jamie rigby

May take a while as i have quite alot to copy and paste haha but thought its worth posting it up on here to show you all my work

My previous car to this was a 166bhp ITB'd Fiesta Zetec S, some of you may have seen around on trackdays or at shows etc-



Kinda got bored of that and i turned 21 in march and thought now's the time for a mk2 xr2 ive always wanted...

so where i began, first week of May this year bought this -

F reg 88 mk2 xr2, its had front wings replaced, new bonnet and a total respray and undersealed in summer 2008 so its in fairly good nock for a 80s ford ! 12 months MOT, 6 months tax!

these were taken that night once i got home from the 400mile round trip to collect it -













spec was/is...

Engine:

* 1600 8v CVH;
* Kawasaki 40mm Keihin zx7r carbs;
* Ported head;
* Kent CVH22 cam;
* Heatwrapped Janspeed manifold;
* Yamaha R1 fuel pump...

Chassis:

* Gaz Gold coilovers fully height and damper adjustable;
* Fully Polybushed throughtout;
* 13" pepperpots;
* Budget tyres y0;
* Standard brakes;

Exterior:

* Standard!

Interior:

* Standard!

had problems within the first few days when i bought it like the throttle cable snapped and everytime i braked the fuse popped, both sorted straight away and now happy days...

Now i could start with some updates/progress...

The thing i like best...





To be continued, LOTS more to come ...

jamie rigby

Continued -




then fitted my steering wheel i first had in my zs, OMP corsica 350mm -



Random pic -



then more strippage -



then fitted buckets from my zs, Sparco Circuits on the XR2 subframes/runners -



then bought an Ashley exhast system -



Then had that fitted and few days later took my car to Mikeancs to get the carbs jetted and a power run... now its at 117bhp & 107lbs ft... in a sub 800kg car its awesome, altho lacking the grunt compared to the zs...

then a mate made a rear strut brace/harness bar for me, so had that welded in the fitted my TRS harnesses -





oh heres a quick pic of the custom 2 1/4" tip i chose over the 3" beast -





then removed the sound deadening...
















Bought some R888s, had them fitted to the spare set of Pepperpots -







then bought and fitted a oil pressure and temp. senders and changed oil and filter whilst i was at it -








To be continued...

jamie rigby

Continued -

Then bought a complete 1800 zetec s2 engine out of a Mk6 escort GTI with 68k on it -







Then bought a S1 RST gearbox -



some holes cut -





randomers -





Stripped some stuff off the engine thats not needed -







Wacked the R888s on to bed them in then went to the meet i organised -











Took the rocker cover off the zetec to send my cams to away to get re-profiled to Piper 285 spec -





New CVH oil filter fitted -



Rocker cover primered -



painted -



ERST Helix Organic clutch -





new exhuast manifold gasket awating to be squeed with a Ashley 4 branch -



New NGK Paltinum plugs -



2m of 13mm hose for breather pipes -



rocker cover laqured -



engine painted -





New Filter king fuel pressure reg and filter to replace my seperate ones atm -



Brand new Ford Mk3 Zetec radiator -



decided to then fit my gaues from my ZS (Oil temp. and pressure) -



New inlet manifold, only payed for it yesterday shoiuld have it early next week -







had a moment with a curb a few weeks ago and bent the rear beam and the front chassis leg, thats now been jigged and straightened out etc...

to make it easier and cheaper for me i took the engine out then they came to collect the car and drop it off... so stripping down and removing engine -













New toyo CF1 tyres for road tryres (still need fitting) -



zetec converted engine mount -



Painted the gearbox -



Ashley 4-2-1 manifold -





new track rod ends -



They all arrived whilkst the car was at the repair place...

got the car back...

fitted the filter king -



new track rod ends fitted -



offside lower arm/ball joint/anit roll bar removed to get clearence ready to fit engine -



To be continued...

Twins

iTrader: (18)

Love it ,did you travel to essex to buy it

Korda

iTrader: (1)

the car looks mint engine spec looked good on old engine top work

jamie rigby

cambridgeshire mate

aye, not even half way there yet :P


continued -

Jon from Shawspeed came round around 6is last night, got the cams in timed up etc... then i fitted new rocker cover gasket -



then cam belt cover on, new NGK plugs and fitted the leads -



lightened and balanced flywheel on -



helix clutch on -



New helix release bearing fited and box ready to go on -



box on and dragged round to the front of the car with some idiot -



got the engine in at 10pm on tuesday night -



Yesturday i got the driveshafts on, track rod ends on, nearside ball joint on, gear linkage is done, speedo cable is done, went over all the engine mounts again with my socket to make sure everythings tight...

then fitted the inlet manifold and took some fresh pics -









then today fitted the Vacuum hose to all 4 inlet primaries -



XR2i starter motor on -



Ashely 4-2-1 manifold on -



Lower arm/ball joint/anti roll bar back on -



Oil temp sensor -



also did the pressure one but forgot to take a pic lol...

wheels on and car back on the ground -



the tightened the HUB and wheel nuts.

