Mk2 Fiesta Xr2 ZT, gt30, now breaking :(
22-04-2012, 03:03 PM
#121
I'm making a start, at the min I'm waiting on money for body panels ( having to spend all spare cash on the bike getting it ready for m.o.t :/ )
Next step will be welding, both rear arches, sils, front flitches, wings and front panel lol... Floors are solid inside tho
Will get a thread up when I get it started, just doing little bits at the min tho
Next step will be welding, both rear arches, sils, front flitches, wings and front panel lol... Floors are solid inside tho
Will get a thread up when I get it started, just doing little bits at the min tho
22-04-2012, 09:50 PM
#122
all our cars have MOT's in the next six weeks, i know of a couple of problems easily fixed, but it's the unknown that costs. that said i still put fuel in the xr2 and go out for drives, always a mapping session, running fairly well at the moment, just a little lean on cruise making it a little hesitant and too much fuel on boost, but hard to capture what is happening till in high gears but breaking clutch back in at the moment, so got to take it easy on that bit.
newly made parts going on tomorrow and setting up camber and tracking with some gear i've bought to get this spot on this last week
camber is 0 degrees on one wheel and 1 degree negative on the other, tracking is a mile out, drivers side is spot on, passenger is in excess of 3 degrees out minimum.
newly made parts going on tomorrow and setting up camber and tracking with some gear i've bought to get this spot on this last week
camber is 0 degrees on one wheel and 1 degree negative on the other, tracking is a mile out, drivers side is spot on, passenger is in excess of 3 degrees out minimum.
10-05-2012, 09:47 PM
#123
been a couple of weeks since an update, suspension is much better now, no rubbing apart from full lock on innerwings, so not all in vane at least and pulls much better in a straight line, just tweeking with a bit of toe to help through corners.
since doing this engine build i have suffered with little electrical gremlins on the engine loom, so i've ordered up a load of new cable, connectors, loom protection etc. so will be making a new loom next week, should behave better and look spot on (got to be better than the recycled old ford items). also bought a few other little bits to get on in the next week so should have some updates on this shortly.
on the plus side, clutch is happily holding a BAR peaking at 16psi at the moment, just taking it easy for now, hoping to break into the 20psi+ area soon as it's needed after third gear to get it moving a bit quicker.
i'd definitely recommend the FRS brakes too, it really has shortened the stopping distance over the cosworth 4wd setup, but you have to go to big rims. They don't stand out too much though, even everyone at a meet that commented on the bigger wheels thought they were 15's
and i've misplaced my standard lights, so no movement on the clears lol!
since doing this engine build i have suffered with little electrical gremlins on the engine loom, so i've ordered up a load of new cable, connectors, loom protection etc. so will be making a new loom next week, should behave better and look spot on (got to be better than the recycled old ford items). also bought a few other little bits to get on in the next week so should have some updates on this shortly.
on the plus side, clutch is happily holding a BAR peaking at 16psi at the moment, just taking it easy for now, hoping to break into the 20psi+ area soon as it's needed after third gear to get it moving a bit quicker.
i'd definitely recommend the FRS brakes too, it really has shortened the stopping distance over the cosworth 4wd setup, but you have to go to big rims. They don't stand out too much though, even everyone at a meet that commented on the bigger wheels thought they were 15's
and i've misplaced my standard lights, so no movement on the clears lol!
16-05-2012, 09:42 PM
#124
well i got a delivery this week
that was all i needed to make a new engine loom up from, there was major issues with the tps and i wanted to get rid of much of the old ford wiring that was used for the previous loom. Good news is the tps signal is incredibly stable, virtually no smoothing required, so can now get the acceleration enrichments sorted.
A new usb to serial cable arrived also, it uses ftdi chipset and hasn't cut out yet, much better than the prolific ones. If you are using self programming ecu's then i'd recommend one especially megasquirt and megajolt.
when i made my adjustable TCA's i ruined a couple of adjusters in the process :blub:, but managed to salvage one with the help of the lathe, so will be modding the panhard rod tomorrow along with converting the rears to studs to match the front.
hopefully i'll get some time painting the kit and bumpers, just a bumper paint, no colour coding going on as they're well past their best.
that was all i needed to make a new engine loom up from, there was major issues with the tps and i wanted to get rid of much of the old ford wiring that was used for the previous loom. Good news is the tps signal is incredibly stable, virtually no smoothing required, so can now get the acceleration enrichments sorted.
