Mk6 JWRC fiesta cosworth
18-04-2011, 05:20 PM
#1161
looking good marc are you going to machine the throat of the body down to a knife edge as well to get rid of the step between boost pipe & throttle body like the one in this link .
http://cgi.ebay.co.uk/FORD-SIERRA-CO...#ht_4239wt_752
http://cgi.ebay.co.uk/FORD-SIERRA-CO...#ht_4239wt_752
18-04-2011, 05:34 PM
#1162
I am not sure if i'd bother doing that Andy as it will never make a noticable difference but the TB could be put in the lathe, it would take a little while to set it up so its spinning dead centre but the 4 jaw chuck would do it & once that was done it wouldnt take long to turn it down,
19-04-2011, 07:31 AM
#1163
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what size is the blanked off plug on the oil-take-out here? i'm gonna use the same setup og the oil as you, and i'm having a hard time finding a 1/2" BSP plug in Aeroquip-style to fit in the Mocal-unit.
also really liking the way you are doiing the project, slow and steady when the money is there, nice!!
also really liking the way you are doiing the project, slow and steady when the money is there, nice!!
19-04-2011, 11:15 AM
#1164
Hi Olek, thanks for the comments.
My blanking plug in the oil filter take off housing is M18x1.5 metric thread to -10
If you want a fitting for -10 aeroquip to 1/2"bsp then this is what you want and where to get it.
website link to what you want
http://www.thinkauto.com/acatalog/On..._BSP__153.html
THINK AUTOMOTIVE +44 0208 568 1172
MMA-10-8
-10JIC x 1/2BSP- aluminium
Ł9.40 (Excluding VAT at 20%)
Hope that helps mate
Thanks
Marc
My blanking plug in the oil filter take off housing is M18x1.5 metric thread to -10
If you want a fitting for -10 aeroquip to 1/2"bsp then this is what you want and where to get it.
website link to what you want
http://www.thinkauto.com/acatalog/On..._BSP__153.html
THINK AUTOMOTIVE +44 0208 568 1172
MMA-10-8
-10JIC x 1/2BSP- aluminium
Ł9.40 (Excluding VAT at 20%)
Hope that helps mate
Thanks
Marc
19-04-2011, 03:21 PM
#1169
Andy Escos -
You got me thinking so i popped to the garage and an hour later came up with this, i didn't want to go to thin on the edge as i want to keep a bit of the outer lip for securing the hose, so the step is down to 1mm and once a hose is clamped round it, it wont even be that much of a step.
BEFORE
AFTER A TICKLE ON THE LATHE
Also drilled a hole for the safety R-clip to secure the idle screw
And this is the beggining of the 5 bar map sensor manifold
.....watch this space
You got me thinking so i popped to the garage and an hour later came up with this, i didn't want to go to thin on the edge as i want to keep a bit of the outer lip for securing the hose, so the step is down to 1mm and once a hose is clamped round it, it wont even be that much of a step.
BEFORE
AFTER A TICKLE ON THE LATHE
Also drilled a hole for the safety R-clip to secure the idle screw
And this is the beggining of the 5 bar map sensor manifold
.....watch this space
Last edited by M K; 19-04-2011 at 03:23 PM.
19-04-2011, 03:26 PM
#1171
Cheers Dave
I am not sure yet mate, i may never even use it but this is costing me nothing to make ready for ALS so im doing it while its there,
it will only be mild if i do run it as i will be using a gt series turbo, some people say you can't run it with als but i ran it before for long enough on a gt30 and it was fine, as long as its mild.
it will only be mild if i do run it as i will be using a gt series turbo, some people say you can't run it with als but i ran it before for long enough on a gt30 and it was fine, as long as its mild.
19-04-2011, 03:33 PM
#1172
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Cheers Dave
I am not sure yet mate, i may never even use it but this is costing me nothing to make ready for ALS so im doing it while its there,
it will only be mild if i do run it as i will be using a gt series turbo, some people say you can't run it with als but i ran it before for long enough on a gt30 and it was fine, as long as its mild.
I am not sure yet mate, i may never even use it but this is costing me nothing to make ready for ALS so im doing it while its there,
it will only be mild if i do run it as i will be using a gt series turbo, some people say you can't run it with als but i ran it before for long enough on a gt30 and it was fine, as long as its mild.
