Turbo Zetec

iTrader: (1)

Hi all,

unfortunately last week, i sold my project of 7 years (https://passionford.com/forum/restor...rth-build.html), just decided it was getting nowhere! So instead, i've decided to modify my daily driver, a 50k from new 1.8lx Sapphire

Here are a few pics:




had a little go at making the spoiler red:



some pikey twat decided to try and take it from outside my house, luckily enough i caught them at it and administered a beating the damage:



Also got some nice new bits yesterday for the body in exchange for a few of my escos spares:



i've got alot of the mechanical parts sitting around, will update later with what the plan is, as i've gotta head to work now .

Marcyg

Should be good. Not many Zetec Sierras around, will be watching with interest. Hope you gave the theiving scum bag the beating of his life and the little fucker needed an ambulance to get home

jonny s2

iTrader: (12)

will be cool with the zetec in

Adam31

These are rare with zetecs, should be done more in my opinion. Good luck with it.

Turbo Zetec

iTrader: (1)

right, a bit more info! i have a collection of parts here for the car, some others on their way. the plan is:

body:
cossie kit, radiant red, mmm.

Suspension:
2wd konis, 20mm rear arb

Brakes:
4wd calipers all round, 4wd discs rear, st170 discs front.

Transmission:
MT75 2wd box, cossie clutch, supra rear diff.

Engine current plan:
1800 Silver top zetec bored to 81mm (0.4mm oversize), vag pistons on modified zetec silver top rods, standard crank, standard pulleys and flywheel. Head will have 1mm oversize inlets & 3mm oversize exhaust valves, slightly ported but ports kept small. standard 2.0 cams, although i may end up using a smaller profile exhaust cam. 1mm shims under springs to cope with extra pressure from turbo. T3 cossie 4wd turbo or similar on modified 200sx tubular manifold. Inlet will be a modified pulsar plenum to accomodate a single throttle body connected to the head with a weber dcoe type zetec manifold.

management will hopefully bee saab trionic 5 (see http://trionic.mobixs.eu/ for why i'd use it), just need to make sure i can get it to work on the car.

thats all for now, let me know your thoughts!

Byrnes1

Make sure this one doesn't take 7 years!
Have you managed to knock up a bracket for the calipers yet from the measurements I gave you the other day?

Turbo Zetec

iTrader: (1)

Having just worked out some compression ratios, i've decided to rethink the engine and will instead be going for a 2.0 with vaux XE pistons.

in other news, i'm now the proud owner of this:

http://cgi.ebay.co.uk/Toyota-Supra-M...item4aaa682b17

and this arrived in the post today:

http://cgi.ebay.co.uk/Cosworth-AP-4-...item3f0993865b

Turbo Zetec

iTrader: (1)

i'll try to do this one a bit faster

not made/making any brackets until i buy the discs, just incase i see something else that i fancy instead

Turbo Zetec

iTrader: (1)

small update time! i've recieved a couple of bits and had a little play around. i started tonight my replacing my knackered rear speakers with some out of my old cossie, but this time i made them fit in the original holders with the original fixing setup . this is how they're looking now:



i also removed the lock that was damaged so i can get it welded up sometime this week, taped over for now:



my bargain clutch turned up! best thing is, it fits in this zetec cover plate. just hope the pressure is enough for the power! the regular cossie friction plate overhangs the edges slightly whereas the paddle is perfect :



i also recieved this diff:



another bargain, toyota supra! supposedly from a N/A, but it seems by the rough working out of the ratio and the fact that it has a clutch type LSD its most probably from a turbo model. hopefully the fact that it has twice the amount of planet gears as the ford one means it won't break so easily.

thats all for now, sorry it's nothing really interesting! will get some engine progress pics up when i can

-beefy-

iTrader: (6)

well done fella,

glad to see u aint given up completely

Turbo Zetec

iTrader: (1)

i'll never give up . just thought as the saff is a nice example, i'd have a play around with it

it'll be slow progress, but i'll hopefully have a nice unique car by the end of it

Zetecfiesta

looks like a good start!