A new usb to serial cable arrived also, it uses ftdi chipset and hasn't cut out yet, much better than the prolific ones. If you are using self programming ecu's then i'd recommend one especially megasquirt and megajolt.
when i made my adjustable TCA's i ruined a couple of adjusters in the process :blub:, but managed to salvage one with the help of the lathe, so will be modding the panhard rod tomorrow along with converting the rears to studs to match the front.
hopefully i'll get some time painting the kit and bumpers, just a bumper paint, no colour coding going on as they're well past their best.
16-05-2012, 09:59 PM
#126
loom took me forever, but the tps signal is superb now though. i've turned the lag factor down to 100% and at worst it gets a 5%/s fluctuation at worst, which is far better than around 200%/s (with a 15% lag factor) it was before and better than the 15%/s (with a 30% lag factor) i had on my zvh setup. bigger lag factors mean less smoothing so more accurate and responsive.
brand spanking cabling pays dividends
it's about time i took it out more, i've washed it more than driven it in the last fortnight
brand spanking cabling pays dividends
it's about time i took it out more, i've washed it more than driven it in the last fortnight
23-05-2012, 10:50 PM
#129
well the re-wiring of the loom didn't go to plan, there was a slight break in the link cable from ecu plug to the cps wire, it ended up causing a massive pain finding out why the tach signal kept dropping out. took days to find the fault, rechecked every join, connection, changed cps and the shielded wire. sorted it though and there is virtually no noise on any sensor, even the tps which are known for noise.
other things done were to make the pan-hard rod adjustable, converted the drums to studs, painted bumpers in Halfrauds bumper paint along with starting to paint the kit. There is most of the kit to finish, but looks so fresh now to how it was.
i also fitted form S/H poly bushes for the rear springs, the old ones were properly knackered, feels much tighter on the rear now.
so on that i took it out for a spin, clutch held well up to 17psi, but the exhaust is still full of oil from the last turbo leaking oil, it's a little embarrassing as is the gearbox fluid burning off the heat wrap on the exhaust just need to get those two issues sorted and i will be a happy man.
just need to get my tickets sorted for Ford Fair now and get some track time
that's all so far
sean
other things done were to make the pan-hard rod adjustable, converted the drums to studs, painted bumpers in Halfrauds bumper paint along with starting to paint the kit. There is most of the kit to finish, but looks so fresh now to how it was.
i also fitted form S/H poly bushes for the rear springs, the old ones were properly knackered, feels much tighter on the rear now.
so on that i took it out for a spin, clutch held well up to 17psi, but the exhaust is still full of oil from the last turbo leaking oil, it's a little embarrassing as is the gearbox fluid burning off the heat wrap on the exhaust
just need to get those two issues sorted and i will be a happy man.just need to get my tickets sorted for Ford Fair now and get some track time
that's all so far
sean
25-05-2012, 07:01 PM
#131
i skimmed the clutch cover and been breaking it in for a few weeks, upto 17psi now and holding very well so far.
another few hundred miles and get it up to 2BAR, If that doesn't work then i'll look into a replacement as i have a little more cash spare these days.
another few hundred miles and get it up to 2BAR, If that doesn't work then i'll look into a replacement as i have a little more cash spare these days.
02-07-2012, 10:02 PM
#133
i bought all the new wiring and parts through autosparks, easy to find, took ages to process all the individual colours though.
well, i've had a bit of a saga with this lately and had written up a price list for stripping it, then i thought one last stab at fixing it and found a massive power loss issue in the form of a collapsing air hose into the turbo. when i hit boost it sucked so hard the pipe crumpled and stopped airflow causing all power to be lost, changed pumps, had bits modified, new coil, leads etc.
all this has done is made me enjoy driving it again and fund a new clutch setup, so will have the AP 6 paddle ordered tomorrow and fitted next week, about time i dug deep and bought one, not a bad price at Ł432 delivered.
other than that, it's brilliant just needs to get upto 2BAR and on some rollers as soon as i can.
