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Old 13-06-2012, 04:37 AM   #31
steve w
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Quote:
Originally Posted by andy b View Post
Some great work there mate, that manifold looks superb.
What car did your engine come out of? I always thought the duratec engine was a chain driven engine not belt driven.
The belt driven engines were actually zetec engines dressed up as duratec.
That's correct. The engine is from an 03 plate focus rs. Ford cheated with the rs and st170 engines. They modded them, and rebranded then duratec. The focus rs is basically a low comp blacktop Zetec, but has different cams, some head work, and sodium filled valves, etc
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Old 25-10-2012, 08:21 PM   #32
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Been a struggle to get out to the garage with a 1 and 3 year old terrorising the mrs. But managed to get a few bits done in my lunch hours!

Had a go at a set of Carbon door skins



Had this idea in my head for quite a while, and had to know what the gains would be. Whilst the new skins fit, and sit flush with the outer skin. Its just doesnt have the weight saving I was after. Its has the "Carbon" factor, but thats not what I'm about. But I have a new plan, I'll take a mould off these before completing, and selling them. Its all about learning I suppose.




As I cant weld, there was only one way I was ever going to make a new alternator mount!



Made a top mount aswell.





Also had a go at a new throttle stop for the Inlet. Fits great, but may have to remake if it flexes too much, as its bloody light!



Drilled and tapped the inlet plenum for the Air Temp Sensor




Also started looking at the feasability of fitting coil-on-plug. The RS lads seem to swear by the standard ford setup, even for high BHP setups. So I may abandon the idea, although it does look good!?

Disc bells and Caliper brackets are in progress. Ive also started fitting the flywheel/clutch setup ive sourced.

The next project is the crankcase oil breather. there seem to be 2 ways to go. Standard catch/flame trap with a modified breather setup, or a totally custom idea. I'm looking at a way of making my own version of the two!
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This is FORD country....on a quiet day you can hear Vauxhalls rusting.

If at first you dont succeed, Destroy all evidence that you ever tried

Last edited by steve w; 25-10-2012 at 08:25 PM.
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Old 22-07-2013, 08:56 PM   #33
steve w
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Thought I'd update this, as progress has been slow lately.

My clutch and flywheel are fitted.

I've plumbed an aeroquip fitting the Sump for the oil return, and fitted the oil feed.

Also made a carbon, baffled crankcase breather. Just got to trim it a bit more, and fit a b/head fitting and that's done.

Disc bells and calliper brackets have arrived, sending them over to get hard anodised before bolting the wilwood 10" discs and wilwood calipers.

I'll post pics at the weekend.
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Old 23-07-2013, 06:34 AM   #34
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good to see its not stopped .. and yes to pics
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Old 23-07-2013, 05:44 PM   #35
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Here's the crankcase breather








And the clutch fitted




Brake bells and adapters went to anodising today
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Old 06-08-2013, 04:09 PM   #36
steve w
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Brakes have arrived



Put a wheel on as I was too curious!



Also got a male-male adaptor an fitted the fuel reg directly to the end of the rail.



Think I should still add a support bracket. (I do!)
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Old 06-08-2013, 08:09 PM   #37
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Nice wheels. Them brakes look huge! Liking all the carbon stuff, how did you make the thick stuff?

Ben
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Old 06-08-2013, 08:15 PM   #38
steve w
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Originally Posted by Muffyvaux View Post
Liking all the carbon stuff, how did you make the thick stuff?

Ben
Added more layers! 😂 (does help to add 100 psi aswell though!) why, what you need???

Brakes are 10.5" wilwood vented discs. I claim zero credit for the bells and brackets though, all I did was get a friend to arrange the hard anodising.
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Old 06-08-2013, 10:37 PM   #39
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Added more layers! 😂 (does help to add 100 psi aswell though!) why, what you need???
Just wondering. I only have just started making parts, always gaining info from were I see it learning as I go. 100 psi - you must have access to an autoclave then?

Ben
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Old 10-09-2013, 03:17 PM   #40
steve w
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Had a spare hour, an engine crane, and a 2 year old to help.

Its in!



Was real worried whether the plenum would clear the frame, and it does.





Now the car is unwrapped and in the garage for the first time in a year, the winter mods can begin early!
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Old 11-09-2013, 03:23 PM   #41
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Glad to see this is moving on, looking good.

Andy.....
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Old 11-09-2013, 08:14 PM   #42
steve w
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First issue hit tonight.

Had a top mount alloy wrx intercooler for a while. After I had the idea of mounting it into the engine cover, and ducting down off the roof vent. Not going to work, doesn't really fit.

So tried the boot space


It sort of fits, the outlets line up, but it doesn't look right. Going to see about sourcing a long intercooler like a sierra cosworth one???

Also templated the back piece of parcel shelf, will cut it out tomorrow.
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This is FORD country....on a quiet day you can hear Vauxhalls rusting.

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Old 13-10-2013, 02:16 PM   #43
steve w
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Been getting bits and pieces done









Fitted the centre shaft, gear cables, starter,and bits of loom.

Made a parcel shelf, now just got to make a centre engine cover. Thinking of doing a 1 piece one, with a Perspex window in it.

Also Prefitted the turbo, and starting looking at the cooling and exhaust system.

Cooling system needs completely replumbing rear of the tunnel. I'm going to rotate the down pipe for the exhaust through 90 degrees, fit a small silencer and exit out of the LH rear quarter.
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This is FORD country....on a quiet day you can hear Vauxhalls rusting.

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Old 21-10-2013, 07:15 PM   #44
steve w
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Oil return made tonight. Finally found a way of making up hoses without getting stabbed/slashed to pieces by the braid.



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Old 28-10-2013, 09:09 PM   #45
steve w
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Engine cover made





Just a little fettling to get it fitting properly. Then have to fit the anchor nuts.

Also starting to have a little play at making some boot hinges

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