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300hp fiesta 1.6tdci project

Old 19-07-2012, 01:04 PM
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Default 300hp fiesta 1.6tdci project

i've used this site for a few years, i used to be known as turboboss and played about with a red frst but due to buying house i broke my frst for the deposit, then when things had settled down a bit finance wise purchase i bought a fiesta zetec s 1.6tdci just because it was cheap to run with only £30 a year road tax.
i started to do some mods remap, exhaust then i wanted to go a bit further well more then just a bit most bit have been through trial and error so far upgrades focus 110hp injectors, turbo dynamics kp35 hybrid turbo,ss exhaust from turbo back,fcd2 ( thanks stewart),FMIC, kevlar clutch, methanol injection kit and a rs tuning custom map giving me 156hp 260fbt.


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focus 110hp njectors
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kelvar clutch
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FCD2
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for my next incarnation
injectors modified with bmw 335d injector nozzles thanks dieselbob
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you know how one thing leads to another i wanted bigger valves, but due to the lack of room between valve and bore wall this was not feasible, so my fabricator has been speaking to his engine shop its taken quite a bit of convincing of hwy we want to pursue tuning a 1.6 diesel but they have now come round to the idea and are fascinated about the project. 0.05mm oversize pistons are only available which is no use to me reason for this the engine comes with liners so a rebore is not possible. The engine shop state they have repair liners on the shelf which can take the bore from 75mm to 80mm increasing capacity from 1560 to 1775, but locating a set of pistons seams to be a tad difficult because of the small end, but i am just going to get farndon to make me a set of rods with a small end of my choice........Increasing the bore size allows a whole host of alternative valves sizes, best combination seams to be 26mm exhaust and 29mm inlet from standard 23.4 exhaust and 25.5 inlet so a gain of 23% and 29% respectively which is quite a lot, All the porting is done to a spare head I will put pictures up as soon as I can

I have been looking at the gearbox side of things without this the project wont start, now building a stronger Ib5 box is simple but building one with the right gear ratios is causing me headache the fiesta 1.6tdci comes with a 3.7 F/D with 205/40/17 tyres giving a rolling radius of 6.14 @ lets say 4800rpm gives a top speed of 113mph, there are two other F/D available which suit a diesel perfectly a 3.3 and a 3.1 the 3.3 comes with the same 8-bolt fixing as the 3.7 but good old fords for some reason decided to change the later fiesta 3.1 to an 12-bolt fixing 8mm screw and a totally different carrier, so I am waiting on a machine shop on a cost to see if the parts can be machined to fit

turbo GTB1756vk off an audi q7 3.0tdi good for 32 psi at 2000rpm new generation vnt want to go to a hybrid GTB2256vk at a later date

audi 2.7 tdi fuel pump and pressure sensor

ported head with larger valves
custom inlet manifold

straight through 2.5" exhaust system with no box

tubular manifold placing turbo over gearbox
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Old 19-07-2012, 01:20 PM
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And an st fiesta disc read beam

Nice project and good to catch up again mate
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Old 19-07-2012, 06:26 PM
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Hi m8

I thought I'll start posting 0n this site again, having te gearbox built now, which I was going to do in te first place I hate te standard ratios
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Old 19-07-2012, 07:01 PM
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How much did the hybrid turbo set you back if you don't mind me asking?sounds like a cracking project mate.
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Old 22-07-2012, 01:32 AM
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Hybrid. Set me back £1875 which includes te price of a new turbo, I requested turbo dynamics for te largest compressor and exhuast turbine which could fit in te fiesta kp35 turbo. Housing. They had to cnc fcd te 1.6 diesel engine will do 150hp with ease, this hybrid will be for sale soon at a good price because I am going bigger
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Old 22-07-2012, 11:49 AM
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liking this love to see new approch to tuning
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Old 22-07-2012, 12:45 PM
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nice project
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Old 31-08-2012, 12:50 PM
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gearbox standard ratios are not good with a 3.7 C/W weak diff and fragile teeth not much use for big power or top speed, so i enlisted a transmission company called G.E.A.R.S tv to build me a box....................Specification is as follows

3.05 crown wheel & pinion
quaife ATB diff ,modified 12-bolt crown wheel to fit diff
shimmed diff to obtain correct preload
late high ratio gear set (3.15 1st gear) similar to rs turbo ratios
new bearings,syncro rings nub shifing plates and tension springs
cryogenic treated gear set
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Last edited by Badman38; 31-08-2012 at 12:55 PM. Reason: wrong wording
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Old 31-08-2012, 04:55 PM
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Very cool project.Its defo different.
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Old 17-10-2012, 12:28 PM
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Car is nearing completion had a bit of trouble enabling the vnt control, still quite a few bits to do the turbo is a GTB1756 good for 240hp on a 1.9tdi but I will eventually have to go bigger, taken a long time but its still work in progress by station Motorsport.