well, i've had a bit of a saga with this lately and had written up a price list for stripping it, then i thought one last stab at fixing it and found a massive power loss issue in the form of a collapsing air hose into the turbo. when i hit boost it sucked so hard the pipe crumpled and stopped airflow causing all power to be lost, changed pumps, had bits modified, new coil, leads etc.
all this has done is made me enjoy driving it again and fund a new clutch setup, so will have the AP 6 paddle ordered tomorrow and fitted next week, about time i dug deep and bought one, not a bad price at Ł432 delivered.
other than that, it's brilliant just needs to get upto 2BAR and on some rollers as soon as i can.
02-07-2012, 10:56 PM
#135
i shouldn't listen to si , that was one bad piece of advice, well one bad piece amongst loads of good stuff 
i may even get my t04b rebuilt and then get chasing the potential again, crappy turbo on it would be at best hit 400bhp, not full of hope on that though.
, that was one bad piece of advice, well one bad piece amongst loads of good stuff i may even get my t04b rebuilt and then get chasing the potential again, crappy turbo on it would be at best hit 400bhp, not full of hope on that though.
02-07-2012, 11:37 PM
#138
a piece of cheap engineering, literally paid Ł60 posted for it as a temporary fit, but actually is doing well indeed.
i think the ball bearing one will get new seals soon, could have done with a restrictor i think, although wasn't specified in the instructions but started leaking oil more and more.
i think the ball bearing one will get new seals soon, could have done with a restrictor i think, although wasn't specified in the instructions but started leaking oil more and more.
10-07-2012, 10:29 PM
#139
well i'm taking the ball bearing turbo to get sorted this week, i think it's a necessary route to chase stupid power.
still waiting for my clutch to arrive, ended up Ł443 delivered, so not too bad, not that it needs more power as getting it down is a pain, even at 18psi.
hopefully it'll pass it's MOT next week and get clutch in should it arrive soon.
on another note, i'm still pulling fuel out of the fuel map up high, seems to be getting better transitional fuelling across the tables now, much nicer to drive indeed.
so an update once clutch is fitted and get it on a set of rollers at last.
still waiting for my clutch to arrive, ended up Ł443 delivered, so not too bad
, not that it needs more power as getting it down is a pain, even at 18psi.hopefully it'll pass it's MOT next week and get clutch in should it arrive soon.
on another note, i'm still pulling fuel out of the fuel map up high, seems to be getting better transitional fuelling across the tables now, much nicer to drive indeed.
so an update once clutch is fitted and get it on a set of rollers at last.
10-07-2012, 11:36 PM
#141
hmmm, R+B could get one in two working days, i think i'll make a call to J-W-Racing and find out the score on these, not too bad if it is a long wait, but need to know for pulling engine out before ford fair.
update, it should be here by weekend, problem getting the paddle plate, but the cover was in stock, seem a decent supplier so far.
update, it should be here by weekend, problem getting the paddle plate, but the cover was in stock, seem a decent supplier so far.
Last edited by xr2wishy; 11-07-2012 at 12:32 PM.
11-07-2012, 06:31 PM
#142
Too many posts.. I need a life!!
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great work mate 
ive alway's had a soft spot for these great little sleeper..I bet it's great fun to drive about in a right little xr2 rocket 
i bet when people see this drive off they look like this lol
ive alway's had a soft spot for these great little sleeper..I bet it's great fun to drive about in a right little xr2 rocket i bet when people see this drive off they look like this lol
11-07-2012, 10:53 PM
#144
still no power figures, always had issues with the clutch. basically i was advised to use a frs cover and cosworth paddle and would take 550bhp, well that was far from the truth, the best i've had from it was holding 18-20psi tonight, then slips like mad.
new one should be here tomorrow or friday, so engine out tomorrow and can solve the oil leak from feed into turbo and the one from the sump pan too.
tidy a few bits up and put the lot back in again.
been out to a meet tonight so had a little play, the thing is just stupid, the only worry is the injectors are well over duty at 111% duty cycle, doesn't seem right, they are 630cc ones and should easily handle 400-450bhp, something amiss here, may raise base pressure to 4BAR since fuel pump can handle 8-10BAR inclusive of boost raising.
