DanDMC

Hi all Dan here. to my thread on a project I'm starting. Baisically I'm looking to Finnish up with a 2.0l Duratec'd fiesta I can use everyday. Now I know how to use a set of spanners an I know How a car works (more or less) so why not, how hard can it be. (Famous last words haha). I Hope with time an some helpful advice from you guys along the way this should be doable. I will try to document as much as I can on the build in here so with that said here goes.

DanDMC

DanDMC

Firstly I must admit I have done things kinda back to front in that I've bought the donor car first, a mk 3 mondeo not something I really fancy but it was pennies so I had too I'm not a fan of big cars so I thought id bang the engine into somthing smaller so that's were the idea came from to start the project.

DanDMC

An this is where the fun begins

DanDMC

After a couple of days slowly feelin my way through it an between runnin in an out due to the bloody rain showers it's ready to to come out.

DanDMC

Well I've made a bit of progress today got the engine crane built up an borrowed a couple of seat belts from inside mondeo an off I went

DanDMC

Easy does it, little bit at a time.

Stage6

See this on zsoc mate, fair play for giving the 2.0 a go

DanDMC

The gearbox didn't want to let go so it came along for the ride.

DanDMC

And touch down

And here she is in her new home.

DanDMC

Done bit today jus takin anything I mite need later before the mondeo gets scrapped. Finally got that soddin wheel off with the help of a nieghbours gigantic wheel brace.
So I got the 300mm discs and calipers off took the gear linkage out, an all the exhaust just incase I need any of them or bits of them later on. I'd rather have summit an not need it than need summit I scrapped on the car.

DanDMC

Havnt done a great deal today, got the last bits of the mondeo off I might need then turned my attention to the engine cos I've read somewhere about these butterfly flaps in the inlet manni in these, basically there prone to fail big time, get sucked into the engine and f**k s**t up an from what I can gather there not really necessary so had the inlet off an they weren't totally done for but were on there way so got rid of them.
http://www.fordwiki.co.uk/index.php?...ault_-_Duratec
I've also read that the alternator needs moving round the front an I think the tensioner for the belt needs moving too on these conversions so I've started sizing that up today looking at ma options so I need to come back to that tomorrow after work see what I can sort out there and I think that's it for now.

DanDMC

Had a look at the alternator an tensioner relocation situation today an started making a bracket for the alternator, it's only rough at the minute so il get some pics up when it's done before it goes on along with a tensioner bracket. I could do with getting the whole thing cleaned up as well really.

Tensioners goin up here

And the alternators going down here.

DanDMC

Still waitin on a box of nuts n bolts to get the alternator and tensioner brackets done so got to cleanin up the engine an it's bits

DanDMC

Then a bit of primer an colour on a few bits


Paint looks a bit radioactive.

DanDMC

Bloody flies

DanDMC

Anyway, Got the old girl cleaned up some more then ready for paint

DanDMC

An after with some bits back on

DanDMC

here's some of the alternator bracket doin it's job it's not pretty but it's solid so am happy with that.

DanDMC

All back together, I got the tensioner on, measured up an ordered the belt.
Jus need the car now. End of the month for that tho.

DanDMC

Yea I've moved it over here cos I'm not puttin it into a zs now but il carry on the thread in both so long as no one objects, there's all kinds of different projects over on there so I can't see it being a problem really.

Glenn_

iTrader: (1)

These are a decent engine. What car you putting it in.

clairendave

Dan, if you get any issues a Mazda 3 alternator is front mount.

DanDMC

Just to make things a bit more difficult for myself Ive decided to go for a ka.
Not sure itl even fit in the bay yet but the ka should be here the 30th so I guess il have a better idea then.

DanDMC

Thanks il keep it in mind, all input is hugely appreciated as I've never done anything like this before.

clairendave

Mazda3 5 speed is also a lot smaller than the mtx. Although i don't know if cv joints or shafts will be a straight swap. I am in the process of taking the engine and box out of ours atm.
The top engine mount is smaller on the mazda too.
Should fit in the Ka bay i would of thought but will possibly be tight around the downpipe.
Keep us all posted.

Dave

DanDMC

Yeah I have been wondering about the size of the gearbox in relation to the shafts once in the ka, I could be wrong but I think I read somewhere the mazda gearbox won't mate to the fords duratec or may have been the bellhousing, but certainly gives me something to look into as I'm not 100%. Thanks again for the input Dave.

DanDMC

Couple of small things first, today got the belt on, fits perfect so pleased with that and god rid of the mondeo or what was left of it anyway an also the the big news for the project ....




......just as I'd about given up on the zs idea and nearly bought a ka to squeeze the duratec into (as I was runnin out of patience trying to find a mk5 zs an jus wanted to get cracking), Danmc off zsoc swooped in to save me from myself an offered his up for sale with a couple of extras thrown in to sweeten the deal, so if all goes to plan I should have the fiesta in the next week. woohooo!!!!!

Belt runs like this


Bye bye mondeo. I think it was scared it did a little wee on the ramp

essy

Will be keeping an eye on this, keep at it mate.

atm

Like to see a duratec in a mk5

DanDMC

Due to the mystery of the disappearing keys, collection of the zs ha been delayed a little but should be sorted and ready this week fingers crossed. In the meantime I've ordered a few things for the project.

And these also arrived


After many paint strippings and sandings then some painting waiting and painting they look like this


Next update should be with the car fingers crossed.

DanDMC

Il not be giving up on this one, it's the first time I've tried anything like this but I'm learning so much as I'm going

DanDMC

Yea there's not too many around allthough I think there is one over on zsoc up for sale at the minute.

DanDMC

Centres painted

Ran a bead of lead grey silicone round the join to neaten it up between the two colours

Pretty pleased with them