youngben

iTrader: (2)

Thank you. Purchased the Focus DBW now i know it will tie in with the Delta.

So the guys attach a plug to the standard loom or do they just use the connectors? My loom has been cut after the plug so may need to get another loom.

Yeah saw they were ex lotus when reading up on them. Seem to know their stuff.

Loving the updates. Keep up the good work!

Looking to collect 90% of the necessary parts before i take on the conversion so i can still track the car in the mean time but i am itching to get started.

djwilma

So i have the STD engine loom for the Focus ST, this includes the DBW plug (which i will change for a GM one) so i used this and will cut out the Elise loom and splice them together

IF you want to PM me your number and i will give you a call, itll be much easier

djwilma

Yes, basically i use the STD Focus Loom modded to take the ECU

It was cheaper through SCS than Ford with their mods, this has a plug for the DBW

If you want, pm me your number and i will call you to help

djwilma

The new fuel pump turned up today, big thanks to Gaz at Spitfire Engineering. This (small) pump should provide enough fuel for 500bhp at 3.5bar and Gaz kindly sent me a complete unit, i have to send my old unit back. I went for the Deutschewerks pump

This will save me a swirl pot, lots of fuel pipes and i dont need the Bosch Motorsport pump i had on the T series.




Hoping to have the car wired up to the ECU and Ford Loom next week

Rowe

the end is in sight!

djwilma

We are finally getting there

youngben

iTrader: (2)

Have not forgotten to call you. Just a lot on at the moment and the Project is a steady one.

Something else i have been thinking about! Supplying fuel. Looks a tidy setup that. Cant wait for first start up.

djwilma

No worries free when you are

Got the Elise out today and did some work at home



Put the engine cover on and it will be tight but the HPFP pressure sensor and the wastegate both it (when level) but need to get the rear clam on to check

I have the Duratec Silicone Hoses from Essex Autosport and tried to get them to fit. I got very confused until i realised the Ecoboost water inlet and outlet are on the opposite side to the Elise so after doing some searches (yes i know) of the Duratec builds i saw the swap of water pipes. With some pipework from the rover i managed to get it all set up

This makes it a little congested under the inlet, as the water pipes Swap over, the oil cooler water pipes, the remote filter pipes and the throttle body inlet.



Fitted the starter and it fouls the bell housing adaptor, bit strange but an easy fix



Also looked at fitting the fuel pump, and the hole is too small, i think i will go for the easy option of cutting the top rather than dropping to the tank (as no ramp)

djwilma

I think it's best to say my motivation with the car is waning, work, travel, family and work on the house have ground me down.

I cant even be bothered to fit some water hoses and sort out the vacuum......its got that bad.

So tomorrow the car is off to HPE Automotive in Bromsgrove, who are well known for Honda conversions

Monday the engine is then with Specialist Components to map and see what she's got (if the turbo can give it enough air)......

Pick a power figure if your bored, I'm going with 400bhp at 11psi and 8000rpm for a giggle and 480bhp at 23psi and 7250rpm.

But today I suddenly realised I hadnt fitted the rear clam with the new engine in, and I was off to Germany at lunchtime

First fit didn't look too bad at the back



But terrible at the front



So I found the sabre saw and made it fit.



But it hit the wastegate(built when the engine wasn't with the car so can't complain)



I gave accepted I will be losing the boot so will fabricate, sorry asked Dan to fabricate something to lock the hatch too.

Boot will be exhaust as it was way too loud before

Rowe

boot mounted turbo

djwilma

Engine lasted 10 minutes on the dyno last week, then started to have a bad misfire at 2500rpm and load. So the head have to come for a re-check

Spoke to the Engine builder today and its pretty clear whats happened

The head was coked up, one of the down sides of direct injection, so the valves were sticking.

An expensive lesson, yet again, but asked them to strip the engine, check and rebuild. They found a few minor issues and have mentioned that it may be worthwhile porting the head..........it never ends

Should be a couple of weeks to get it put back together

Fudgey

iTrader: (4)

Pisser when its so close. And more money of course.
Shouldn't they have checked that tho when building the engine?

djwilma

Yes it was checked but long story short the engine builder stopped trading half way through so built the engine at his new work.

He didn't have the facility to clean it throughly

I agreed, as engine was low miles, it would be ok...... Hindsight is a wonderful thing

djwilma

So some good ish news today

I havent wanted to "bother" the engine builder, Damico, as he is manic and fitting in mine between jobs for which i am eternally grateful

Luckily today he called and we had a chat so;

The engine wasnt missing, this is my misunderstood (i was in shock and at Duxford with my 4 year old). The engine was breathing badly, and it got to a point that they were not happy with so they stopped the dyno and advised the problem. With the leakage on the valves i asked them to strip and inspect the whole engine, as i knew the

The engine was coked up, see the photos below. As said this wasnt causing the engine to Misfire but was causing the valves to stick. The valves were sealing when the cams were removed, however they hadnt been lapped or cleaned. The engine just sounded sick and wasnt able to pull through the revs.