so when it's back together it will get a rolling road run, hoping to break 350bhp @2BAR, any more will be a bonus i reckon.
new one should be here tomorrow or friday, so engine out tomorrow and can solve the oil leak from feed into turbo and the one from the sump pan too.
tidy a few bits up and put the lot back in again.
been out to a meet tonight so had a little play, the thing is just stupid, the only worry is the injectors are well over duty at 111% duty cycle, doesn't seem right, they are 630cc ones and should easily handle 400-450bhp, something amiss here, may raise base pressure to 4BAR since fuel pump can handle 8-10BAR inclusive of boost raising.
so when it's back together it will get a rolling road run, hoping to break 350bhp @2BAR, any more will be a bonus i reckon.
12-07-2012, 09:58 PM
#146
well all ready for dropping engine in the morning (in laws forgot to bring chains back), then sort leaking sump and get clutch off for new one once it arrives, hopefully tomorrow
good job i'm doing this as one of the cv boots slid off and exposed the bearing on the near side shaft/coupling. luckily still greased up and clean.
ooh and a peak of a proper motorsport pump from a WRC car used for one meeting (on the left):
good job i'm doing this as one of the cv boots slid off and exposed the bearing on the near side shaft/coupling. luckily still greased up and clean.
ooh and a peak of a proper motorsport pump from a WRC car used for one meeting (on the left):
Last edited by xr2wishy; 12-07-2012 at 10:02 PM.
13-07-2012, 10:04 PM
#148
engine and box is all out, ready for engine bay to be cleaned up in the morning.
a package arrived today and contained these goodies:
so now i'm skint, so thought bugger it, engine is out i'll sort rocker cover leak and sump pan oil leak and why not change timing belt and pulleys as it's an engine out job now.
oil and filter, why the heck not, just on reasonable stuff, need to get some tri-ester oil in there soon, so i reckon on a few more miles and drop it before ford fair.
so a busy weekend ahead assuming the flywheel is nice and flat, if not, it's another couple of days holding me back.
wish me luck lol!
a package arrived today and contained these goodies:
so now i'm skint, so thought bugger it, engine is out i'll sort rocker cover leak and sump pan oil leak and why not change timing belt and pulleys as it's an engine out job now.
oil and filter, why the heck not, just on reasonable stuff, need to get some tri-ester oil in there soon, so i reckon on a few more miles and drop it before ford fair.
so a busy weekend ahead assuming the flywheel is nice and flat, if not, it's another couple of days holding me back.
wish me luck lol!
18-07-2012, 07:04 PM
#154
PassionFord Post Whore!!
22-07-2012, 10:02 PM
#156
for a while i've had a bit of smoke causing me a headache, wouldn't clear and only seemed to stay as bad. So i had a parcel arrive and i fitted these this evening:
thanks to MK, great price and fast delivery
so i re-timed the cams and the smoke seems to have cleared up, i may had too much overlap and caused un-burned fuel to go directly into the exhaust/turbo. anyhoo, seems to pull better, really arse to time the cams for the correct lift on overlap, much easier to time with full lift, but Ian Howell from area six recommends doing it on overlap lift.
i thought i'd just give it a bit of a thrashing to break the clutch in, much better.
soon be FordFair and may get some track time booked in.
started remapping and with the new timing on the cams i've taken nearly 15% out of the fuel map on idle alone, time to save fuel
thanks to MK, great price and fast delivery
so i re-timed the cams and the smoke seems to have cleared up, i may had too much overlap and caused un-burned fuel to go directly into the exhaust/turbo. anyhoo, seems to pull better, really arse to time the cams for the correct lift on overlap, much easier to time with full lift, but Ian Howell from area six recommends doing it on overlap lift.
i thought i'd just give it a bit of a thrashing to break the clutch in, much better.
soon be FordFair and may get some track time booked in.
started remapping and with the new timing on the cams i've taken nearly 15% out of the fuel map on idle alone, time to save fuel
Last edited by xr2wishy; 22-07-2012 at 10:08 PM.
