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Thread: Duratec Turbo Fiesta 4x4 (Quattro) Project

  1. #41
    Mechanic Stevenoz's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Excellent stuff there, brilliant vision. I was tempted to buy my old Mk3.5 2litre back as its owner has been banned, but i definately want it back now! Inspired!!!
    Top work fella, keep it up!!!
    Cheers,
    Steve

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    crikey moses.. sounds like a top project!

    Il b keeping my eye on this.. bagsy avin a go!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Wot a crackin project m8

    Fair play to you thats a hell of a melting point of different bits and pieces, look foward to reading next instalment.

    nice one

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    awesome.....hats off to you...mite copy it and do the same to my mk1 fiesta.... .....i aint got the balls

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    this will be some job when done, gotta say "fair play to taken on a project that has never been tackled before", you have defo done some homwork on this project.....this will be awsome & a sreious bit of kit....
    mk 2 mexico 1978
    mk 2 van 1978 (sold)
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    World Champion Decade Plus User markb's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    i think we need an update on this please!

  7. #47
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Please update this is getting intresting.

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    awesome...keep up the wicked work

  9. #49
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Hello all, sorry for the lack of updates! I started a new job a few months back and I've had sod all time to work on the car since.

    I've done a few pretty insignificant things including the following:

    May 06:

    I want to tilt the engine as far back as possible to lower the centre of gravity, and to some extent aid weight distribution. To do this I needed some kind of adapter between engine and gearbox. Two options here: weld Ford gearbox bellhousing on to gearbox, or make an adapter. I selected the latter for ease of part replacement should a gearbox let go.

    After measuring the engine bay to determine clearance, then playing around with the engine/box to determine how far the engine can be turned without fouling the drive shafts, I used a combination of the gearbox shim/gasket for a TT and the Focus equivalent, both of which I traced on to tracing paper. Careful measuring to find the exact centre meant I could lay them on top of each other, roate the correct number of degrees and then take a further tracing of the resultant shape:


    Then the laborious task of measuring all of the points:


    Transfer to cad:


    Put on CD and take to one of my Dads freinds to get laser cut. Voila:


    10mm thick and exact holes for the Ford and TT bellhousing pattern. 1 hole is shared and can be simply bolted straight through from 'box to engine.

    September '06

    I'm the process of shot blasting the enture underneath to remove any surface rust that appeared since I last worked on the car (some parts were left bare metal - I was stupid and didn't put a temp sealer coat on it!). I've turned the garage into a shot blasting 'booth' by suspending polythene from the ceiling. It's a terrible job but needs must!

    I'm using Dinitrol RC800 to seal the bare metal. I was going to use etch primer first but I undestand that it's slightly porous, so if you leave it unpainted for a length of time then you get rust underneath the primer (especially this time of year). The RC800 is organic acid based and it 'etches' in to the metal and leaves a totally impermeable seal. It neutralises rust that's already there and is also overpaintable.


    It's a milky colour, turns blue the minute you paint it on and fully dries black after 12 hours or so.


    Better updates to come when I've finished blasting the bloody thing

  10. #50
    Racer Decade Plus User Stevie's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Cant See Any Pics M8 ?

    MY MK1 ESCORT (Now turbo'd)

  11. #51
    Bodger

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    I've just tried again and when I came to preview the post the same thing is happening, anyone know why? The images are hosted on my own server and there is no problem at that end.

    They're not that exciting so you're not really missing much, puzzling though all the same

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    It was a problem with the site uploader, all fixed now though

    Cracking work as usual

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Good luck with the shot blasting thats one hell of a job.

  14. #54
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Very nice job !!!

    I am building an escort mk2 4x4 with cosworth engine.
    Also a lot of thinking !!!!!

    http://www.mk2cosworth.nl

    Greetz from Holland

  15. #55
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    I hope your measurement to find the centre was accurate, otherwise you'll never get that box and engine together (at worst) or be munching input shaft bearings or clutches!!
    Also, now that youve put this spacer in, are you goin to need a custom gearbox input shaft made, or is it such thickness that the audi input shaft ties up with the engine's clutch splines?

    Well done with it all though, looks very impressive

  16. #56
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    good job marky!!! any updates ;-)
    My 3 door Cossie and Mk3 Escort Pick up Project...

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    thats spot on

    Streetracers
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  18. #58
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    any updates to this yet? looks very well started, lots of attention to detail (lol started my kitcar along those lines too and due to lossing garage and SVA being introduced never continued , getting urges to get back into it as a track racer tho ). good luck with the build should be a top job when its done.

