Badman38

iTrader: (2)

Car now running just an issue with the clutch which is going back to helix for modifications won't be a quick job even though it's an easy fix

salsheikh

nice. keep us posted with updates

Glenn_

iTrader: (1)

That looks mad. Top conversion.

Badman38

iTrader: (2)

Hi

Haven't updated this thread for a while quite a few to post, I think Ford decided to change the ecu on the mk7 fiesta from a bosch to a siemens ecu, not as simple to swap bits over but I will find out for you...

sean

salsheikh

C'mon Sean...you need to get this monster finished soon!
would you not be better off with a standalone ecu? (i know eff all about ecu's!!!)

Mister W

Fiesta Mk7 2008-2010 on Bosch EDC16 like Fiesta mk6 ( same engine and same ECU but different software )
Fiesta Mk7 2010-2013 with DPF on Bosch EDC17
Fiesta Mk7.5 2013-2017 with DPF on Bosch EDC17 with ECU password and the pinout is different to the Focus ECU, I search for 115hp remap

Badman38

iTrader: (2)

Been a while since my last update engine is in bits! whilst in my fabricator workshop a puddle of water appeared leaking from the head, removed the head you could see that the cylinder liners had dropped ever so slightly and in doing so damaged the shim I used in conjunction with a custom head gasket to lower compression. After having a few words with the engine shop who obviously blamed everything and everyone but himself and started going on about materials and movement etc. but when my fabricator explained that he had put the engine in a press and the liners moved again he looked embarrassed and said he does it by feel but it might not have been enough (no S..T) the fabricator then explained that he applied 10MT of force the engine shop looked in shock, he then had to explain about stretch bolts elastic deformation at 78000N which is around 8.2T and that’s with stretch bolts and a compressible head gasket but we are not using either and will put more load onto the sealing rings. The machine shop had no clue what he was on about! We got the engine shop to deck the block and skimmed the head ready for assembly, next we done away with the shim and just increase the thickness of the head gasket the head gasket is made of High Chromium Steel with steel –O-rings manufactured by Redline Head gaskets in south Africa. Redline refuse to post the first gasket to the UK and ended up taking like six weeks to arrive. Delivery cost more than the gasket itself. Station motorsport setup an account with DHL who had a depot in South Africa so we thought happy days but no redline wanted no part to the point they wouldn’t even delivery to DHL depot in south Africa! DHL arranged pickup from redline and delivery to the uk, tracking didn’t start until it hit the UK… three weeks go past then four weeks no word from from the courier so contacted DHL to ask have they at lease collected the gasket DHL replied gasket has been lost somewhere in transit! two week later gasket found now and on route to the UK… gasket arrives but a few days before one of the pistons had fallen from a bench piston didn’t look damaged but did not want to take the risk so ordered another machined the valves cut-outs and sent it off for Ceramic coating taking another four weeks, now Engine finally ready for reassembly next week.
Talking about going aftermarket ecu there is not many choices of Performance common rail ecu that can run Canbus at a reasonable Price Adaptronic is one and bosch Motorsport both ridiculously expensive another one is scs delta which is more affordable but lacks some of the features of the other two but will run and due to the faster processer should run the engine better then the oem edc16 ecu. Specialist Control Systems did start to evolve the ecu but haven’t completed the firmware I may just purchase the ecu and hope that in the future updates are made available

salsheikh

bloomin heck, you've certainly had some issues!
keep your chin up and look forward to the results

Juicy

Hey guys. Any update on this?
just sat and read whole thread.
I'm currently I'm middle of fitting a hybrid GT1752 to my 1.6tdci and curious if there is a way to turn the fuel pump up on this engine? Without custom made like OP has done

Badman38

iTrader: (2)

SCS aftermarket ecu for common rail diesels could be calibrated on the oem ecu but I wanted to keep to the custom theme where oem wont cut it!

Badman38

iTrader: (2)

engine rebuilt again this time with custom valve springs sorry this is taking an age just problem after problem.

