge to get it started the first time.
Engine
Block bored to +1mm.
+1mm Accralite forged 7.8-1 pistons.
New Ford rods.
ARP con rod bolts.
Crank reground and all light and balanced.
AP Paddle clucth, complete kit.
Felpro head gasket.
Heavy duty head bolts
New oil pump with high presure spring.
RS1600 rocker cover and modified intake pipe.
Full Samco water set & custom 60mm intercooler pipe work.
Kent CVH35 cam kit.
Adjustable pulley wheel.
Magnecor 10mm leads.
K&N filter.
Bailey oil breather and swirl pot.
Vibra-tec mountings.
Mocal oil cooler & termostat plate.
S2 LSD box.
Full stainless ERST exhaust cut to fit.
Custom Intercooler.
ESRT fuel pump and tank fitted with swirl pot.
Swaped the small return fuel line for one the same as the larger so both are the same size.
Suspension and chassis
Spax front and rear.
Front & rear strut brace.
Poly bushes.
All tie rods, axle and all removeable underside parts sand blasted and hammerited black.
New front & rear bearings.
New bottom ball joints.
Wilwood 4pots, and 285mm drilled disc's.
Rear disc conversion with drilled 2WD cossie discs & Wilwood ajustable bias valve.
Sheel
Well the shell took a bit of time due to there being a bit of minor rust that needed repairing including the rear arches.
I've seam welded the engine bay and the front chassis rails, plus i've fitted a new front panel and wings, also cut FRST bonnet vents into my new bonnet.
I've already painted the engine bay and the underneath in the new colour, Magenta.
I've managed to fit the bonnet so that it opens towards the back of the car to make it easier to work on but i'm not sure if im gonna have it on hinges yet.
Battery fitted in boot.
The preping will be done by my mate but the shell is in good condition.
Electrics & interior
Well the fitting of the RST loom was a bit of a pain, but i had 2 looms so i could trace all the wires back if i got stuck which made it a bit easier.
I've got electric windows that i made myself from Mk3 Granarda rear motors, I'm also using an ESRT central locking and electric window loom which is just 2 positive's, 1 ignition and 1 constant live oh and 2 earths.
I'm fitting the central locking from my old S2 ESRT along with the alarm.
I've got a Fiesta Festival console to fit the stereo as i'm fitting a boost and oil temp & pressure guage's were the original one goes.
I've got Leather Recaros that i trimmed myself for my old ERST, but have'nt yet finished the rears.
Well that's about it for know, Just a case of putting all together and collecting the few bit that i need.
Some pics to follow.
Trending Topics
29-02-2004, 04:54 PM
#13
Professional Waffler
coming alont nice mate 
he done all this work and he's got a brand new mk2 shell in the garage
cant wait too have my drive of it (aslong as the gearbox is ok
)
he done all this work and he's got a brand new mk2 shell in the garage
cant wait too have my drive of it (aslong as the gearbox is ok
)
07-03-2004, 11:13 AM
#17
Part of the Furniture
Join Date: May 2003
Location: wales
Posts: 176
Likes: 0
Received 0 Likes
on
0 Posts
go on ginger boy you must have lots of inspiration from a great xr2 turbo well done son. I heard it running yesterday it sounds nice not bad for a b.t. technician
08-03-2004, 01:30 AM
#20
awwww man i want one now!looks so cool!
lol, have you got a pressure washer by any chance and been mucking around???(looks at exhaust picture with bike!!! )
rite, gota go find me a 1litre fiesta mk2 to butcher as well as the escort!!!
nice one fella, keep the pics coming too!
PAUL
lol, have you got a pressure washer by any chance and been mucking around???(looks at exhaust picture with bike!!!
)rite, gota go find me a 1litre fiesta mk2 to butcher as well as the escort!!!
nice one fella, keep the pics coming too!
PAUL
11-03-2004, 11:25 PM
#26
LOOK what you've made me go and do now!!!! 
all your fault!
[actually bought car for Ł100 950cc 35K drives nice just needed transport til escort is ready!!]
but already planning mods although the insurance will not be happy
just thought id let you know that your work has been inspiring!lol!!
anymore pics??
PAUL
all your fault!