    David

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    lookin good mark.....

    thought i recognised the no plate!!

    i will have to come and have a look mate, i didnt know you were doing any of this!!

    Im just about to start a bit of a restoration on my capri too.... nothing to this extent though!!

    you have definately put in some hard work on that shell!!!

    jim

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Wow, simply Wow!

  21. #61
    Part of the furniture Decade Plus User Tone's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    excellent work their m8 keep the pics coming top man

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Quote Originally Posted by cossiemetro View Post
    excellent work their m8 keep the pics coming top man
    Your another nutter LOL your car must be mental!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    More updates mate the work that has gone into this is awesome

    Yodi

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    This is a mad project, keep up the hard work and keep us informed with the updates.

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    UPDATE please I love this car

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    any updates

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Sorry for the delay guys I've been exploring Thailand with a friend! More updates to come soon, I'm just waiting on some parts at the moment

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Quote Originally Posted by excursion View Post
    Sorry for the delay guys I've been exploring Thailand with a friend! More updates to come soon, I'm just waiting on some parts at the moment
    No Excuse mate LOL LOL

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    looking forward to the updates marky
    My 3 door Cossie and Mk3 Escort Pick up Project...

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    OK, back from Thailand and things are rolling again. I've had long running concerns about the adapter plate I created so I've re-evaluated and commissioned a CNC part. I've got to thank both Mark Attridge and Richard Jones from R J Engineered Solutions (he mainly deals with VW>Impreza conversions) for their help and machine work. The 02M gearbox is being reverse-engineed in order to ensure the adapter plate locating dowel positions place the input shaft relative to crank C/L within OEM tolerances (0.05mm). I know for a fact my plate would work (as proven in many other conversions worldwide) but I want to make sure everything is 100% from the outset.

    I've got a two week wait for the plate so, in the mean time here are a few photos of my WRC manifold. I just had to have this as the design is excellent (as you'd expect!); ideal primary diameter, length (equal) but most importantly the collector is of high quality which is extremely important for good turbo/throttle response. The primaries are relatively long; torque counts in WRC! This is also exactly what I'm after. The manifold is constructed from Inconel so has excellent heat transfer properties; in fact itís cold enough to touch 5 minutes after a hard drive.







    You can see the WRC thermostat take off (magnesium for insulation!) which keeps the top hose from coming too close to the hot manifold. I've also got some longer leads to relocate the coil pack although I'll more than likely go coil-on-plug.

  31. #71
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Nice!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    About time we had sum updates.
    Love that manifold

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    love;y...check out the welds on that manifold

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Manifold looks
    Are you going to need a support/damper for the turbo to prevent cracking ?

    Mark

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Thanks guys.

    Mark - yes I'll definitely be making one up, don't want to risk that manifold

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    looks awesome mark!!!
    My 3 door Cossie and Mk3 Escort Pick up Project...

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Amazing - Liking the manifold!

  38. #78
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    nice work mate cant wait 2 see it driving around, as im only down the road from you in tattershall.if i had the time and money 2 do sumthin like that i would. but at the mo im still recovering from my car crash last year.
    If u need a hand just give me a bell. also i hav a fue freinds in the car game so might be able 2 help out that way u never know. got one mate who is the dogs b******s when it cum 2 doing one of exzort systems.

  39. #79
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Excellant work

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    Bodger

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    My new adapter plate is finished; massive thanks to Mark Attridge for helping me out with this despite being busy with projects of his own!

    The lug I removed from the rear of the block in order to accomdate the Audi transfer plate has been decked and tapped in each corner for M5 studs. This is so I can bolt on a cover plate with 2 threaded fittings for the breather system:


    Gearbox and engine were put on the mill to get accurate dowel position coordinates:


    16mm HE30 aluminium. Mounting holes being machined/tapped/countersunk:



    Outside edge:



    Internal:



    The following photo shows the new 8mm dowel that's been installed in the block (top right adajcent to existing bolt hole), this facilitates precise location of the plate on to the block. I've had the Titan dry sump modified with 2 fixing points. The outer edge wasn't flat so it's been milled to suit, you can just about make out where it's been milled to accept the plate's profile:


    Complete:



    This shot shows how far the engine is tilted back:



    This has all gained me a massive 3.7" of clearance below the engine, so I can now move it down further to lower the COG.

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