19-04-2011, 03:37 PM
#1173
Yeah if you want to run aggresive als then you need the maram shaft as you egt's will be extremely high, if your running mild and keep temps under 900deg then you can get away with it in short burst's
IMO if you use a gt series turbo it will be alot more responsive to start with so you do not need to run such aggresive als, i had a t34 with maram shaft running agressive als and it was nowhere near as good as running the gt30 with mild als.
IMO if you use a gt series turbo it will be alot more responsive to start with so you do not need to run such aggresive als, i had a t34 with maram shaft running agressive als and it was nowhere near as good as running the gt30 with mild als.
19-04-2011, 08:40 PM
#1175
Marc i can see me banging on your door to get a few bits done at some point, that looks wicked pal 
You thought about opening the throat up some more tho and putting a bigger butterfly in there as iirc you can get it up a nice amount?
You thought about opening the throat up some more tho and putting a bigger butterfly in there as iirc you can get it up a nice amount?
Last edited by Miller 3; 19-04-2011 at 09:53 PM.
19-04-2011, 09:57 PM
#1177
Cheers Andy
Doug - not gonna bother with that as I don't need the extra flow in the throttle body and it is extra expense, I only took out the step as it cost me nothing to do apart from half hour or so of my time,
Markk - I have definitely got the bug for making any little parts I can lol but I really enjoy doing it,
Doug - not gonna bother with that as I don't need the extra flow in the throttle body and it is extra expense, I only took out the step as it cost me nothing to do apart from half hour or so of my time,
Markk - I have definitely got the bug for making any little parts I can lol but I really enjoy doing it,
20-04-2011, 05:29 PM
#1178
Getting there with the map sensor manifold
Faced it off roughly on all sides
Then started about drilling the main hole for the map sensor, i didn't have a 16.5mm drill bit so took it out to 12mm then bored it to a snug fit on the o'ring on the sensor
Marked out, drilled and tapped the 2 mounting holes (m6x1) for securing the map sensor
And that's where i am up to so far,
Will drill through on 3 sides so it meet in the middle and creates a larger chamber where the sensor is then tap the take off's tomorrow or over the weekend, which are going to be M14x1.5, for M14 to -4 fittings one on each side and 1 on the top,
Total cost for it when finished will be Ł4 plus the 3 fittings @ Ł2.99 each and my own time so not bad.
Faced it off roughly on all sides
Then started about drilling the main hole for the map sensor, i didn't have a 16.5mm drill bit so took it out to 12mm then bored it to a snug fit on the o'ring on the sensor
Marked out, drilled and tapped the 2 mounting holes (m6x1) for securing the map sensor
And that's where i am up to so far,
Will drill through on 3 sides so it meet in the middle and creates a larger chamber where the sensor is then tap the take off's tomorrow or over the weekend, which are going to be M14x1.5, for M14 to -4 fittings one on each side and 1 on the top,
Total cost for it when finished will be Ł4 plus the 3 fittings @ Ł2.99 each and my own time so not bad.
22-04-2011, 09:07 AM
#1184
Pretty much finished
Had a couple of bad crashed with the drill press when using as a mill, so i won't try that again, at one point i thought it was a case of chuck it away and start again so im happy i salvaged it.
Due to the crashes i had to rub a few bits down so there is no machine finish anymore so all i need to sort is that and then i will get it anodised
Still, not bad for about Ł4
Had a couple of bad crashed with the drill press when using as a mill, so i won't try that again, at one point i thought it was a case of chuck it away and start again so im happy i salvaged it.
Due to the crashes i had to rub a few bits down so there is no machine finish anymore so all i need to sort is that and then i will get it anodised
Still, not bad for about Ł4
22-04-2011, 09:33 AM
#1185
Im glad you said that bud, as i havnt had a chance to get to mine yet' and i felt a bit bad
I had a bit of a result yesterday tho as we have got in some new MAN 7.5 ton tippers at work and they run this Map sensor so i can sense one braking down in the near future
Have you already got the re wire lead sorted for yours yet or is it getting hard wired? something i will need to sort out myself soon!!!