Glenn_

iTrader: (1)

What problems have you had.

Mburns212

Seabs

Badman38

iTrader: (2)

sorry haven't been on the site for a while, to achieve 200hp is quite easy

bigger intercooler like an airtec cooler from superchargered fiesta
110hp injectors
State two GT1544 hybrid turbo cheapest option best is to change to a bigger turbo like a gt1752
3.5bar - 4bar map sensor
vnt boost solenoid off a focus
Panel air filter
custom map involving enabling vnt control

Badman38

iTrader: (2)

using a MTX75 gearbox off a focus with shot peened polished gears, clutch wise Helix 215mm single plate race clutch

Badman38

iTrader: (2)

engine is up and running mapping starts next week, should be done by Ford Fair.
changed from a quaife diff to a gripper plated diff and added a CAE shift which is meant for an myx75 from a mk1 focus rs, only found out afterwards that the mtx75 box from the focus rs work totally different from all other mtx75 so needed to be modified to work.
cae shifter


Plated gripper diff


completed engine bay

Declan Harvey

Hiya Mate,

i have a fiesta 2007 Zetec S 1.6 tdci, what is the cheapest and easiest way to get the BHP up close to 200?

Cheers

visa_broke

Do you mind sharing which company you used? I'm thinking of adding a supercharger to my project but that would require putting it in the place of the aircon compressor and with the heat we've been getting lately I don't want to lose that.

There's a big thread above your post with all the issues if you have a read.

RibbleTechnology

Fantastic work gone into this

Badman38

iTrader: (2)

another update idle part throttle mapping completed, coolant system started to pressurise first time blowing my radiator changed for a new rad then again the ecu shut the engine down. stripped the engine again! turns out the liners have spun letting in combustion into the coolant causing high pressure, instead of trying to fix what the machine had cocked up in the first place, so I have bitten the bullet and now going for a full closed deck conversion from Westwood liners and going to their machine shop of choice Stanwood engineering in Doncaster who are the only ones to have a brand new RMC CNC machine and can profile and fit the new liners to suit, turns out quite a few of the big players in the tuning world will only use these guys shame I didn't know beforehand could of saved me months of headache and money! six weeks lead time making the liners then the machine work, most probably looking at another three months in total.

Badman38

iTrader: (2)

in the interim I want to increase the size of the turbo but the M45 supercharger will become a restriction so I acquired an M90 from a xj6 jaguar

Badman38

iTrader: (2)

I always wanted an AP racing brake kit I phoned Reyland about their four pot Caliper brake kit 330mm kit for the mk6 fiesta but before Purchasing I asked if I wanted the best road/track brake kit what would you offer me? they suggested a six pot calipers with RSL29 pads i wanted red calipers seeing as everything on the car is black need to break the colour up a bit and fully floating on the rear AP are out of stock and I am looking at lease 12 weeks lead time!

Andrew Brown

Hi there, interested in your project and read through the thread. A very cool build!

Any updates so far?

Also best of luck with this project, I can see you've had a few problems.

Cheers

Badman38

iTrader: (2)

Hi
Not much of an update bloody waiting game for more custom bits Stanwood Engineering who are doing all the machine work have said my pistons and head-gasket are no longer of any use, I need a set of custom pistons and a compressible head-gasket this is due to the closed deck liners will protrude the block, my current head-gasket is of a thickness to lower the compression ratio and is a reusable solid plate, now the block will get built the proper way with pistons that can stand mega heat Stanwood never do anything by half measures. With a bombproof block be rude not to up the ante a little! so I bought myself a Darkside developments GTD2872VRK 5th generation ceramic roller bearing turbo with a billet 71mm comp wheel capable of over 400hp just hope its not too extreme.

salsheikh

niiiiiiice

xr2john

sierra1off

impressed with your perseverance.

I would have thrown the towel in years ago.