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Old 17-10-2012, 12:54 PM
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wow.......
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Old 22-10-2012, 12:58 AM
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That is fricking awsome. Cant wait for the outcome.
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Old 31-10-2012, 08:45 AM
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Excellent, nice to see something so different!
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Old 31-10-2012, 10:58 AM
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top work good project
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Old 23-11-2012, 01:10 PM
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currently trying to find a suitable fuel pump the car comes with a 70cc pump good for 190hp attempting to make fit a 135cc pump which can supply enough fuel for 300hp, i want to ensure pump on working with larger nozzles before the mapping
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Old 23-11-2012, 01:49 PM
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what did you have to do to get the focus injectors to fit? was it just re-code them or did it need mapping?
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Old 24-11-2012, 06:54 PM
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the focus injectors are the same size as the fiesta but supply more fuel, no coding neded.......... we thought they might need coding my mapper put them in writing down the codes for coding but he thought lets just try it" turned the key and the engine fired up
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Old 25-11-2012, 07:18 PM
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i dont sopose you have a part number for them?
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Old 25-11-2012, 09:55 PM
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Originally Posted by LukeDaisley View Post
i dont sopose you have a part number for them?
Bosch part number 0445110188
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Old 25-11-2012, 10:12 PM
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thanks
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Old 17-01-2013, 04:46 PM
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larger pump fitted to dummy engine modifications to the bracket connecting the pump to the engine, remachined sprocket relocated tensioner, larger fuel feed pipe, pump being fitted today i am surpised at the size of the common rail high pressure compared to a the old mechanical pumps but even this pump is much larger then standard.
i have been waiting nearly two months for this pump from design to completed unit, wont take this long for the next person because all the development work been done i hope its worth the wait... this pump will work on both variants 90hp & 110hp

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Old 23-01-2013, 03:52 PM
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All the best an awesome project. It won't take 300 though, I'd be amazed
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Old 23-01-2013, 04:05 PM
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Thanks ran I tried to leave her aloan but I am doing so much research in re dv6 engine te same engine in te mini, peugeot hdi, citreon hdi, volvo.... to make 300hp re engine will be far from standard re nozzles and fuel pump can exceed 300hp turbo wise I can either go gtb2265 which is a hybrid version of a turbo fitted to te audi q7 3.0tdi or te best of both worlds compound charge, but then te block would be in need if some serious strengthening to handle 70+psi and te high cylinder pressures that goes with it.
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Old 23-01-2013, 04:17 PM
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Originally Posted by Badman38 View Post
Thanks ran I tried to leave her aloan but I am doing so much research in re dv6 engine te same engine in te mini, peugeot hdi, citreon hdi, volvo.... to make 300hp re engine will be far from standard re nozzles and fuel pump can exceed 300hp turbo wise I can either go gtb2265 which is a hybrid version of a turbo fitted to te audi q7 3.0tdi or te best of both worlds compound charge, but then te block would be in need if some serious strengthening to handle 70+psi and te high cylinder pressures that goes with it.
If you need any info just shout, I'm on the dev team. Personally I think it'll shit itself way before 300 but then again we never actually tried
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Old 23-01-2013, 05:15 PM
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Top work matey.This will be cool when its done.
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Old 23-01-2013, 06:01 PM
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In Portugal where they regularly race 1.6hdi there r a few over 200hp, but trying ti get any info is trying to get blood out of a stone so all te research is done by ourselves, what do u think will fail? Knowledge which I lack is a good thing
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Old 23-01-2013, 06:09 PM
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Originally Posted by Badman38 View Post
In Portugal where they regularly race 1.6hdi there r a few over 200hp, but trying ti get any info is trying to get blood out of a stone so all te research is done by ourselves, what do u think will fail? Knowledge which I lack is a good thing
Valves are known to recede and wear cams.

Usually the rods go first, bolts are only torqued to about 20-30nm, but if you're changing them you'll hopefully avoid that issue.

Main bearings would be my other concern. The alignment of the bores isn't great and the bearings are slightly oval, mains are only done up to 40nm on m9 stretch bolts. The bottom end is very weak in general.