23-04-2011, 09:01 AM
#1187
Got my fittings through for the external wastegate, -4
And got the fittings for the map sensor manifold, 1 to plenum, 1 to boost gauge and 1 to fuel pressure reg, blanking caps just fitted for now to keep dirt out,
And got the fittings for the map sensor manifold, 1 to plenum, 1 to boost gauge and 1 to fuel pressure reg, blanking caps just fitted for now to keep dirt out,
Last edited by M K; 23-04-2011 at 09:02 AM.
23-04-2011, 06:59 PM
#1190
Nice work there mate . all so you are doing very well but you could do with running your tools closer to the tool box and when cutting ally use a bit of parafin or WD40 it help to stop the ally from picking up on the tool but saying all that well done mate
Last edited by COLEYST200; 28-04-2011 at 04:09 PM.
23-04-2011, 09:48 PM
#1194
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Would put everything on its own separate line.
Should see what some of the vauxhal lads do then wonder why there pretty standard engine has just gone pop.
24-04-2011, 08:15 AM
#1195
Cheers for the comments guys they are all welcome,
The fittings on the wastegate are dowty seals but I just used them to gauge how much I needed to take off the fitting as they were bottoming out on the diaphragm, I have the proper silver crush washers in the box but left it at the garage so will remember to swap them over.
The hints and tips for using the lathe are very welcomed Coley, I'm new to this metal working so I'm happy to be taught anything that will help
Jimbo - I have 2 blanking plugs for the manifold so I can run it soley for the map sensor and blank the other 2 off, I see what you mean about the leaks if all lines are connected but they all come from the same place anyway, so you would still only need a leak elsewhere to affect all 3, and even though will rather play safe and run individual lines now but it's not like I am using push on hose like a normal map sensor or fuel regulator as both are proper aeroquip with swaged hoses so I think it would ben ok, but better to be safe then sorry, so thanks for the advice, you guys have been doing it long enough
Ok
The fittings on the wastegate are dowty seals but I just used them to gauge how much I needed to take off the fitting as they were bottoming out on the diaphragm, I have the proper silver crush washers in the box but left it at the garage so will remember to swap them over.
The hints and tips for using the lathe are very welcomed Coley, I'm new to this metal working so I'm happy to be taught anything that will help
Jimbo - I have 2 blanking plugs for the manifold so I can run it soley for the map sensor and blank the other 2 off, I see what you mean about the leaks if all lines are connected but they all come from the same place anyway, so you would still only need a leak elsewhere to affect all 3, and even though will rather play safe and run individual lines now but it's not like I am using push on hose like a normal map sensor or fuel regulator as both are proper aeroquip with swaged hoses so I think it would ben ok, but better to be safe then sorry, so thanks for the advice, you guys have been doing it long enough
Ok
26-04-2011, 10:48 PM
#1197
Thanks mate
Milled out a section on the oil take off adapter tonight and drilled it out for the safety lock wire to attach
will secure the lock wire to a bolt on the block once everything is in place
Also made up another set of drop links as i sold the last set on ebay, but i may sell these ones as well and make a few more, im not sure
Tomorrow i think im gonna weld in the -6 bulkhead fittings for power steering pump and aeroquip the aeromotive fuel pressure boost pipe fitting by drilling and taping the housing
Milled out a section on the oil take off adapter tonight and drilled it out for the safety lock wire to attach
will secure the lock wire to a bolt on the block once everything is in place
Also made up another set of drop links as i sold the last set on ebay, but i may sell these ones as well and make a few more, im not sure
Tomorrow i think im gonna weld in the -6 bulkhead fittings for power steering pump and aeroquip the aeromotive fuel pressure boost pipe fitting by drilling and taping the housing
28-04-2011, 04:00 PM
#1200
Cheers guys
Having a play with the Hart inlet, new 83lb siemens and billet rail today as I have heard the billet rails give slight up and down play so want to check it's all sealing ok
Will post pics in a while
Having a play with the Hart inlet, new 83lb siemens and billet rail today as I have heard the billet rails give slight up and down play so want to check it's all sealing ok
Will post pics in a while
Last edited by M K; 28-04-2011 at 04:01 PM.