SyKaTurbo

Here you go. For those who wanted to see it/hear it.

http://freebsd.cx/~ronnie/Simon/the_beast.mpg

right click and save target as. Its a pretty big file at 20+ meg for seeing it move 5 or so yards

Kavid

Looking good Sy! Glad it is running!

Can you sent me that scheme of the wiring loom when you dont need it yourself?

Cheers!

SyKaTurbo

keep your eyes on www.katurbo.co.uk (as seen in performance ford lol) over the next week and ill try get them on there for downloading with complete fitting instructions including sensors and plugs for the whole loom to make it easy to understand.

zvhturbo

Web site not found

The KA is looking great mate, keep the pics coming.

luke89

iTrader: (1)

looks mint mate get some more vids up do u think it will be going to ford sport ??

flipkadan

couldnt have sound at work but that is one big grin on your face!

SyKaTurbo

Right the link to the site should work now all being well

No vids at the moment as im borrowing a camera
Here a is smaller version of the same video

http://freebsd.cx/~ronnie/Simon/the_beast.wmv

Probably not going to be at the FordSport meet. Im hoping for completion about the middle of october.

Kavid

Thanks Sy for now! Your Ka is looking superb!

Your waiting I think on the chargepipe made by Blakey?

luke89

iTrader: (1)

wanted to see this oh well good luck getting it all sorted proply better to do it proply or do it twice lol

Alloy

Sy that thing is beautiful. Is that pic really how low it is or is that a photoshop? Its going to look super aggressive if it is that low, not to mention it will stick like shite to a blanket around corners!

About the gearboxes, what boxes do the SportKa's run? Is it just a modified Ib5 or what?

I need to find out as im thinking of doing an RS turbo KA again as i cant find out much info on the 2.0L Zetec conversion, maybe you know a bit more about it? Or possibly know someone within the KaKlub who knows about it?

Blakey

Alloy
Not sure about the spec of the gearbox in the Street and the Sport KA but they do have the starter motor at the front of the box rather than the back, like the normal KA's. This will save a fair bit of trouble with getting the starter relocated for the turbo conversion.

Good to see the KA running Sy, getting on well with the charge pipe, ill send some pics soon.

Blakey

SyKaTurbo

nice one mate, the sooner the better

no pressure or anything

fitzy_88

Yeah mine needs a bit of work - full post to follow though!

Blakey's done a fantastic job for his part.

Sy, kept me sane on a night that could have been quite miserable!

Thanks to you both.

Much to do!

It's currently running a bit shit at the moment, but it'll get sorted and when it does a full post will follow.

Euan

pd

Car looks proper!!
Where did you get the door cards from??
And the painful question... how much were they??

Alloy

Im near sure DJM make the door cards mate, pretty expensive i would imagine.

pd

Sorry mate who r DJM???
Do they make door cards for other models??

Blakey

Up date about the charge pipe!

Would post some pics but cant get the photo bucket to work.

OK. I have Fabricated two from aluminium and i think they look realy smart even if i do say so myself, they are all tacked up and ready to weld.

But,

The last thing i want to do after all the work i have put in to shaping them, is mess them up with a bit of bad welding. Therefore i have made the decision to take them to Pace products where they have some of the best alloy tig welders in the country, and get them welded there. Because they will be the first thing you see when you open the bonet i thought it was important for them to look top notch.

Hope you understand Sy and sorry again for the delay, im just obsessed with getting things spot on i guess.

The best thing is that these can be chromed or POWDER COATED PINK or pollished as you wish.

Also i am going to try and get these made as a casting to try and insure quality, and these will also be available chromed, powder coated or pollished.

Euan, glad to hear you are getting on ok, hope you dont mind a little longer wait for the charge pipe. hope you understand whats the latest?

Same to Dan and Kavid, spend every spare minuite i get on these. lol

Blakey

Oh and i forgot Krysti, Doh, my sig has broke too, no time to fix that, back to the garage.

SyKaTurbo

No worries at all mate.

You are allowed a weekend off ya know. All work and no play makes Blakey You sound stressed to hell.

I think your sig is broken cos of photobucket being down as mines broken too at the moment. Top idea about the welding, i won't be coating it pink though if so much effort has gone into the appearance. It would ruin it. Take all the time you need as i know it will be worth it. Just hope i get some more gentle postmen this time.

Muska

wow! that is mint! the charge carrier on your website is gorgeous aswel! top stuff

Kavid

Well it is sounding great Blakey!

I'll think I would like to have a polished one or a chrome, depends on the prices!

Keep up the good work!

Alloy

DJM are the ones who made the 302bhp Cosworth Ka. I dont think they make a stream of products for other cars to be honest, they sell a number of goodies for Kas but i think it would be one offs for any othr cars. Try their site and see though as i could be wrong, heres a link:

www.djm-motorsport.co.uk

Blakey

OK, photo bucket is working now, ill put some pics up for ya.

Dont worry mate im not stressed, ill sort it for ya. (sorry some of the pics are a bit dark, not much light at 1130 lol)

First stage, the tightest bends i could get were these and they looked pants that big




Then i came up with this idea Reluctant to cut them up as they are Ł17.50 each



Then i cut the top off for bonet clearance, although a small part of the panel suport rib of the bonet has to be cut away anyway.



Then made a reducer from 70mm to 50mm then tacked it all together



Then after all i said in my last post i decided to weld them myself anyway because i thought there were too many welds to look any good, (if you know what i mean?) i would then polish them off anyway.



So now they can still be pollished, chromed or powder coated.





Had a bit of a funny turn one night too?