Can tell the zetecs a lighter engine as the car sits like 10mm higher ta the fornt than it used to lol

The trackings a mile out so going to get that done once i get the new tyres on and the wheels checked out to see if they're buckled or not.

Just chopped off what i had to of the exhuast manifold and system and measured up a piece including a flexi joint ready to go Pipewerx on my way home from work tomorrow.

cut up the exhaust and measured up for the section that i needed making...

so cut this lot out/off -



went to Pipewerx on my way home from work and had this made -



fitted -



the sleeve and all the measurements are spot on apart from one thing... as you can see the flexi joint is hitting the shell slightly underneath so that'll be ittirtating vibrating whilst driving so once its all up and running and mapped ill shoot back upto Pipewerx and get it sorted and also get them to make me a 3rd hanger

auxuilery belt and alternator fitted -



hen cut down the carb hoses to 50mm and fitted the carbs -



then fitted the Rad, Fan, header tank, coolant hoses then filled it up with anti freeze/coolant ready mixed stuff form halfords -





Then filled the engine up with some 5w30 oil and the gearbox with 75w90.

Then fitted the clutch cable

then fitted the oil catch tank -







Omex wired up -



and after alot of fking about with problems it lives...

quick vid from when i was bedding the cams in and letting the coating burn off the manifold-

http://www.youtube.com/watch?v=ryMSd...layer_embedded

Only drove the car like 20miles so far over the past 2 days, having problems wth the gearbx really struggle to get into 2nd and 4th gear as and cant get onto reverse at all after adjustingt he linkage like 20 times so gonna have to contact the guy who i got the gearbox off and see whats what

also the engines smoking alot like just revving to like 3k which is another dissapointent

Done the tracking today with help from f0xy and a piece of string.

whilst the car was in the air thought may aswell fit the new Brembo Discs and Ferrodo pads so they're done with -





not drove the car today to bed them in will tmoz tho

Mappings booked for Monday so it'll be going there with no reverse lol

beeded in the brakes they're awesome!

done around 150 miles in the car now and its smoking quite alot, a mate thinks the pressure relief valve is blocked or jammed as the pressures high too ( like 3bar on 100degress idle).. so going upto his monday...

Had the car Mappe don monday, was running really rich when it went in and was suffering was bore wash slightly... so thats maybe kicked off the problem with the rings and maybe thats why it smoks so much, it isnt as bad as what it was but still pretty bad, will see how it is as ive only put like 100miles on it so far...

It made 158bhp @ 7k, pretty happy, atm thats what the limiter is set at as i need arp big end bolts as these cams are meant to make power upto 7.5k... so should brake ther 160 mark once i fit them, not worth fitting them yet if this engine is fked tho, will just have to see...

no torque figure tho as Mikes computer froze so he said he'll ring me back with the figure once its sorted as it still should be saved on his hard-drive, feels way torquier than the zs tho so should be high 120s... wheel spin in 3rd is fun!

also the car now goes into reverse too with abit of a struggle and grind lol

then on monday evening -





carbs jammed open whilst driving 'enthusiastically' lol, just went straight to the limiter... which wasnt pleasent. on tuesday i found the problem -





problem was this screw had popped out so there wasnt enough slack on the return spring, which was causing the butterflys to be around 1/4 open, so just found a screw to suit, fitted the carbs back on started the car, sweet as a nut, was expecting the worst tbh but glad it was only minor.

that night before the carbs jammed open we went out to get some vids of our cars, heres mine -

http://www.youtube.com/watch?v=itVWg...layer_embedded

yeh as i said it smokes alot lol, goes well tho altho as i said it does need to rev more.

after the crash i had when i bent the front chassis leg, i also bent the rear beam, so swapped that wednesday -



old vs new -



new one already been painted in some hammerite -



fitted and car back on the ground, no more positive camber -



had the Toyo Proxes CF-1s fitted yesterday, they're awesome even just after 5 miles bedding them in you can really tell the difference over the Champiro Gts lol

then got back and gave the car a clean -

















then decided to paint the rear of the car in Satin black, will do the front next week probs, just looks alot tidier as it is tbh -



then last night i went to a mates to help work on his car on the way there my exhaust fell off... where the 2-1 part joins the 4-2 on the manifold, just slid off even tho i hammered it on originally and used lots of silicone sealent, so bren brought his jack and axel stand out and i fitted it back on just as tight as i could get the brackets on, just checked it and its slid back off another 5mm too (FFS), so again just undone it and tighetend the clamps up as much as possible, going to ask andy very nicely will he weld it together on monday for me as it needs to come off to get the sump off to check the oil pump, if he'll do that for me then theres no chance of it slipping off again then, good old ashley!


