Well a lot has changed since my last post, will get loads more pics up soon, just a couple to start with,
had issues with the block on the zvh so i built a zetec turbo instead, had it all mapped on boostmonkeys ofam ecu by Karl at FPT, got it home and the box shit itself! so slung the spare box i had in and took it to Ford Fair 2015#

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Pic of it on the way home from Ford Fair

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Have done a fair bit to it over this winter so will update soon

Very cool.

The engine looks like is been in there since the car left the factory.

Thanks Glenn, yeah i must admit the zetecs do sit well in those bays!

Took the car off the road end of August to tidy it up properly
on its last outing the whole thing died on me and had to get the rac out to tow me home lol!

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Turned out to be a melted fuse on the live to the fuel and injector relays so sorted all the wiring out and fitted a new alarm as this must have taken the alarm out aswell

stripped out again (got the misses involved she loves it!)

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Was fed up with the exhaust manifold adaptor plate as it kept leaking so i had a tubular manifold made up

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Fitted a master cylinder for a hydraulic clutch conversion but didnt take any pics of it, also got an ib5 from a 1.3ka and had my mate put the rst lsd in it for me
so got the engine back in, had cam cover powdercoated and put some studs on top to secure the charge carrier as i had problems with it popping off last summer

http://img.photobucket.com/albums/v4...45AF4E81_1.jpg

can just see the flexi clutch pipe on the gearbox

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Having the tubular manifold made has pushed the turbo forward a good inch or so and as it was already close to the rad ive had to move everything forward which meant i had to take all the foam out of the front bumper and mount it on aerocatches, had to angle the radiator which has meant i can only run one fan on it, not sure if its going to be sufficient but time will tell i guess.

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as you can see its pretty tight

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Picked the bumper up from paint shop lastnight

http://img.photobucket.com/albums/v4...97940BD376.jpg

got the aerocatches fitted and new black strips on

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All thats left to do now is make a downpipe up and give it a service then should be back on the road

Anyone know how i can change the thread title?

Looking good matey. Shame you broke down theres nothing worse is there.

If you go to your first post and go to edit it. You will see a button saying go advanced click on that and then you should be able to edit the title.

Thanks mate, yeah tell me about it, had it a few times now!

When i first bought my cossie it was always breaking down in the first few weeks of ownership. I changed the fuel filter and it cured it.

Touch wood the old girl has been ok for ages.

An easy and cheap fix then

Ive taken a bit more pride in my work this time so hopefully wont be having any more of that

Good project, looks like you have had as many engines in and out as me lol.

Clean looking escort mate and nice engine

https://cimg0.ibsrv.net/gimg/passion...b8878d87d9.jpg


here is my mk3 xr3i was going to turbo it but this engine came along no cutting or welding to body as said these look standard fitment that zetec is lovely (what brakes have you used

cheers guys :)

Stephen; looks a nice conversion that, ive got 4x4 cosworth calipers up front with 2wd discs and 2wd cosworth brakes on back with rs2000 handbrake cable

https://cimg9.ibsrv.net/gimg/passion...2b7de82b71.jpg


cheers cameron .just got to find some now ..

Very nice mate

Thought id do an update as its been a while, a few things have happened since i last posted,

Had the turbo rebuilt with bigger compressor and exhaust wheels from billet

http://i.cubeupload.com/JHjJdR.jpg
http://i.cubeupload.com/fILC3J.jpg

Not long after this i had a feature in Fast Ford Mag

http://i.cubeupload.com/gETNGk.jpg

Couple of Ade taking pics

http://i.cubeupload.com/TnfUIz.jpg
http://i.cubeupload.com/DYiF5v.jpg

Had it mapped up by Karl at FPT and we were struggling with high water temps and high inlet air temps, i had the fans between the radiator and intercooler, which wasnt helping coolant temps, also the fins on the intercooler ran the opposite way to the radiator so there wasnt much airflow over the rad, most of the cooling fins on the intercooler were hidden behind the bumper too, so i ended up getting an rs500 style intercooler from airtec (the fins run the same way as the rad and the fans fit to the front) overall a much better setup
Picture of the original setup, as you can see not many fins exposed, and the bottom runner of the intercooler sits in the opening of the bumper

http://i.cubeupload.com/rCaFrw.jpg

Started the strip down

http://i.cubeupload.com/iwIpL3.jpg
http://i.cubeupload.com/vBFqff.jpg

And new intercooler fitted with fans on the front, a much better fitting design than the last one, the brackets holding it to the car are loads better, i have removed the tubular manifold and gone back to a standard cast item with adaptor plate as it gave me a lot more room between the turbo and the rad

http://i.cubeupload.com/wT2DpE.jpg

And fitted behind the bumper, much better :top:

http://i.cubeupload.com/xAc0pt.jpg

This kit also came with a reverse charge carrier for an mfi engine, so i had a friend of a friend weld some tube to the side for the hose to iscv and plugged the hole on the opposite side for the mfi ACT sensor

http://i.cubeupload.com/rxjHoI.jpg
http://i.cubeupload.com/CcudSW.jpg

Will be getting the charge pipe powder coated along with a new cam cover, ill get some brackets welded on to the cam cover for the charge pipe and also an extra outlet for breather system once thats been made up