So there you go, all i have to do now is weld the small pipe on for the idle control valve. I am going to get these made in cast form too so i dont have to keep fabricating them.

Do you think you might get yours powder coated now Sy?

SyKaTurbo

Those pics look superb! Im glad you decided to have a crack at the welding yourself because it looks the mutts nuts. I take it the pic of two of them together is before and after the welds were ground back smooth? Really impressive stuff to see the work involved in them.

Whats the plan now then first few are hand made and from then on cast?

No i dont think ill have it coated, i may have it engraved though

Pmsl at the last pic,

Kavid

WOh you did a nice job Blakey! Looks awsome!

It just fits on al turbo Ka's with the fiesta turbo lump?
I'm asking that because I'm gonna use a chargecooler, or that doesn't matter?

Sorry i'm a newbe...

Blakey

Sy,
You were right, the two charge carriers side by side - one had the welds removed, the other yet to be done. You can have one of the fabricated ones if you want mate as you asked first. My plan was to keep hold of the other one for a while to get the pattern for the castings made. If you decide you want a cast one i will be happy to take yours back, although it looks like the cast ones are going to have to be made with a join at 50mm after the reducer on the 50mm diamiter straight. see pic below.



This will have to be joined by a short section of 50mm boost hose, similar to how the charge carrier is joined to the throttle body, with a couple of hose clips. This is to reduce production costs of the pattern as it is a very intricate(sp) shape to mould.

Kavid,
can you send me a pic of the charge cooler you have and i will be able to tell you hopefully? if you have a pic of it installed that would be better. Think they go in place of the battery dont they?

SyKaTurbo

Tough desicion but ill have one of the fabricated ones please They look top.

The fabricated ones may be better for general use as the pipe can then directed for a wider useage of applications depending on position of cooler, turbo etc.

Big question now - when can i get my oily mits on it?

Kavid

Blakey I've sent you an email!

And sorry for the questions, but the airfilter where is it to connected? Normally it is on the throttlebody right? I can't see on the pics where it is connected to? The chargepipe is connected to the turbo right?

Yes, again i'm a newbe..

Blakey

Euan,
If you dont want it polished or chromed, all i have to do is weld the pipe on for the idle control valve, (presume you are going to get it powder coated the same colour as the inlet manifold? ) you should be able to have it by the end of the week, then you can run some boost.

Have to send me your address again, got it somewhere, not sure where.

Did you manage to get the "?" shape hose you wanted in purple? as you will also need a purple 50mm inside 90 degree elbow, this is very close to the two brake pipes and the ignition module, but the only place for it.

David,

dont see any probs with the pics you sent me, might like to get one long water rad made for the charge cooler, rather than the two little ones, only for looks though. To fill the gap in the front bumper at the bottom. Also did you get a water pump for the cooler?

Blakey

David

Bit hard to describe where the pipework leads in words, I look for Sy to back me up. Got to go out now, already late, ill get back to you soon.

Not worried about the questions mate i like to help.

Kavid

Ok thanks Blakey!

Yes I've got a waterpump aswell...

But how about these questions?

Maybe you have the answers for me?

Do you know the price already for the chargepipe polisted or chrome?

Thanks!

SyKaTurbo

Right. Ill try answer Davids question. Ive not seen your chargecooler but ill give a rundown of how Blakeys system is.

1.The air comes in through the air filter behind the battery
2.Is sucked down a pipe and over the manifold into the turbo
3.The air is forced out of the turbo and into the left hand side of the intercooler
4.The air comes from the intercooler and up the front of the rad
5.It passes over the radiator into the engine bay and runs next to the battery
6.The air then passes up the charge carrier pipe and round into the throttle body. In it goes.

Hope this makes sense?

Blakey, by Euan i take it you mean me lol? Ill take it as it is as soon as the icv pipe is welded on and ill get it too the coaters as i have some bits to take anyway that i need doing.

Im still waiting on the "?" pipe in purple but ford are trying to get me a standard one in at the moment. I have lots of 90deg 50mm pipes, i ordered too many incase i ruined a few cutting. Ill pm my address, let me know the costs so i can send you some money for the bits.

Kavid

This makes a little bit more sense to me, thanks Sy!

krysti KA

Hello again its Blakey @ Krystis,

Thanks for explaining that Sy i had to go out last night, and didnt have time to explain. Sorry i did mean you not Euan, he already has a little something to get him by, im sure he will understand.

SyKaTurbo

No probs.

So what is euan having on his and whats krysti having on hers then now?

Did you get my address via text?

Blakey

Krysti is having the other fabricated one in chrome, Euan, Dan and David are going to have the first of the cast ones. I did get your address mate, hoping to get it sent on Saturday, guess you will have it on Monday if all goes well?

Alloy

Kavid, air filters are usually connected to the throttle body by a pipe. But once you get into turbos its completely different.

Basically when you get a turbo installed that is what the filter connects to - the turbo, air is sucked into the filter and into the turbo, then a pipe goes from the turbo into an intercooler and then from there it goes to the throttle body.

So if you can imagine Blakey's or Sy's engine bay and were his filter is look at this little diagram.

(TURBO)------<----(FILTER) air enters filter
l
l
l goes through turbo and into intercooler
l
l
l passes intercooler THEN goes through throttle body
l
l----------(INTERCOOLER)-------(INLET MANIFOLD)

Kavid

Thanks for the explaining mate!

Blakey

Hope this helps mate, Apart from you will have a charge cooler where the intercooler is.

Kavid

Even better Blakey! Thanks mate!
Any progess on the charpepipe yet?