Turbo Zetec

iTrader: (1)

done a little bit today! pulled my block apart, resulting in:



one bare block ready for some machining! and:



one scrap bin full of useless parts!

also i sorted out my pistons today, had 9 to choose from, so i picked the best 4. here's a pic of one of the pistons i decided to use:



the block is going to be rebored & plateau honed, line honed (with early caps instead of late, as i want to fit the early sump and windage tray) and faced.

should hopefully get some of that done tomorrow and possibly get my rods and pistons together too

Turbo Zetec

iTrader: (1)

righty ho, another update! i've got a fair bit of work done today, so all is good . had a hunt around last night and found a mint looking st170 crank and oil pump, a set of early main caps and bolts, a front pulley, flywheel and clutch cover. hopefully i can get these balanced before the weekend gets here.

anyway, when i got into work, my block had been bored (by somebody who was 'bored' ):



so decided to face it, here's a pic before:



and after:



i also honed the rods to take the vauxhall pin as an interference fit:



lastly, here's a pic to show why i'm converting to the early mains:



those blacktop ones seem very thin!

anyway, more to come tomorrow hopefully

Byrnes1

Progress is going at a decent rate.
Are you using a black top 2.0 or silvertop, it looks like a blacktop from the pics?
Anyway the move to early mains looks like a wise one.

-beefy-

iTrader: (6)

your a jammy git lol !

Turbo Zetec

iTrader: (1)

It's a black top block, chosen because its what i had kicking around at the time

why jammy beef? jealous of my machines? haha

small picture updaye today really, only got this one to show you:



got it line honed today . I also checked the st170 crank for straightness and balanced it, checked the ST170 oil pump which was perfect, cleaned the ring grooves and faced the flywheel

just gotta balance the fly and clutch cover tomorrow, then should be able to start putting it together

Turbo Zetec

iTrader: (1)

Mini update - the project was cancelled due to lack of funds and i almost sold the car. I decided to keep it as a daily driver as i love sierras really... This week however it let me down. The cambelt snapped on my way home from work, so now i've got to pull my finger out and sort an engine. A nice 300bhp will do me for now!

I've already sourced several parts including an exhaust, FRS clutch cover, cossie t3, CVH sierra mounts and sump (although i may make a big wing ally sump).

Aiming to get this done by my birthday in a couple of months, as i've got a couple of friends coming down from up north and want to scare the bejeesus out of them on the way back from the train station!

Glenn_

iTrader: (1)

I thought what a cool project then realised its nearly 3 years old.

So are you putting the zetec lump in the sierra now. I like all the sierra models too.

turbo m

iTrader: (2)

Good to see you still sticking with it.

Turbo Zetec

iTrader: (1)

well it's been a while...

Unfortunately after the cambelt failure almost 2 years ago and i decided to buy a vectra as a runaround. due to having a perfectly good working car, i lost interest in this a little, Until now!

basically all of the progress from this thread may as well be disregarded, as i sold most of my parts. I am however sticking with the zetec turbo idea. the car is currently stripped with the engine, box and diff out, dash out, doorcards off, etc. Amazingly i've found a scrapyard local to me that has a ton of sierras, so the car is now getting an electrics upgrade including full electric windows, mirrors, possibly sunroof, Air con, variable intermittent wipers (connector was hidden behind the dash!!), heated screen and washer jet loom. i was tempted to cut the main loom out of one of the cars to get the door/lamp/fuel display thing working, but that's a little too much work for me right now. i plan on making the AC work on r134 by using the mondeo/focus parts with the sierra evaporator.

tomorrows plan is to finish off the wiring in the doors and to rivet the rear window regulators in.

Glenn_

iTrader: (1)

Glad you still have this car.

Im after a rear bumper. Is there any in that scrappy lol.

Mark V8

iTrader: (2)

It's good that you're sticking with it

You are lucky to have found a scrappy that still has Sierras !

Turbo Zetec

iTrader: (1)

Had another trip to the scrappy today as i discovered another sierra that had AC, this time it was RHD, so i got the right scuttle panel for it too . Also managed to remove the entire engine and AC loom, as well as the electric sunroof and all the bits that go with it!

not much to show really in the way of pictures, except these:

Out with the old...:



Big hole to make way for something a little different:



Here's what it's for:



Focus RS pistons fitted:



Steel Rods and ARP's:



Modified CVH sump almost ready to fit:



Temporary door cards fitted over new electric window regulators until i can find matching cards or material (sapphire cos 2wd):




that's all for now! hopefully i'll get some more pics this week as i've ordered quite a few bits now 500 style intercooler, 023 pump and fuel pipe should all be arriving soon!

turbo m

iTrader: (2)

Looking good will be following this again as you local...

lacey

What scrappy did you use ?
As there's one very near which have loads of old school stuff
And I think you live near ish to me

Turbo Zetec

iTrader: (1)

turbo m - was that always your username?

and

lacey - the scrapyard is in red lodge, where are you? I'm close to Soham.

made a little progress today, i've been stripping the air con loom (which is part of the 2.0 efi engine loom). i've spent hours on it so far, but it's mostly sorted

turbo m

iTrader: (2)

Yes always been turbom.
is that the scrappy at red lodge with the fiesta van hanging from the crane???