Suprisingly hard to get hold of these days

http://i.cubeupload.com/LWTcvF.jpg

Brand new mongoose exhaust system fitted, i had to have the front section extended on the downpipe as it was hitting the sump, im now running a blacktop sump with external oil pump system which was an absolute arse to fit, the pump itself hit the anti rollbar once lowered to the ground

http://i.cubeupload.com/R3H1nr.jpg
http://i.cubeupload.com/Nye6oV.jpg
http://i.cubeupload.com/z6Zi7R.jpg

so i ended up taking the car to jamsport to have some sierra compression struts fitted, they did a top job of sorting them
Some mega stuff in there

http://i.cubeupload.com/q2vwVb.jpg
http://i.cubeupload.com/GA6FTL.jpg
http://i.cubeupload.com/aFoOuW.jpg
http://i.cubeupload.com/xMu2Te.jpg

Also the alternator needed moving a small amount as it was hitting the bracket for the new oil pump, good job i had an old zetec block knocking about so we set about making a bracket out of some 15mm steel plate to move it up and outwards

http://i.cubeupload.com/3eW2yT.jpg

used cap heads countersunk into the plate to fix to the block, worked a treat

http://i.cubeupload.com/22xZe7.jpg

mocked up on engine, got painted black afterwards

http://i.cubeupload.com/2TdzCA.jpg

I found out that lockwood had started doing black dial sets so i ordered one of those to get rid of the taccy looking white dials

http://i.cubeupload.com/lVhrVx.jpg
http://i.cubeupload.com/ZIE8y9.jpg

dials fitted, looking much better

http://i.cubeupload.com/MbZT6S.jpg

all lit up and with new leather wheel, replacing the worn suede one

http://i.cubeupload.com/GjTWPn.jpg

Had a couple of door mirror covers made up in carbon, they only cover the back of the mirror so i had the front side of them painted black to blend in a bit better and bonded them on with some pu adhesive

http://i.cubeupload.com/GEwPLj.jpg
http://i.cubeupload.com/jo62YY.jpg

Fitted to the car

http://i.cubeupload.com/Gbzojf.jpg

And thats about where its at at the minute, will be going to FPT again for a quick mapping session for the new intercooler, so will update after that
thanks for looking

Good update

Top work mate .

Cheers Mat, been following yours, very tidy motor that :top:

You happy with the dials and how they light up?
They look good from here :top:
Did you peel the old ones off?

Very nice

Yeah they light up identical to originals, very pleased with them
i did peel the old ones off and used a little bit of solvent on a rag to get rid of any residue before fitting the new ones, you have to remove the needles to fit the black dials, didnt have to do that with the white ones as they slid over the needle and had a circle with a slit in to go around the middle, i used two teaspoons to pull the needles off

Did a couple of small jobs to the car lastnight id been wanting to do for a while
opened the door to be greeted with water on the floor under the front of the car, great! so new rad ordered should be here tomorrow

http://i.cubeupload.com/NRdkjW.jpg

The weather seals on the doors were long past it, bubbling up underneath, i'd heard that you can use 3 door corsa c ones, so i found a cheap used set on ebay, offered them up and they werent far off at all, trimmed down a little with a hacksaw and knife and they fit spot on, dont think anyone would notice unless it was pointed out

Usual knackered mk4 escort weather seals

http://i.cubeupload.com/CNICnj.jpg

Corsa C ones fitted

http://i.cubeupload.com/BNrdtK.jpg
http://i.cubeupload.com/QUk3gW.jpg
http://i.cubeupload.com/mzRErd.jpg

Not bad

Then was time to replace some really thin vacuum tubing for some decent stuff

http://i.cubeupload.com/2cVIUH.jpg
http://i.cubeupload.com/1jyPAw.jpg
http://i.cubeupload.com/Xl3Spo.jpg

Need to relocate the boost control valve as the radiator top hose is now in the way with the new intercooler setup

http://i.cubeupload.com/JAeEmK.jpg

Put new rad in this morning

Nice shiny new one

http://i.cubeupload.com/dXfGD3.jpg

Battered old one

http://i.cubeupload.com/dkcrRP.jpg

werent taking any chances with this one hitting the turbo whilst being installed

http://i.cubeupload.com/RHSfrZ.jpg

http://i.cubeupload.com/lCx9LJ.jpg

Thanks mate ..nice to see you back on and updating the build ..top work once again ..look forward to more :top:

Any update on this mate?