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Thread: Fiesta D-TEC

  1. #1
    Racer Decade Plus User Adam B's Avatar

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    Fiesta D-TEC

    right, i apologise if the wording seems a bit weird, i've copied it all from another forum...

    Apr 15 2006:

    Right, as i've just put a deposit down on a Duratec engine, i thought to start this thread off, over the next few months, i will hopefully document my progress.

    This will be done as quickly as funds allow, i have an engine (4000 miles), gearbox, driveshafts, mounts, and a few other bits and piece on their way...

    I have a new shed to build (pics will follow) for me to store my parts in and hopefully build up the engine.

    Then will be to buy a stand-alone ECU, the OMEX 600 is looking most favourable at the moment, although i'm currently conducting some research into whether there are any alternatives.

    once i have all the main parts, work will commence on stripping out the 1.25, the bay i am hoping to seam-weld, remove any rust that may be hidden and give it a fresh lick of paint.

    The engine will run a standar inlet and t/b at first, then once its all fitted and i'm certain its running properly i will investing in a set of roller barrel t/b's...

    anyway, enough of that...

    this is the first step to make sure i'm comfortable and safe once the engine is in...




    My Project... Fiesta D-TEC

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    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    April 17th 2006:

    An Update...


    My Workshop is built!!!

    well, almost, looks like a shed atm, but will soon be boarded, insulated, have power and light, and some heavy duty work benches...

    This shall be where i build my engine and store my parts, will also be a good place to finish my speaker builds.

    Only prob... its 70ft away from my driveway!!! not a prob though as the engine i have planned is to be pretty light.

    plus having it hidden away behind a big hedge... i can use it as a place to sit with my mates over the summer. its my own little secret garden.

    anyway, this is how its shaping up... 2 days solid work, and i ache like a mother ****er...









    so yes... either i will go and collect my engine next week (what i'd prefer), or i will crack on with sorting the facilities.

    My Project... Fiesta D-TEC

  3. #3
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    April 30th:

    Aladdins Cave (shed)


    Lump:


    another angle:


    Gearbox:


    mit shafts:




    Box of Bits ( Interior loom, engine loom, pedals, gear-linkage, brake servo/master cylinder, reservoirs, engine mounts)


    Can you guess what it is yet?!?


    oh yeah, and i got this a few weeks back to replace my bent one... has to be sand blasted, and powder coated


    if anyone wants it, this is for sale, but needs new gaskets (doesnt have t/b)

    My Project... Fiesta D-TEC

  4. #4
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    May 28th

    thought to add some more pics... this was the workshop about 3 weeks ago, just about insulated and pannelled... alos had the lights and sockets wired in too:



    and this is it now, i finished about an hour ago







    so time for me to get an engine stand, stripping back to the bare block and head (to work out what i need to keep and what i dont), and start sorting through and organising the parts i have...

    as for throttle bodies or management, as i'm paying out for my insurance in a few days i'm back to square one, gonna keep the car running until i can afford to buy all the bits (hopefully in a couple of months with some luck) then i will set to getting the bad-boy in

    in the mean time, there will be some light bodywork done, and attack some small patches of rust that are appearing (majority will be sorted sometime next year, as i plan to get a full de-dent and respray), and the engine bay/behind front bumper will be done whilst the engine is out

    watch this space!

    My Project... Fiesta D-TEC

  5. #5
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    May 31st

    ordered one of these last night...



    and also found out my grandparents have paid for the engine crane i "borrowed"... so its all mine... yay!!!

    My Project... Fiesta D-TEC

  6. #6
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    June 4th:

    well... i got i mounted, so no need for an impact driver just yet


























    My Project... Fiesta D-TEC

  7. #7
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    June 17th:

    a small update:

    engine stripped back as far as i want it to be...







    this will new be cleaned and painted... block, head, and front cover will be silver, sump will be black

    rocker cover has been primed as i want to see what it looks like in radiant red...

    My Project... Fiesta D-TEC

  8. #8
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    June 30th:

    couple o bits come through from raceline...

    EGR Blanking plate


    Oil Filter Housing (to replace bulbous original item)


    Inlet Manifold for Throttle Bodies



    Throttle bodies being ordered hopefully in next few days :thumbsup:

    My Project... Fiesta D-TEC

  9. #9
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    July 3rd:

    right, on saturday i made a little progress...

    Pumps and tensioners start to be bolted back on...


    starter motor back on


    Hole where the EGR valve used to be


    another pic of the block


    Where the original oil filter mount used to be


    New Raceline Inlet Manifold Fitted (still need to get some proper bolts)



    New Raceline Oil Filter Plate



    Raceline EGR Blanking Plate fitted

    My Project... Fiesta D-TEC

  10. #10
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    July 29th:

    Rocker cover on

    its not perfect, but its not far off, and will only be there until i can afford a raceline item.








    My Project... Fiesta D-TEC

  11. #11
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    August 20th:

    Right, thanks to Peewee, i can give you a quick pictorial update...

    got these:




    then did a mock fit, and as expected, the power steering pump doesn't fit, so i'll defo be going to manual steering

    anyway, more pics:






    My Project... Fiesta D-TEC

  12. #12
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    September 30th:

    Small Update:

    Bought these:




    then had to drill out the mounting holes (these were designed to fit roller barrels)

    and temporarily got them on (need to order some more alloy fixings)





    oh and i think this is one of the best cardboard boxes in the world



    shame it doesn't contain anything very exciting, but no pic of the contents until the rest of the items have arrived (tues/wed hopefully)

    My Project... Fiesta D-TEC

  13. #13
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    October 4th:

    another little update:

    everything finally arrived (i hope)



    my favourite bits:

    lightweight alternator


    Tensioner (from ford), modified to give more clearance (by cosworth)


    lightweight water pump pulley... my one and only cosworth branded part, lol


    hopefully this weeked should get it all bolted on and then i'm not far away from starting the conversion.