To be continued

mr_joe0606

iTrader: (1)

top work pal looks good

TimC

iTrader: (1)

Looking forwards to actually being able to read this without having to sift through a load of shite posts like on zsoc.

Roll on 6am when im home from work.

Have to take us for a ride out in it, ill return the favour in the Corsa.

Glenn_

iTrader: (1)

Top project mate.I bet its a hoot to drive.

jamie rigby

Cheers mate

haha project is on 2 other forums too thought it was time i added it on here!

and yeh that'd be awesome

aye its alright, bit scary atm, ill get to that later haha...


anyways more progress from a couple of months ago...

exhaust is sorted now, screwed a self tapper into one of the secondries so its going nowhere fast now lol

also we did check the oil pump and breathers etc etc and all was well so turns out it was the rinbg that shat the bed.

Had quite alot of problames woth the carbs sliding off lately just having to keep on top if them all the time.

also was having problems with the fuel pump so ive changed that now and happy days again.

also sanded the II16v Zetec and ford logos off the rocker cover so they stand out.

Took the front spot lmaps off too think it looks miles better.

Few pics from on the way down to ford fair -











The 0-60 went err... not bad i suppose, managed 7.68 with 2 missed gear changes so should well be in the 6s really if it wasnt for the **** box (cant wait to swap it with andys FRST one, once i source a new enigne)... a mk1 fiesta with a 170bhp 1800 managed 5.36 with 888s so shows what these cars can do with zetecs in them

Got back tho and thought enough was enough...Found a 2.0l Zetec E, 70k came out of an Automatic too, and already fitted with a 1800 sump and pick up pipe which is 2 out of the 3 things needed to go for a 2.0 over a 1800


the following day went to collect it from a 564 mile round trip after leaving at 6.30, turned it over with a spanner and feels perfect







the only bad thing of the day is that the fornt grill flew off my mk4 and hit the windscreen lol -



So the next day this was the progress -

Drained the Oil and Coolant and disconnected all the coolant hoses
Disconnected the gear linkage
Disconnected the track rod ends and pinch bolts
Removed axhaust manifold and system
Removed alternator
Removed the starter
Remived the carbs and inlet manifold
Removed the Piper cams out the 1800

then swapped over from the 1800 to the 2.0l -

Dipstick
Crankcase breather plate
Spark plugs
HT leads
Coil pack
Thermostat housing
Rocker cover

the following day the 1800 stood like this -





Andy came round around 10ish the following morning, so started out by dragging the 1800 out from under the car then , Swapped the waterpump over, all the tensioners and Cam belt, re-timed the cams up too, Lightened flywheel and helix clutch on, then fitted my new box, andy put FRST gears into a Fiesta mk3.5 Si box as they're a stronger box than a FRST one (bearings/casing etc) so where here at this stage few pics form along the way -













Nearly there, who needs engine cranes lol -





then fitted everything back together, whilst it started pissing down -



Bye bye 1800 and a Knackard S1 RST box -



Then started it up, and listen to how sweet this sounds, its the alternator whining btw lol -

http://www.youtube.com/watch?v=yUDY9...layer_embedded

all running sweet as a nut...

then put around 200miles on it before mapping, few pics from the mapping day -













and the graphs -





Vid from the mapping -

http://www.youtube.com/watch?v=4SY2L...layer_embedded

and the final power run -

http://www.youtube.com/watch?v=whnWO...eature=related

Ordered a new 10" cooling fan off ebay on monday, that arrived this morning so just fitted and made sure it pulls and not pushes ubike the Kenlowe one did and couldnt be reversed lol





Booked Oulton Park for next wednesday (1-9-10) too so that'll be the cars first outing
swapped the wheels for the R888s saves fkin about when we all get there in the morning but im still going to take 2 of the road wheels/tyres just incase too

also gave the car a wothy clean -
















To Be Continued...

jamie rigby

Continued...

The trackday didnt go as planned to say the least lol...

