Looking good not long now !!!

 

 

been a while since i've updated, well the thing runs.
got it all together, oil pipe was leaking to cooler, so got them sorted out and then dropped oil and all back together and started fine.
had a faulty spark plug and so got some denso irridium ones, fitted those and ran fine.
but then i started trying to map the idle and then get it moving properly and found a fault with ecu causing calibration to go out for the afr, so mapping was damn near impossible using logs. ecu has been sent off and should be back shortly with some upgrades added too.
so this is how it stands so far (forgive camera phone quality pics):





going to move alarm unit and fit washer bottle in it's place, still needs loom tidying up and relocating when i fit it back in. then tidy interior and fit all covers back in place and get it in for the MOT and get mapping/running in/abusing it before FordFair track time.

 

 

I've just looked into the sound limits for track time at Ford Fair and i'm thinking i'll have to quieten down the exhaust. I'm not sure how load on a dB meter it is, but it's loud on idle.
still it's not running at the moment due to no ecu, but i'm off work soon for a week or so and will be getting it on the road fully then.

 

how does heatwrapping the exhaust pipe affect the performance? was considering doing it to mine!

 

no idea how it effects performance to be honest, it should reduce under bonnet temps which is crucial and keep gas velocity up due to the extra heat.
to be fair it only cost me Ł20 for the wrap inc ties, got a massive discount for helping a lad out.
i've not had it running well as the tps/afr signal was screwing up running for mapping and couldn't make any real boost or power.

 

right, i've had the ecu come back with LC added and coil on plug mods for when ichange to those instead of the central pack and leads.
fiddled with a few things and it's alive, idles nicely, no hunting.
drives ok bearing in mind the ignition and fuel maps are way out, even felt a little boost on way back from MOT, which it passed today.
just need to change tyres and get radiator changed as it's leaking a little and i've an oil leak, i think rocker cover, but may be sump pan too.
either way will be sorted asap.

only other thing to sort is another silencer as it's way too loud.

happy days

i'll get some newer pics up tomorrow of the other bits i've added and/or had to move.

cheers
sean

 

will be a flyer

 

Amazing work there mate

 

Looking good mate

 

been a while, had a lot to do to this for FF last week, lots of last minute changes and so i didn't get it how i wanted it, but a little time today and i have now got it right.
last week i added an additional silencer, however this really messed up the position of the exhaust but to get to FF, i just ran with it, so chopped it a bit and re-welded and all is good again.
also fitted a much bigger power cable from alternator to battery, that has helped get voltage up to 14v, but i suspect my electrical gremlin which is the earth carrying a small voltage is to blame for not getting more. I will investigate more by removing earths till i find the culprit.
having doen the journey to FF and back the heat wrap on my screamer pipe dropped off and so that's back on
managed to do 400miles now since building and no major issues, apart from clutch is slipping a bit, i suspect it's just bedding in or slave isn't releasing fully, i'll know for certain in a few weeks if it doesn't sort itself out though.
front wheels are slightly buckled (i must stop buying used wheels), they balanced up ok, but at 130mph on the stack speedo some of the weights fell off, so need sorting or replacing, i am looking at getting some BN comps though
so 400 miles of running in and running only 9psi of boost and this is how it stands as of today, feels so quick compared to the old 1.8zvh even on such low boost.
and here's some pics of how it looks as from today:









still loads to do, might go out and get some miles on the engine tomorrow, still got 600miles till run in fully.

 

that looks great pal!

 

looking good mate im running 305hp now and got some shafts from your guy under his house lol realy small down there lol

 

it's like aladdins cave isn't it
i've had no probs on the shafts so far, just a slipping clutch on boost, but that is settling down already. i plan to get on the rollers asap when i've got a little more live mapping done, would be good to see how the turbo end engine perform to give a figure of the output, should be good though given the time and money put into it this year

 

yea he sent me round the side of his house en he nearly knocked me over when he kicked the door open

he had just enouth steel left after making your shafts to make mine WINWIN LOL

i walked passed your fez at ford fair but dident see ya near it that and i have no idear what you look like or i would have said hello lolol

i was on the fast ford stand

 

it is really odd, but you can't argue at the price, far cheaper than anywhere else. i did think of getting them hardened, but being the hardest material he could work with, i didn't think i'd have anywhere enough power to break them ever.
i kept going wandering around at FF, didn't make i to half the stands, missed the PF one completely. i didn't even make it on track either, prob best for a barely run engine i guess lol!

 

well the rewire of a couple of things worked, wideband and ecu are talking properly and voltage is up to 14v, just need to solve the low voltage issue and job done/
did a bit of driving and mapping and it's so much nicer, pulls really well, only taken it to 6100rpm though, well of limiter
bit of a tweak tomorrow to alternator wiring and a drive should see charging good at last, along with revising auxiliary tensioner setup as it's slightly out of line as a direct fit.

