RST Cossie Management

[Clint]

Ok time has come to do the conversion to sharons car I started by stripping the dizzy and inlet plenum off as most of the clever time consuming work is required in these two components.
I am going to make the loom from scratch as a cossie loom seems to still be expensive.

[Clint]

First things first is the Dizzy,
For cossie management to run properly we need to run the internals from a cossie dizzy and the base off the RST. Luckly the bearing in the RST dizzy is the same diameter as the cossie shaft so we basically copeed down the RST dizzy and machined flat the cossie one cut the shaft to size fitted a new sprung oil seal and checked all our heights and turned over the pickup trigger (as the dizzy spins in the opposite direction and the trigger is directional)
bingo a hybrid dizzy.

Take two dizzys:
http://media.turbosport.co.uk/2002/3/2002315195158771022.jpg

chop them up and cook on gas mark 5 for 1.5 hours:
http://media.turbosport.co.uk/2002/3/2002315195254350612.jpg
http://media.turbosport.co.uk/2002/3/200231519525480802.jpg
http://media.turbosport.co.uk/2002/3/2002315195254922856.jpg

[Clint]

All the electrical sensors need replacing with the cossie ones as they are electrically different:

The Throttle Position Sensor from the cossie will fit straight on so thats great :
http://media.turbosport.co.uk/2002/3/20023152039996837.jpg

The best way to keep the Idle Speed control is to use a valve and bracket from a Fiat Chroma; you can reuse the entry and exit pipes for the original cold start valve:
http://media.turbosport.co.uk/2002/3/200231520629596126.jpg

I am going to machine out the Air Temp Sensors and Water Temp Sensor holes to a bigger bore so I can make some reducers with a big enough sidewall.

Below are the cossie sensors on the bottom air on the left and water on the right:
http://media.turbosport.co.uk/2002/3/2002315201112968410.jpg

[Clint]

Next week I am going to concentrate on the Inlet plenum and fabricating a TDC sensor bracket and the four pickups on the bottom pulley.

The inlet plenum will use an Escort EFI injector fuel rail and a 4x4 cossie fuel regulator two brackets will be made and welded to the lower plenum, a set of standard cossie yellow or blue injectors will be suffice for 250HP.

[jasonp]

cheers clint keep it coming m8 im gonna make a book of instuctionshttp://www.turbosport.co.uk/images/smilies/smile.gif

[Toppy]

Sorry for being a thickohttp://www.turbosport.co.uk/images/smilies/sad.gifbut is this just for better fueling

[Scott_R]

Hows it all coming along Clint, and will I still have it all fitted and running right by National Day??

[Clint]

Scott yes m8, I have done a couple now for zetecs not made a cvh pickup yet. will get there other projects have taken priority for now.

Toppy, the cossie management give far better fuel and ignition control and both can be mapped unlike the standard RST system.

[Toppy]

So in theory u could run anti lag too? Or am i talking rollocks again. http://www.turbosport.co.uk/images/smilies/sad.gif http://www.turbosport.co.uk/images/smilies/grin.gif

[BigDave]

Far to technical for this thicko! Now I know where to go for my next engine rebuild tho...?

[EIL132]

Good stuff Clint.Keep us posted,very interesting. http://www.turbosport.co.uk/images/smilies/laugh.gif

[BigP]

How would this compare in performance and costs to a 5th injector kit?.

Paul

[Scott_R]

With the cossie management you are able to do a complete 3d map to iron out all lean burn/detonation issues that are big problems for high bhp rst. Couple with this the ease of which to increase the Flow rates of both Fuel and air,( depending on what throttle body you use, and intercooler), you can acheive good safe power figures.

I do not know enough about the fith injector install to comment on it, all that i do know is that it seems that the rst with this on still struggle with detonation problems, hence why water injection is then used.

[BigP]

CheeRS Scott, the standard Ke can be 'altered' to alledgedly achieve 250@wheels, but his means it runs really rich at lower speeds.

The fifth injector gets round this obviously, but as you say there maybe still the potential for it to run lean.

Clint- do you have a cost comparison for these two?.

Paul

[blackRS]

How much would it cost to get pro tuner to do it to say my car ?? http://www.turbosport.co.uk/images/smilies/laugh.gif http://www.turbosport.co.uk/images/smilies/confused.gif

[Scott_R]

As for cost, so far the most expensive part has been the Dizzy that i bought off of Clint.
Alot of the parts you can get very cheap, as it is all just plain standard cossie stuff,
2.5 bar map senser
ignition amp
water sensor
air temp sensor
yellow injectors( which most people throw away anyway)
Idle speed control valve
engine loom and ECU( probably the second most expensive bit)
crank position sensor
2wd throttle body
4x4 presure regulater
2wd fuel pump( still waiting to find a cheap one)
Fiesta EFI fuel rail
All the above has so far cost me only £200 http://www.turbosport.co.uk/images/smilies/laugh.gif and yes i do know i have been lucky in finding bits so cheap, but soooo many people have bits and pieces laying around.

For me the most expensive bit is yet to come, getting it fitted, as there needs to be a fair amount of modding done to alot of my standard parts, as i want to keep the S1 inlet manifold, the cheaper option is to use the EFI head and inlet, works as well( if not better), but only half cost, as this has all connections ready. But as i am a tart and want it to still look 'Normal' i am doing it the hard way http://www.turbosport.co.uk/images/smilies/confused.gif http://www.turbosport.co.uk/images/smilies/jester.gif

Also there is a new system that Clint has been working on that turns it into dizzyless ignition. http://www.turbosport.co.uk/images/smilies/laugh.gif

As soon as i start doing it i will post my progress in the project section, first i want to concentrate on the intercooler project. ( coming soon) http://www.turbosport.co.uk/images/smilies/jester.gif

[Toppy]

I got a 2wd fuel pump u can have cheap http://www.turbosport.co.uk/images/smilies/smile.gif what do u mean by cheap anyway http://www.turbosport.co.uk/images/smilies/wink.gif http://www.turbosport.co.uk/images/smilies/smile.gif

[roosie]

i always wanted to do this conversion on my 2.1 but im getting a 5th injector it was ok on keiths old one so i can be ok on mine