Went out for the first session Oil got upto 140degrees after 1 warm up and 1 full-on lap, was pretty gutted tbh so i just thought itd be best to come in and let the car cool down and see what it was like next time...

when i came in and lifted the bonnet noticed coolant pissing out all over the gearbox from the thermostat housing, so took the thermostat housing off, re-siliconed the gaskets then refitted it, also whilst the coolant was drained i previously blanked off the bottom part of thje thermostat housing to save running a hose right past the exhaust manifold and to the lower rad hose, but then i thought it could be building up pressure so thought so then as i tooka load of coolant hoses and jubilee clips luckily had a T-piece too i added in that extra hose then bled all the system, happy days no more leaks..

then i noticed oil on the floor.. form where my breather hoses were pointing and kinda pointing towrads the nearside wheel arch, then i looked and noticed oil EVERYWHERE in the wheel arch, was pretty annoyed at this point considering i only done 1 full on lap in the first 2hours of the day,s o then got a 1liter conatiner to act as a catch tank, thanks to mark for that, so that sorted that out...

so after 2-2 1/2hrs of pissing about i headed out just before dinner, but still can only do 2 laps max before the oil temperature was creeping the red on the gauge, so just had to keep doing that all day...

after i came back in after that session looked in the catch tank and noticed it had 1/2 a litre init already after like 2 full on laps, maybe just down to the temp of the oil and how thin it got or what but still 1/2 a litre after 5mins hard driving!?

so as i said only managed probs 6-7 full on laps all day as i thought i wanna drive home tonight so next ont he list is an oil cooler and some thicker oil, thinking of some 10w40 would be ideal...

Had some fun having a play with the tyre pressures and damper settings tho learnt abit more about my car, and the R888s are awesome but not worth 80quid a tyre imo!

also weighed the car, it had 3/4 tank of fuel in (so around 25litres/25kgs) and wioth the r888s on which are around 5kgs a tyre heavier than your normal road tyres... the car weighed in at 768kgs which i thought is pretty light lol...


some more pics from the day -




























Bought a baffled sump off ebay the other day that arrived this morning -





also ordered a Mocal 13-row oil cooler and a thermostatic sandwich plate etc, should be here ealry next week..

going to go to ford to collect the new sump gasket then go halfords to get some new oil shortly

fitted the baffled sump yesturday...

so Drained the oil, then disconnected the exhaust system -



then disconnected the battery and disconnected the starter motor, exhaust manifold then removed the sump -

then disconnected the battery and disconnected the starter motor, exhaust manifold then removed the sump -





then fitted the baffled sump which was an absolute nightmare cos of the baffle plates they kept hitting the pick up pipe so i ended up having to disconnect the alternator to get the clearence, all fitted and back together -



removed the bumper ready to mount the oil cooler -



so picked up the oil cooler etc etc last night so just fitted that...

so take one piece of meccano -



one mocal 13-row -



Sanwich plate and new CVH oil flter fitted -



piped up, was a nightmare but got there in the end with pushiong the fittings on once putting them in boiling water -





Then started the car check the sump gasket and all the fittings etc etc, not one leak im proud to say altho when i started the car there was a loud ticking noise and all of a sudden the dipstick shot up, so pulled it out and it was bent at the end and mustve hit the baffle pplate and was fouling the crank when the engine was running, so chopped abit of the dipstick off so not i have no dipstick below minimum lol -



random pic of the bay -



then chopped the rest of behind the bumper out using a hacksaw blade -



and how it looks all fitted and back together -





My bad luck hit me again last sunday night

going down a dual carriage way braked for the roundabout and locked up, so i lifted off to stop them locking up to try and free them and they stayed locked up couldnt do anything about it and just slid into the kerb on the right then kinda bounced to the other side of the road, hit that kerb then went into the kerb on the roundabout

really dont see how the brakes locked up and wouldnt free up thats the scary part, f0xy recons its cos i never pressed the clutch in and the box locked!? but it is natural reaction to try get the wheels to free up then slow the car down with the brakes...

pic sof the damage anyways -











at the same time as the accident another coolant hose burst so carbs off -



hose that had split right just before the heater matirx -



so i went round to brens, pinched his ZS hoses which we took off his car on the weekend and made one of them fit, system all filled up and bled again, jobs a good un' (for now ) as i dont know whats causing the high pressure in the pipes as its all plumbed in EXACTLY how zetecs are in mondeos/escorts/fiesta etc..

found a rear beam on xrtwo.com so went and collected that on thursday and also went to collect my spare Pepperpot too form f0xys dads factory...

friday i planned on fitting the new beam, so old one vs new one -





i used my drums and wheel bearings so just swapped everything over fromt he old beam after i took this pic

fitted it all finished at 8.30 friday night lol, luckily everything just about lined up, re-bled all the brakes and fitted the wheels on with the R888s for now till the new road tyres arrive -



drove it round the block, need to bleed the brakes again as theyre spongy and also need to redo the tracking slighlty but it all drives absolutely spot on, well chuffed!!