 

more stuff done, sorted alternator pulley setup out so auto tensioner actually works and in-line by mounting it on a newly made bracket. seems the mazda part that mounts perfectly to the PAS bracket isn't a straight fit for running after all.
also sorted wiring prob for electric window on pass side, just a broken wire.
found a slight oil leak from the oil return, clearly my welding wasn't as good as i hoped, tiny leak, but still there. got a little smoky sat in traffic for a couple of minutes once in several hours of an outing.

then the weirdest thing happened after pulling out a right hand turn hardish on throttle through first and second, car started pulling all over the place and off throttle it was pulling to the left and right on throttle, then did some medium braking and all sorted itself out. will investigate tomorrow i think.
other than that, mapping is going well and pulls crazy at only 9psi on the base setting of wastegate on current spring (got another waiting to be fitted later)

 

Love this car apart from the tints and the wheels!!

 

i'm thinking of RS7's actually to replace rims
tints, on when i got car seven years ago and hide things inside like speakers etc.

 

well, now got 730miles on the clock, been a long time coming. but apart from an alternator failure it's been pretty much spot on.
went to Blackpool day today and it was a complete joy to drive it, first time i've just gone somewhere without timkering first.
i did turn the boost up on my last time out and took it to 15psi, but clutch started slipping, so i've stuck with it and it's breaking in nicely, by the end of the day no slipping

hopefully i'll get to the magic 1000miles and then get oil changed again and get it on the trollers for a couple of hours and get some print outs of final figures of power

 

That is gonna be a very quick xr2 defo try get some rl7s for it will look stunning keep the pics coming great build

 

i'll get some more pics up when i get round to cleaning, it's not a very clean car to be honest :blub:
just debating stripping the subs and amps out and turning it into a track car instead, however it's so nice to have a rediculous road car though.

 

Looked great at Blackpool Ford day yesterday mate.

I have a very big soft spot for this car!

 

who modded your exhaust mani, as we want our to be rotated like yours? cheers

 

Different wheels, they look horrid

Awesome car though, bet you can't wait to reach that 1k mile mark

 

his manifold has not been rotated! his turbo has tho .

 

thats wat i was implying, is it a modded 200sx one that you do gary?

 

yes , aswell bespoke ones.

 

the manifold was from gary, i added the external wastegate and rewelded the flange as i wanted turbo the other way round, reduces pipework and sits much tighter to the block.

wheels are like marmite i guess, can't afford some comps or speedlines d
sadly, so they'll be staying till i can.

and yes it's bloody good fun, very strong pull and very grippy even on toyo t1r's.

 

barely had any time of late, but managed to get the charging issue solved, cleaned the battery terminals and the crappy corroding terminals from burton power and that helped a little, then changed rectifier to a 15v one and i'm getting a solid 14.4v to the battery now.
so at last i can use some electrics in the car and have no worries about stopping away from homeother than that, i think the gaz coilovers are ready for a rebuild, shocking how quickly these fail in my opinion, barely done many miles on them really.

 

thats not good to hear i wanted a set of gas coilovers lol

 

i'm not greatly impressed to say the least, even worse is i have no spares to pop on either.
i'll wait till winter, they're still useable, but not their best anymore.

 

love it, you doing really well with that. very cool xr2

 

cheers
just started making the kit black again today, got a whole day set aside for sanding it back and matt black painting it for winter, the test bit i did looks loads better and was with little prep work, so the finished effect will be so much better.

 

just found this vid mate recorded on his phone about a week ago when i took it up an airfield on an alfa romeo club meet thing:

crap quality i know, but pulled in fifth from 70 to just short of 120mph in about seven/eight seconds, only a BAR of boost, was a spur of the moment run really.
it'll be mental when i've changed the oil again next week and up the boost some more, and had it on the rollers if the weather is cold on saturday morning.

 

awesome mate,love it.cant wait to do mine now

 

you'll love a zetec turbo, far better than a cvh or zvh turbo setup.
i tried to get more boost out of my controller today but the limit of the wastegate springs has been reached, so i'll pop the other one i have in along side the current one and should hold a BAR minimum and i'll control the rest.
also i need to send coilovers off for rebuild and get stiffer front springs, on lift off over run the car pitches quite a bit handling isn't as good as it once was. very disappointing given the shocks have only done around 6k miles in two and a half years.
good news is that i'm nearing the first thousand miles now and no dramas to report and mapping is getting there, fairly smooth delivery of power and drives nicely around town (clutch engagement is a little jerky sometimes though).
hoping to get it on the rollers as soon as the weather cools a little

 

going well mate keep it up