The piston rings were on the large side, but in tolerance, however the second ring had a larger gap than the first, all now being fixed

The head was in tolerance for flatness but only just, head is now being skimmed, de coked, cleaned and then ported. Sealing face wasnt as clean as Damico would of liked (polite for had gasket marks, same for the block)

The crank, and bearings, are all fine. Some evidence of a "dirty build" but all can be cleaned up and in tolerance

So I wasnt charged for the engine build (long story), but at least now i know its been done to the highest standards. I just hope the wife doesnt find the bills and this thing had better work !!!

djwilma

Damico have kindly sent some shiney clean photos...........getting closer....again...again

djwilma

OK results are in and dont know whether to be happy or sad.......i should be happy looking at the curve, i really really should be

Anyway.......

It’s a mixed bag of news

The engine wanted to boost, way above the 11psi set in the actuator. So the dyno removed one of the two springs and got this down to 20psi. The spring should set actuator pressure to 4psi so need to find out why this is happening.

It may be connected to the vacuum pump, this was disconnected and open to atmosphere and caused the crankcase to pressurise. Once disconnected, or sealed up, the engine was fine. Took a while to find out why but hey ho its not been done before.

Weirdly the std gdi injection was ok at 410bhp, auxillary wasnt needed (was tested and wasnt great when injects as the injector opens to much for the need) but does work if needed. Theory is 350wbhp so 400bhp is the limit, which its not as they still had some headroom.

But the major issue was detonation, at 20psi (1.4bar) the sensors were detecting knock, so the ignition was retarded to a point where the egt's got too high......This though should not happen, inlet temps were 30C so even if the compressor was blowing hot air (which its not according to the comp curve) this shouldnt effect detonation.

A theory, which i need to confirm, is that the pistons are higher than the 9.3:1 they should be. This is because i used the 2.3 crank and rods, and the 2.0 pistons. The std 2.0 and 2.3 have the same comp ration, so longer stroke and short rod should ,ake the same as they share (i hope i am right) the same piston diameter. However, the 2.3 and the 2.0 use different heads so i dont know if the volumes change to compensate.

As is normal here Dyno session finished late, so i will get more information tomorrow.

So it may 410bhp, 300lbft at 3000rpm and 350lbft of torque with a flat chunky curve with lots of room under the curve.

So i should be happy, right

Fudgey

iTrader: (4)

What power were you expecting?

That looks fairly linear so should pick up and accelerate well.

In a light chassis that should be a bit of a handful.

djwilma

Was hoping for 450bhp

Issue isnt the power it made, but more that this was the most it would do and it should do more. Lots of detonation, boost creep and lack of revs.

It should rev to 8k and of held 11psi.

Need to check the wastegate functions ok, its been sat for two years and that the connection to it can flow enough.

Two ideas as to why, dynamic compression is rising with the different cams.
Cant get the exhaust gases out the manifold and wastegate (which is 44mm and really surprises me that it would restrict but hey ho)

Fudgey

iTrader: (4)

Did this ever get finished?

djwilma

Should be done by Xmas, just not decided on year yet
it's been a tough year, ECU was wired in incorrectly so it fried the main board looking for an earth.

I lost my job in December and haven't really pushed it as it needs more than I can do myself

But I will finish it, I have to, it's my destiny

Rsmat

iTrader: (2)

Wicked build thread this .

Stoka1.

Where did you buy the gearbox adaptor plate and engine mount kit ?

djwilma

Holy thread revival batman

​​​​​​Engine mounts were custom made by engineering company

Adaptor plate, it's the same as a duratec so used duratec adaptor plate and custom flywheel with clutch pcd from the Rover 620ti

Stoka1.

And where can I buy the adapter plate ?

How do you go with your conversion also ?

djwilma

http://www.swlotus.com/lotus-elise-d...n-details.html

​​​​​​Not actually finished it yet

Stoka1.

Do they actually sell individual parts ?

How far off are from finishing it ?

And does the ecotec gearbox not fit in the
Elise as in is there no room ?

djwilma

Yes to individual parts
I just need to sort the alternator wiring and TPS, engine runs and has been mapped
Gearbox will fit, but I went for the uprated PG1U box as I already had it and the clutch so just needed the flywheel. Starting again I'd go for the Ecoboost 6 speed box as it has similar ratios 1-5 but with a taller 6th. But would need drive shafts, mounts and gearshift brackets making etc

djwilma

Yes to individual parts
I just need to sort the alternator wiring and TPS, engine runs and has been mapped
Gearbox will fit, but I went for the uprated PG1U box as I already had it and the clutch so just needed the flywheel. Starting again I'd go for the Ecoboost 6 speed box as it has similar ratios 1-5 but with a taller 6th. But would need drive shafts, mounts and gearshift brackets making etc