Just ordered some new Toyo proxes CF1s they should be here by wednesday and also cars booked in for 2.30 on thursday at pipewerx to get the exhaust sorted, manifold welded, flange instead off a sleeve joint on the manifld and a smaller flexi

To be continued...

jamie rigby

continued...

new tyres fitted -



manifold welded so its all one now, had a flange fitted instead of a sleeve joint and also now got a 5" flexi istead of an 8" so its not all over the place anymore... was pricey but well worth it now and no need to keep messing around with it all the time -



new 88degree thermostat -



Went for a drive over Rivington Pike last night, first time ive drove the car really since its all back together, went well apart from the odd lock up and revs sticking which was abit scray at times (fkin bike carbs!), also had comments on my car popping/banging rather large orange flames too haha


Collect the 30m of 2" black exhaust manifold heatwrap and ties earlier -



then thought it deserved a quick clean -







some fresh pics from sunday night -





















then yesturday...

alternator, starter and manifold off...

manifold before -



sanded down and painted -



more paint as i rad out of red -



progress -





done -





after leaving the manifold overnight i spent another 1/2 hour drying it with a heat gun -



painted in VHT black -



manifold, starter and dipstick fitted -



system fitted -



went to the local factors and ordered a 6pk900 auxuilery belt earlier, no where stocks that size so theyve had to order it, will be collecting that tmoz and then fit the alternator.

Collected the 6pk900 aux. belt and fitted, started the car manifold was smoking for agains and did for a couple of days afterwards, all sound now tho


Mounts arrived monday, went to collect come nylock nuts as it only came with standard M10 ones -



so... new vs old -



fitted -



Miles better but doesnt half make the car shake on idle now

Had the car aligned last friday too, the rear is spot on, 0.2degrees neg camber and both toeing in spot on, so happy about that as it

the front i knew the camber was odd all along but not as far out as it actually was lol... nearside = 2.2degrees neg, offside = 0.4degrees neg... so the guy told me what to do...

where the lower arm/wishbone bolts to the chassis he said to oval the hole slightly by a further 5mm... get a new nut and bolt to allow for the 5mm washers, as he said there needs to be 2 threads showing, tighten the bolt up, drive to them (only 1mile from mine) they'll set the camber up correctly to match the nearside then simply weld round the 5mm washers on either side of the chassis leg... which i did on the weekend and went back earlier to have it all aligned again... unfortunatly i didnt oval; the hole enough but its alot better than what it was and drives awesome now the trackings all done too, heres the read outs now -



Now the cambers still quite abit out as you can see here but still everything else is spot on and it corners great, the guy said to do the same on the other side but take camber off, i will do that at some point

Bught a Mk3 Zetec lower rad hose and bypass pipe to the thermostat last week to, that arrived today...

before (lots of joiners and bodged hoses) -



Now -





Not one pipe joiner anywhere on the whole coolant system/set up now all direct hoses and just one T-piece where it goes off from the lower rad hose to the heater matrix and header tank.

Also put 2 liters of anti-freeze too hoping that ill never have to drain the coolant again now and hope no more hoses burst

That night seen the manifold was glowing -



so as im abit of a child -

http://www.youtube.com/watch?v=86AIN6mIpCY



To Be continued...

jamie rigby

Continued, Last big uptodate-update...

Bought a few goodies on tuesday consisting of...

Jenvey 45mm Throttle Bodies
45x45mm trumpets
Jenvey throttle linkage and Fuel rail
Bosch 330cc injectors

Should be here tmoz with abit of luck...

as the bodies are off a Puma 1.7SE, ive bought them off him minus the inlet manifold... so ive contacted Jon @ Shawspeed about a Jenvey inlet manifold, he ordered one yesturday, should be here for the weekend with abit of luck then Jon is going to drill and tap it for the Brake servo vacuum for me. You can get DCOE inlet mnaifolds off ebay for cheaper than the jenveys but the jenvey ones keep the same angle as the Port iteslf rather than upright then the bodies pointing directly horizontal so with the jenvey manifold they should have a really nice angle just like the DTH jenveys i had on my ZS

With going down the fuel injection route, im needing to change the Fuel tank, Fuel pump and Fuel pressure regulator too...

I Bought a brand new Mk2 Injection fuel tank yesturday that should be here within the next few days too...