I am at bulbeck and work at prior so your very local...

Turbo Zetec

iTrader: (1)

Aha, i work in Burwell, so incredibly local. Can't be many places in Prior to work, so i'll take a guess at Meads?

The scrappy is a different one lurking quietly behind scrapco, well worth a look!

lacey

The scrap I am on about is mic Jennings in sible heddingham
Loads of old schools stuff
I used to work in Newmarket

turbo m

iTrader: (2)

Yes your right, i gathered you work where you do, either there or searles

turbo m

iTrader: (2)

Any updates????

Turbo Zetec

iTrader: (1)

well updates and progress are both slow, but i think we're heading in the right direction! Firstly, the engine is now together:



although at first, there were problems with the belt being misaligned:



instead of making a spacer plate and shrouding the impeller, i decided to press the pulley back a couple of mm. Trial fit:



then when i knew everything was working as intended, i welded the pulley to the shaft and refitted it. i also had to make a small spacer for the tensioner:




I also set about fitting the AC, starting with stripping the useless engine parts from the loom. the starting point:



scrap wires:



some of the wires i have remaining. i've worked out what they all do except one of the brown/green wires, but i assume that it goes to the TPS for a full throttle cut off switch. I also have a yellow/black on the ecu end, but i believe that it just tells the ecu when the AC is switched on.:



I've also fitted the AC panel on the bulkhead, wired in my new alarm, wired in some footwell lamps, fitted the heated screen circuit (future proofing), and fitted the electric sunroof:





here's the AC wiring fitted, but needs sorting. i left most of the tape off the loom so i could trace the wires when fitted to the car:





it's a bit of a mess at the moment, but will be tidied soon

I've also worked a solution for the engine mount, here's a trial fit of the plate i made:



now welded up ready to paint and fit:



also grabbed a nice steering wheel from an impreza at the scrappy :



Another job i had to look at was the inlet manifold, i've decided to try to adapt one from another car with slightly larger ports, so first i purchased a flange from danst engineering on ebay:



i also bought some tube at the same time and i ended up with this:





doesn't look bad for an hour in the shed with a saw and a hammer :



should fit something like this:

Turbo Zetec

iTrader: (1)

Got it all welded up and then faced it flat again:



here's the manifold mocked up on the engine:



It's almost finished, i've made gaskets and ground all of the important bits smooth, so should be able to fit it soon!

my next issue to sort is how to fit my 023 pump in the tank as the original fitting is too flimsy to take a pump that's twice the size and weight:



i've cut the side off an old tank to have a look at this:



it seems that the original pump sits quite a way away from the bottom of the tank, i'll probably give my new pump a little less clearance though:





that's all for now, i'm currently waiting for my exhaust manifold to arrive from boost performance and need to sort my release bearing out as it needs a spacer, then i can stick the engine in and sort the wiring!

turbo m

iTrader: (2)

Great progress,inlet looks very smart
doesn't look bad for an hour in the shed with a saw and a hammer lol

gcfcos

Awesome work your doing there Matey

phillgti

Good project, glad to see your sticking with it

Turbo Zetec

iTrader: (1)

haven't updated this for a while... will do soon though as the engine is in

Turbo Zetec

iTrader: (1)

right, it's come a long way since the last update really. i've done loads of little jobs, but the major ones are as follows:

I made a longer release bearing on the lathe by hacking up a used one and a new one... turned out pretty nicely:




Fitted the balanced focus RS clutch assembly:



and finally got the engine in the car! :



Received my new exhaust manifold from boost performance and trial fitted with water rail:



I decided that there may be enough clearance to fit the turbo if i faced the turbo flange at an angle, so i took it to work and had a play:




Found out that the 200sx inlet won't clear the master cylinder , so i trial fitted some others to see what would have room and what wouldn't:




started to wire in the ms2 ecu, also trial fitted the manifold and turbo to see if the water rail would clear:




Unfortunately even with the manifold face milled at a slight angle, it still didn't have room for the water rail, so i took it to a friend who could sort it for me




a much better fit now! i've now moved the car to my house, so i can get on as soon as i finish work. hoping to have most of the wiring done this week!

turbo m

iTrader: (2)

Great progress,is that a standard t3????

Do you know anybody local that does tig welding??