25-07-2012, 08:21 PM
#157
i must have caught the boost controller and changed the setting, i got 26psi today, went alright, fuelling was fine as i'd put some rough figures in and not far off at all, ignition i think could do with a little more timing, but will see when i'm det canned up.
still getting a little smoke though, much less than before, so i may have a tweak with the cams to see if that can help, no oil in exhaust ports or exhaust after turbo, water not being used at all.
it's a bit odd, will get an adaptor for compression tester and have a check, i did initially think stem seals, but i'm not so sure now.
can cam timing make it smokey?
i'd think the only way would be unburnt fuel entering the exhaust, so later inlet opening or earlier exhaust port closing could be a reason if the exhaust is scavenging through the cylinder breifly.
still getting a little smoke though, much less than before, so i may have a tweak with the cams to see if that can help, no oil in exhaust ports or exhaust after turbo, water not being used at all.
it's a bit odd, will get an adaptor for compression tester and have a check, i did initially think stem seals, but i'm not so sure now.
can cam timing make it smokey?
i'd think the only way would be unburnt fuel entering the exhaust, so later inlet opening or earlier exhaust port closing could be a reason if the exhaust is scavenging through the cylinder breifly.
26-07-2012, 11:42 PM
#158
well the smoke is oil related, i opened the waste gate with the air compressor and no smoke, the system was smoky.
cheap turbo's are rubbish and do not like 26 psi, on the hunt for a replacement this week, budget has been blown big time, gtx2867r, or similar in power and spool is the way to go.
cheap turbo's are rubbish and do not like 26 psi, on the hunt for a replacement this week, budget has been blown big time, gtx2867r, or similar in power and spool is the way to go.
05-09-2012, 07:48 PM
#159
well, not updated for a little while, i did end up replacing the turbo, got a GT3071r, got it for a good price and it took a fair amount of mods to get it in as the turbine housing put it all in a slightly different angle.
the breather was chopped about, compressor housing machined to clear block along with new oil return, exhaust adaptor made and water cooling fitted.
the only issue was a leaking rocker cover, as i'd replaced the gasket a week before i knew it wasn't that so applied a thin bead of sealant to the face, put it on lightly and let it cure before clamping it down fully.
ran it to fordfair and back, suffering failure on the alternator as the bearings ate into the casing though, so didn't get it down the 0-60
replaced that now, still not spot on, voltage doesn't rise to the correct level, but could be an electrical gremlin in the cars wiring somewhere, it is 25 years old though.
nice and tight in there, just the braided water pipes running to either side of the engine so it flows all the time.
it runs pretty well, just surges a bit when i got to 1.6BAR, should be able to map that out though.
the breather was chopped about, compressor housing machined to clear block along with new oil return, exhaust adaptor made and water cooling fitted.
the only issue was a leaking rocker cover, as i'd replaced the gasket a week before i knew it wasn't that so applied a thin bead of sealant to the face, put it on lightly and let it cure before clamping it down fully.
ran it to fordfair and back, suffering failure on the alternator as the bearings ate into the casing though, so didn't get it down the 0-60
replaced that now, still not spot on, voltage doesn't rise to the correct level, but could be an electrical gremlin in the cars wiring somewhere, it is 25 years old though.
nice and tight in there, just the braided water pipes running to either side of the engine so it flows all the time.
it runs pretty well, just surges a bit when i got to 1.6BAR, should be able to map that out though.
08-09-2012, 11:30 AM
#160
surge, surge, surge!!!
it doesn't rain it pours
basically when over a BAR of boost the boost oscillates, i don't think it's boost controller related though, more boost level.
i have yet to swing on the cams to find if there is a mechanical way of combating this, or maybe pull some timing out to see if that helps. absolutely doing my head in, all that's been changed is the turbo and inlet timing is a couple of degrees different to make it idle better as it was a right mare.
anyone local to help out a poor user who can't afford a pro to sort it
it doesn't rain it pours
basically when over a BAR of boost the boost oscillates, i don't think it's boost controller related though, more boost level.
i have yet to swing on the cams to find if there is a mechanical way of combating this, or maybe pull some timing out to see if that helps. absolutely doing my head in, all that's been changed is the turbo and inlet timing is a couple of degrees different to make it idle better as it was a right mare.
anyone local to help out a poor user who can't afford a pro to sort it