A friend is going to be the brains of this conversion really, Im buying his Omex 600 off him and for that hes going to be sorting me a Engine bay loom too wirirng it all together at his house then just come to mine with it on the day and we'll simply plug it all in and hopefully itll fire up, obvioulsy once the bodies are one, fuel tank etc etc are all plumbed in. Also im having a ERST fuel pump and a FSE regulator too off him which are 2 of alot of random parts andy owns lying around lol

Just taken the carbs, manifold, regulator and fuel pump off -



Manifold arrived thursday, join drilled and tapped it for me and here it is fitted -



brake servo vacuum -



tank arrived friday -



Painted the fittings on the oil cooler to make it look more stealthy -



removed the sound proofing from under the bonnet and cleaned it up -



Got a new fuel filter yesturday, the narrowest one i could find and which was an inline one and had 8mm in/outlets, meant for a 106 xsi lol -



Bodies etc arrived Monday night



... so tuesday i cleaned them all up, worked out how the linkage goes and took the trumpets off ready to fit them... then tuesday, fitted them, mounted the boides then fiddled with the throttle cable and pedal till the butterfyls were perfectly level...

after bending the stopoer bracket on the throttle pedal -



i got this -



then re-fitted the trumpets -





Cant wait to hear them

Fuel tank painted now, had 2 coats of smooth hammerite -



mega progress.........

saturday -

started work on it at 12pm, finished at 8pm, this is what we got done.....


Old tank off (hi andy) -



New tank and fuel pump all fitted after about an hours fiddling -





Filter plumbed in and mounted lol -



FSE fuel pressure regulator (power b0000000st valve) mounted -



then finished plumbing all the lines etc, then put 18litres of tesco 99octane in...

then onto the wiring only pic ive got of any of the wiring -



then finished all the wiring, swapping the pins over onto the omex 200 plug, wired up the fuel pump, conected the battery, fuel pump primed for 2 seonds when turning the keyonto stage 2...

took the key out about 15-20 seconds later we spot smoke pouring out from inside the car... turned out to be this -



all the plastic casing/coating on the wire right from the battery to the fuel pump relay (which is behind my drivers seat and the battery is in the engine bay still) was all like this and burnt off/melted.

with having no more wire and it dark we had to call it a day specially as my internet couldnt get a decent enough connection to download the omex software onto a mates lap top...

ALSO noticed, fuel pissing out all down the side of the front of the tank, looks like ts coming form where i blanked off the existsing lines where they come out the top where you can see n the forst picture, so tank and pump, drain the fuel all again

sunday -

what another day lol............


Went to halfords got 5m of 27amp wire and a fuse holder for the 12v feed for the fuel pump relay, and a new 35-40amp relay which cost a fiver LOL...

got back then andy came we wired the fuel pump etc back up first, i jumped underneath to connect the connections only to notice i wired it up backwards, no wonder it burnt ...

connected the battery and wahey we have a fuel pump that primes spot on and a wire that doesnt set on fire

then tried to link 3 different laptops upto the ECU, all 3 were having none of it, so off to maplin to get a new USB-serial cable... tried that, still no joy...

then tried a direct earth from the omex to the battery and wahey, Brens majic laptop liked to talk to my Omex 600, then after a few touches to the map from andy he truned the key, after lots of Pops/bangs and flames from out the bodies, it wouldnt come to life, went throgh every wire and sensor on the loom, turned out when we swapped the wires on the coil pack (no idea why they are different to the omex 200 as every other wire is exactly the same on the plug)... it livvvedd, not very well but it came to life for about 20seconds...

Also checked the tank when it the car was running and no leaks, so must be leaking from the filler neck, so tank still has to come off etc, sigh

heres the engine bay completed and a new addition -









so as soon as andy can when he comes back to mine, we need to swap the pins over on the coil pack again after bodgeing it up with a spare connector, sort a new earth out for the omex, then go from there hopefully it runs, can mapp it so itll drive nice enough till i can get to Mikeanics, then get the tank down and see where the leaks coming from.


Monday -

Andy came round about 12ish, swapped the pins over on the omex plug for the coil pack, new earth and ignition live to the omex too...

then tried to connect the laptop upto the ECU, still wasnt connectong for some reason ... then tried everything, then went to maplin to get a serial to serial cable and took the car battery, omex and my spare loom in the house to try link it all to my computer and great success! it worked, so then andy sorted all the settings on the omex, took it outside car seemed to run a little better, then took my computer outside, fired in the lambda sensor in the exhaust and begin mapping lol -



did it once took it for a spin, then back again to adjust the fuelling, back out again, then back to adjust the fuelling, then back out again, andy is happy hows its at now, he also took a litle vid which im sure he'll post up when he gets a minute, its still quite rich upto 2k but sweet after that...