Your misses must be very understanding

Badman38

iTrader: (2)

after nine months work has started on my block DV6 Liners machined and ready Crankcase being cut Liners fitted after crankcase heated Deck plate applied to hold liners fully on the machined seat area. Liner tops will be milled to achieve 0.002 inch protrusion. Final bore of 79.5mm Deck plate re-fitted for final hone. Built to withstand 4x its original BHP.

jonny s2

iTrader: (12)

Serious dedication

Badman38

iTrader: (2)

Too much time and money has gone into this project to give up, been close on many occasions

Badman38

iTrader: (2)

Block Is now complete

3i Jim

Mental! What will it rev to?

Glenn_

iTrader: (1)

Nice to see your still plodding on with this project. Its nice to see something different too.

HeavyOil

Hiya, just read through this forum and I must say I'm bloody shocked by how much time and money you've put into this engine. I own a Focus with a GTD12 hybrid and she makes about 170bhp and 360nm. This was very easy and cost about Ł2k to do, so I do wonder how much you've plowed into your Fiesta?

How's the build going now? Is the 300hp target attainable? Are you expecting more now you've got the new turbo? I must say I've never seen a compound charged DV6 before and I admire your bravery and tolerance to power through, I nearly gave up when my paddle clutch started slipping and that's nothing compared to what's gone wrong with this build. I assume this car isn't road legal?

Keep up the good work, man, I'd love to see her quarter mile when she's done!

Badman38

iTrader: (2)

Hi

The rebuild is going good new set of pistons have been machined to move the oil squirters over to the hot side of the piston and valve cut-outs, currently getting a triple ceramic coating. I wanted to change the cams the oem pair are hollow with press fit lobes and gear, too much of a risk to use in this engine I've seen cams where the lobes have moved bending the valves and literally destroying the engine, Newman are making a custom billet set for me keeping duration the same but increasing lift these are on a six week lead time which goes for most of the custom bits on this car............ lets not talk about cost I had a budget but that's been blown into space, several times I thought of stopping this project which is very unique, there is a compound charged diesel fiesta using twin turbos but the engine is standard, we have come across many issues in terms of restrictions that you have to overcome to achieve big power, 300hp should be an easy task the turbo can flow over 400hp then the air is getting compressed again by the supercharger should see 60psi at the manifold hopefully we manage the heat so it doesn't become too big of a problem,

HeavyOil

Bloody hell, you've completely rebuilt the thing! Yeah I can imagine it's cost an absolute arm and a leg to fabricate so many parts. This must be the most extensively tuned DV6 I've ever seen. What does the supercharger do for the economy? Can't imagine it gets 70mpg anymore. My Focus'll still do about 65, but I've really not changed much internally. What sort of torque figures are you expecting? I can't imagine 500nm+ does miracles to traction?

Very, very interesting build, will be following

rsseko

hi, is there any improvement in the project? congratulations

Badman38

iTrader: (2)

Just waiting on a set of custom billet performance cams from Newman cams I have been waiting since the end of August Newman I several issues with cutting the gear etc, they only just got the cams back for machining. The lobes are going to be increased in width and more lift added, duration on the exhaust side going to reduced.

Badman38

iTrader: (2)

The problem with diesels in general you have a slow burning fuel high energy fuel even more energy than petrol, long stroke engines so pistons speed not great, and unlike petrol where you can generally ignite the fuel anywhere in the stroke the pistons has to be at tdc to heat the air with really high compression ratios to ignite the fuel, there is a delay before ignition happens. Also the higher you rev the window of opportunity gets smaller for combustion.

so to combat this to enable me to rev high and have peak torque higher up in the rev range I have a much larger fuel pump and custom fuel rail to increase fuel pressure to 2200 bar, bigger injectors now with eight orifice compared to the three on the oem injectors, lower compression with 4 bar of boost pressure, lighter rotating parts one of the standard rods weighs as much as the set of steel rods and a slightly shorter stroke, I only want to rev the engine to 6000rpm max with a 3.4FD that is plenty.
sean

Orifice