Only thing I'd say re the Portugal scene is the plumes of smoke they produce to make the power, I ran a 1.9tdi golf in Portugal spec once and I painted lines of pure spot on the floor
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Old 23-01-2013, 07:51 PM
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Have you try to find a EP6t (mini cooper S and 207RC for ex.) , the bottom end are very similar , maybe crankshaft , rods are stronger for 200hp+ tdci
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
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Old 24-01-2013, 08:47 AM
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Also I don't think there's room for 80mm liners. Standard liners are 3.5mm thick approx all the way round. Block thickness liner to water jacket is approx 4.5mm and liner to liner block (ie between cylinders) material is approx 2.5mm, so unless you liners are as thin as shit custard there's no room?
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Old 24-01-2013, 11:30 AM
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Shaun with the red Fiesta?

Great little project this!
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Old 24-01-2013, 11:36 AM
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yeahh si, the very quick red fiesta

hello chap (long time)

great little project will keep an eye on this

hope alls good your end
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Old 24-01-2013, 12:20 PM
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Ah thought so!

Was a mental car that red Fiesta - 400+ bhp was it not? Shaun helped me out with a few parts and advice when I was building my old ZT XR2.
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Old 24-01-2013, 01:11 PM
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Originally Posted by gus View Post
yeahh si, the very quick red fiesta

hello chap (long time)

great little project will keep an eye on this

hope alls good your end
Hi gus

Yes its been a long time I thought I'll try something different, bought a house which is why te fiesta had to go now i have a five month baby girl I purchased te car as it was cheap to run but u know how it goes from a basic remap to this..

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Old 24-01-2013, 01:15 PM
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Originally Posted by XRT_si View Post
Ah thought so!

Was a mental car that red Fiesta - 400+ bhp was it not? Shaun helped me out with a few parts and advice when I was building my old ZT XR2.
I remember u well hows things want to see how far these engines will go
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Old 24-01-2013, 01:20 PM
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Originally Posted by the_frozen_one View Post
Also I don't think there's room for 80mm liners. Standard liners are 3.5mm thick approx all the way round. Block thickness liner to water jacket is approx 4.5mm and liner to liner block (ie between cylinders) material is approx 2.5mm, so unless you liners are as thin as shit custard there's no room?
That's te plan I dont have enough knowledge on these engines as yet I had a guy measure everything up but re engine hasn't seen an engine shop yet so I will have to see whst they say........ but u seem to have quite a bit of knowhow on te dv6 lump?
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Old 24-01-2013, 01:39 PM
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Originally Posted by Mister W View Post
Have you try to find a EP6t (mini cooper S and 207RC for ex.) , the bottom end are very similar , maybe crankshaft , rods are stronger for 200hp+ tdci
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
For starters te 110hp focus 1.6tdci doesn't come with a vnt turbo its wastegated I think a tdo3 the mk6 fiesta comes with te edc16 ecu same in as the Peugeot/citreon vnt software is there just need a mapper to enable, then do some mapping on te duty cycle, only difference between 90hp and 110hp is injectors/turbo......... I use rs tuning and cc tuning, vnt is the way to go I've got the third generation vnt type turbo.. gtb normally on 2.7tdi I get boost from idle full boost 32 psi @ 2100rpm

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Old 25-01-2013, 03:06 PM
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Originally Posted by Badman38 View Post
That's te plan I dont have enough knowledge on these engines as yet I had a guy measure everything up but re engine hasn't seen an engine shop yet so I will have to see whst they say........ but u seem to have quite a bit of knowhow on te dv6 lump?
I had one on my desk so I measured it. But yeah I work on these everyday
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Old 29-01-2013, 11:08 AM
  #38  
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Looking good chap

Question for you.

Which gearboxes carry a lower ratio final drive as i want to reduce my engine speed whilst cruising?
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Old 30-01-2013, 01:01 PM
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Originally Posted by jghs83 View Post
Looking good chap

Question for you.

Which gearboxes carry a lower ratio final drive as i want to reduce my engine speed whilst cruising?
i think the c/w came off a fusion but the gearbox carrier needs machining to fit due to the bolt pattern changing but i will find out for definate
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Old 30-01-2013, 02:23 PM
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Originally Posted by Badman38 View Post
i think the c/w came off a fusion but the gearbox carrier needs machining to fit due to the bolt pattern changing but i will find out for definate
Cheers, might just fit the fusion 'box then

Thatll help with mpg pmsl!
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