And had it mapped yesturday heres the results -






exactly what i expected tbh, and the drive of the car is sooooo much nicer/better now, rediculously smooth and the sound is fkin epic

Problems of the day were...

throttle linkage seperated on the way there and on the way back, so just got a m6 niut to sort that so hopefully no more problems there now and also set the idle to 850rpm.

also noticed the fuel dripping out as it were being mapped like constatly dripping from a few different areas, think its the sender seal on the top of the tank so job for saturday is to drop the tank and see whats what, sigh! so tank off tomorrow job

also just started the car to see how the map is from cold, started without even having to press the throttle at all and after 1min of running its spot on just a little boggy for the first minute nothing major or nowhere near as bad as the carbs were


Current Engine and Transmision spec -

2.0 Zetec E s2 silvertop
Baffled 1800 Sump
Omex 600 Management Mapped by Mikeanics, 175bhp & 143 lbs ft.
Jenvey 45mm throttle bodies with 45x45mm trumpets
Jenvey inlet manifold
Bosch 330cc injectors
ERST fuel pump
FSE fuel pressure regulator
Ashley Heatwrapped Modified 4-2-1 manifold
Ashley 2" single box system with added in flexi joint and custom 2.25" tip
NGK Platinum Spark plugs
Modified Zetec & CVH coolant hoses
Mk3 Zetec radiator
Mocal 13-row Oil cooler with thermostatic sandwich plate
Mocal Catch tank
Lightened & Balanced 1800 flywheel
Helix organic clutch
FRST ratio'd Mk3.5 Si gearbox
XR2i Starter motor


Sorted the tank leak, was the seal on the top on the sender, was a faff after getting fuel in my eyes and hair but got their int he end and no more leaks and after going out for a drive init tnite i must've avereaged 30mpg over the whole journey of very mixed driving which im pleased with...

Heres a couple of Drive by vids for y'all -

http://www.youtube.com/watch?v=GRHVFwkihnk

http://www.youtube.com/watch?v=2GC1xwz2Tk0

http://www.youtube.com/watch?v=XZD3ZDgOLQg

First ones my fave as thats the best spound quality off my mates phone, the other 2 are off my camera, still sounds ace tho


So there we are after nearly 6 months


Ideally could do with a new throttle cable as its sticky quite badly atm and its not nice when your at high speeds and you lift off and your car carries on lol, will get one ordered very soon...

going to re-paint undere the tant tmoz after where all the paints came off where the fuel was leaking too.


Hope you like

jamie rigby

With having the sticking throttle cable issue ive just ordered a Brand new Genuine ford one off ebay, should be here tuesday/wednesday

Also got a Black sunstrip today as my cars a bitch to drive when the suns low, especially was on track, i like the standard look, but function over form is needed sometimes lol

Rab

Nice project!

marky_g

crist this one clean mk2 credit to you on all the work well done!

jamie rigby

Cheers

SiST

iTrader: (1)

Cracking little project you have going on there mate. Lovely motor and great ideas - it must be one great track toy!

Keep up the good work

Si

jonny s2

iTrader: (12)

awesome project mate

i need another mk2 xr2

ZetecSX

you know how i feel about this car Jamie.. ive told you enough times on ZSOC lol.. absolutley love it.. and such a better read on this website, not full of 80 pages of shite..

TimC

iTrader: (1)

When you say your car was smoking earlier in the thread, it looks to be because your breather catch tank (which you have now replaced with a mocal ) wasnt actaully allowing the engine to breathe. Was suposed to have one inlet and a vent to atmosphere on the old breather but it seems you used both ponts for engine only, with zero ventage to atmosphere.

Old - No Ventage


New - Ventage through screw on cap

jamie rigby

Thanks , and not really had enough time with it on track to give an opinion on it tbh haha, bring on february/march time next year

Cheers

yeh haha ive just copied and pasted it all from another quiet forum which gets about 3users online per day lol

when i fitted that old catch tank i binned it off straight away and just pointed the hoses to the floor, which then i found out gave me a wheel arch full of oil at oulton park, all inside the nearside R888 too lol

was breathing like a bastard at Oulton, Oil was like water in the temproary catch tank on that day at 140+ degrees, some people said i needed thicker oil, some people said a baffled sump will help, and obviously a oil cooler will, so ive stuck with the same standard 5w30 oil as the pressure was still good even at 140+ degrees and obviously fitted a baffled sump and a 13-row cooler, see how i get on on the next trrackday

Zetecfiesta

really nice xr2 mate!!

Twins

iTrader: (18)

mattseries2

iTrader: (1)

Really like this!

xr2imetalhead

lovely read m8 a credit to you keep up the good work

zetec-Sam

iTrader: (2)

I want your car

jamie rigby

Cheers for the replies

will keep the progress coming slowly... next plans are -

Throttle cable
Fit the sunstrip
Flush the coolant out as i have a air lock problem somewhere
Paint the road wheels
Custom Cages Full cage
RST LSD
Cams & Arps etc etc

jamie rigby

Throttle cable arrived thursday -



removed the trumpets to get access to the throttle linkage, undone it and slid the old cable out here you can see where its all freyed and where it was catching on the linkage -



so new cable fitted, trumpets back on, much better now hopefully no more sticking throttle pedal!