[actually bought car for Ł100 950cc 35K drives nice just needed transport til escort is ready!!]
but already planning mods although the insurance will not be happy
just thought id let you know that your work has been inspiring!lol!!
anymore pics??
PAUL
06-04-2004, 10:12 PM
#30
Just a quick update, The cars almost ready for the paint shop. I've been fitting my brakes this week along with a willwood brake bias valve for the rear's, also fitted a full new set off brake lines. I bought a set of plazma dials which are well bright when it's dark. Hopfully it should be on wheels by neext week. There's a few pics below.
I made the rear disc conversion myself, with a bit of machince work done by Gareth T
The 2nd pic is'nt that great as i had to put my finger over the flash.
I made the rear disc conversion myself, with a bit of machince work done by Gareth T
The 2nd pic is'nt that great as i had to put my finger over the flash.
07-04-2004, 11:38 AM
#32
15000
Join Date: Sep 2003
Location: Essex
Posts: 26
Likes: 0
Received 0 Likes
on
0 Posts
I havent the first fucking clue about engines, but i know what looks good and it looks the bollox mate. Should be a bloody fast festa once its done. Good job on all the work, wish i had half the knowhow you obviuosly have.
16-04-2004, 04:17 PM
#33
Bit of an update on the progress, Well the car went on it's maiden voyage on Wednasday night up and down the street a few times 8) 
. It felt really wierd as every thing is so stiff compaired to grey XR2, What with the engine mounts and paddle clutch it felt really stiff and a bit judderey, but i suppose it'll just be a case of getting used to it. But apart from that it was nice to finally drive it again after it being on stands for about 18-20 months.
The only problem was a knock that came from the drivers side front strut, which is due to me not tightening it up enough
, and the rear shocks having no top nuts on them just a rag wraped around with a pair of mole grips (nuts are on order).
It runs sweet, and just running on the drive the temps all stay really low which i'm really pleased with. I had it running for about 10-15 mins and the ACT gague did'nt go over the mid 20's. Looks like the time spent waiting for the Samco's was well worth it.
Well I finished the brake lines off (pics below) and i'm glad i spent the time replacing them as they look much better with the red hose on them.
I've spoken to my mate Rob (AKA Mk2 Peachy Turbo) and he recons defo 2 weeks until he has finshed his Cossie, and then mines in there for a nice new coat of paint .
So it's looking good for the end of May.
Rear bonnet pin fixings.
Relocated the gauges to fit in the festival console.
Brake lines.
Wheels.
Some front view pics.
Cheers
. It felt really wierd as every thing is so stiff compaired to grey XR2, What with the engine mounts and paddle clutch it felt really stiff and a bit judderey, but i suppose it'll just be a case of getting used to it. But apart from that it was nice to finally drive it again after it being on stands for about 18-20 months.The only problem was a knock that came from the drivers side front strut, which is due to me not tightening it up enough
, and the rear shocks having no top nuts on them just a rag wraped around with a pair of mole grips (nuts are on order). It runs sweet, and just running on the drive the temps all stay really low which i'm really pleased with. I had it running for about 10-15 mins and the ACT gague did'nt go over the mid 20's. Looks like the time spent waiting for the Samco's was well worth it.
Well I finished the brake lines off (pics below) and i'm glad i spent the time replacing them as they look much better with the red hose on them.
I've spoken to my mate Rob (AKA Mk2 Peachy Turbo) and he recons defo 2 weeks until he has finshed his Cossie, and then mines in there for a nice new coat of paint
.So it's looking good for the end of May.
Rear bonnet pin fixings.
Relocated the gauges to fit in the festival console.
Brake lines.
Wheels.
Some front view pics.
Cheers
18-04-2004, 09:45 PM
#39
Cheers guys,
Nickateen, Yer thats the colour mate. It's Cossie Magenta.
Wes RS, Yep i'll defo be bring it along to a few events when it's finished.
J871yhk, I replace the brake lines, but before i made the ends off i put 6mm vacume hose over it.
Nickateen, Yer thats the colour mate. It's Cossie Magenta.
Wes RS, Yep i'll defo be bring it along to a few events when it's finished.
J871yhk, I replace the brake lines, but before i made the ends off i put 6mm vacume hose over it.