Fitted the sunstrip last night, looks alright considering it was dark and raining at the time lol -



Just drained the coolant out the heater matirx then filled the system back up and bled it, heater seems to be working again hoefully it'll stay that way and not be inconsistent like it was doing. Just gave the car a clean too after all the firework sh!t all over it lol -

jamie rigby

Problems.......

Went out to a meet saturday night, went to boot it, throttle cables sticking again, just had a look at it now and the problem was the linkage catching a little so a little bend with some pliers and it clears now

heaters blowing out cold air still

and my car started misfiring badly when we came to move on from the pub at the meet, Ive tried the HT leads on my 1.25, there fine, plugs are around 1k miles old, just took them out gave them a clean, they look to be in great condition... waiting for a new coil pack and leads to arrive in the post, should be here tmoz, hopefully its the coil pack, cant see it being anything else!

Just touched up underneath the fuel tank where it all came off from the fuel leak so now i can keep an eye on that but im 99% sure its not leaking now

Minirotty

fantastic project!

jamie rigby

thanks


Coil pack and leads arrived...

Plugged them both in, started the car, misfiring exactly the same ...

had a fiddle with the TPS moved it slightly as it didnt look square on the bodies, that didnt do anything apart from just make the revs rise on its own lol, still running on 3 cylinders... so ive put that back to as it was...

then thought cant see it being anything else other than the Spark plugs, so went to Euro Car Parts got 4 Bosch spark plugs for 5.59 lol, got back fitted them and happy days its running on 4 cylinders again

as ive rounded the bolts off on the coil pack, i need to replace the coil pack and bracket together, the new one came with a bracket but i cba removing the thermostat housing to get to the coil pack bracket bolts so for now im still running on the old coil pack with the new plugs and leads.

Hope its running smooth now and with adjusting the TPS it hasnt altered the map!? as i say its back to exactly how it looked and when revving the car on my drive it feels exactly how it was...

nickwrxstiv2

Nice project!

I used to own a 1.6 cvh on twin DCNF cars with a piper cam. Listening/watching your videos brought back some memories!

Does it keep up with your friends 172?

Judging from your accents are you from the Chester area?

Keep up the good work!

nealo

I enjoyed reading through this dude, great little project and you seem to have perservered with it!!!

Gutted about the Oulton day for you because its a wicked track, my favourite iv been to.

jamie rigby

yeh its quicler than my mates 172, got 3 mates with them, and got another mate with a 172'd Mk1 clio,this is very similar to that

nah warringtoin mate, mates are from leigh area

yeh doen 2 gtrackdays previoulsy in the Zetec S, loved oulton its awesome to have it only 17miles away too


Nothing to update on this really, crashed my 1.25 daily yday, folded 2 of the wheels and bent rear beam, so ive got some coilovers and a new beam on the way, will post some pics up of that when thats sorted too, so now for a week or so gotta use this as my daily, not looking forward to it tbh

Silver'Scort

Looks a cracking piece of kit that does, you've certainly put the hours into it! fair play and well done

jamie rigby

Cheers much appreciated



Fixed the daily, MK5 rear beam, Ap coilovers and a set of Pots later -



anyway back on topic....

Little catch up since the start of december...

went for a drive upto snakes pass and got these couple of pics when we got back to manchester










Drive by vid sounding awesome if i do say so myself -

http://www.youtube.com/watch?v=DJXwf...eature=related

random pics -






Tbh the cars hasnt missed a beat since it was mapped, which im really happy about, not used a drop of oil after some hard drives and abuse, everytime i drive it it puts a smile on my face i just try drive it as less as possible so that feeling wont go away any time soon...

Then on Saturday just gone, took a trip up and over Snakes pass to Rotheram in my MK4 1.25 daily weapon -



to collect this (just resting in place obv.)-



Full Safety Devices cage, got for a good price, looking forward to having some plates welded into the car then going to bolt the cage in through them, dont fancy welding it in.

also picked this up too which the guy was selling...

Fibre glass single skinned carbon wrapped bonnet with 5 bonnet pins ready to be fitted to car for a STUPIDLY low price, its like a feather must be at least 10-15kgs weight saving over the standard item -





Can't wait to get them both fitted, more soon

jamie rigby

Oh and 1st Trackday of the year booked... Oulton Park, Saturday 5th March

Shilly

looks mint surprised i havent seen you around
should be doing a few track sessions at oulton this year may see you there

jamie rigby

i hardly ever drive it tbh lol, once a week if that, cars pretty useless in the wet on the raods tbh...



Cage all done plates welded in and bolted in -











note there are no door bars in yet, due to the ones i got with the cage are s**te and dont fit, well they do but at chest height so going to sort some proper ones once ive had a few words with f0xy also going to add one or two more bars into the cage too for more strength