    My Project... Fiesta D-TEC

  14. #14
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    October 7th:

    update...

    alternator is on :thumbsup:










    pncool, will let you know a price soon, its done only 4k miles, i gave it a quick blowover with silver paint

    dont have a rocker cover unfortunately, on the look-out for a metal one myself, as i wanna get one powder coated (dont know whether to stay red or not) because the paint finish isnt perfect on my plastic one.

    My Project... Fiesta D-TEC

  15. #15
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    October 23rd:

    Some pics thanks to mike105e:











    My Project... Fiesta D-TEC

  16. #16
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Dec 17th:

    whilst at peewee's the other week, he kindly took some pics as the car had been back into the bodyshop to have the bonnet sorted (wasn't happy with the way it'd been done), and to have the paint on the wing and grill sorted (bad sprayer).







    and i just like this pic


    cheers peewee :thumbsup:

    may spend a little time in me shed again today, its about time. anyone seen the insides of an IB5? coz i will be soon

    My Project... Fiesta D-TEC

  17. #17
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Dec 19th:

    Well, no updates still, finding it hard to motivate myself when its so cold, but to keep things up to date, i have bought a few new parts..

    these are thanks to Peewee :thumbsup:

    Omex Series 600 ecu


    Vibratrechnics engine mounts (hopefully i can use/mod for use)


    Quaife ATB Diff



    Also, these came through the post this morning:

    330cc injectors (plus 1 spare)


    and i didnt mention this, but a few months back i purchased:

    this GRS alloy rad and fan (from a zetec turbo FRST) again, should fit with a little adjustment.


    and fingers crossed, i think i've located a couple of other cages which i'm currently negotiating with the owners to sort a deal for one.

    so anyway, thats the current update, this w/e after i've wrapped presents i'm gonna make a start on the gearbox with an aim to have it rebuilt by the end of my christmas holiday (2nd Jan)

    My Project... Fiesta D-TEC

  18. #18
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    December 27th:

    this is what will be greeting me once i decide to get out of bed:


    My Project... Fiesta D-TEC

  19. #19
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Dec 28th:

    so i finished taking these bits out:



    leaving this:


    so gave it a quick wipe around inside (i'll be cleaning the outside as well before re-assembling)

    this is the original diff


    this is the comparison to the new ATB diff


    had to take the final drive ring off the old diff to swap across, so unbolted and used one of the other "useful" workshop tools to get it off:


    final drive attached to new diff ready to be tightened up:


    job done, all torqued up, ready for new bearings and re-assembly

    My Project... Fiesta D-TEC

  20. #20
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Most Recent Update:

    I have purchased a cage, the gearbox is re-assembled , and the car is in Milton Keynes getting new turrets and top mounts at a rally prep place

    My Project... Fiesta D-TEC

  21. #21
    Part of the furniture Decade Plus User

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    Re: Fiesta D-TEC

    Superb progress. A lot of money has gone into that and I'm sure it will all be worth it

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    Re: Fiesta D-TEC

    ace project love the car wat bhp will it be producing

  23. #23
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    it should be between 180 and 200 bhp when it goes in...

    aim will be to build a crazy duratec once finances are back under control, and rest of car is sorted.

    My Project... Fiesta D-TEC

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    Way too much free time Decade Plus User PIG's Avatar

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    Re: Fiesta D-TEC

    great work on that m8,should be a flyer when its done as well.when do you think your have it all in and running then m8

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    Pit Crew boombang's Avatar

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    Re: Fiesta D-TEC

    Looks good!

    Just a quick question - how do you set up cam timing with chain driven cam like that? I see you could shift one link at a time, but they must make vernier pulleys for them, and you could make up offset woodruff keys.

    How does it tension, fit and remove?

    Being a Pug man, every engine I've played with has been belts.
    Quote Originally Posted by boombang View Post
    Not entirely sure what point I was first trying to make or even sure what point I have made.

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    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Quote Originally Posted by PIG View Post
    great work on that m8,should be a flyer when its done as well.when do you think your have it all in and running then m8
    The original plan was for FITP in May this year, but i think it'll prob be ford fair.

    will just have to work on it as time and money allows.

    My Project... Fiesta D-TEC

  27. #27
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Quote Originally Posted by boombang View Post
    Looks good!

    Just a quick question - how do you set up cam timing with chain driven cam like that? I see you could shift one link at a time, but they must make vernier pulleys for them, and you could make up offset woodruff keys.

    How does it tension, fit and remove?

    Being a Pug man, every engine I've played with has been belts.
    the chain is tensioned by running through loaded guides, as for setting up timing, thats a good point i havent looked much into yet, mainly because its all built originally by machine, so the tolerances are spot-on from factory.

    there are vernier pulleys available, but they're not tried and tested yet.

    My Project... Fiesta D-TEC

  28. #28
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Well, first things first...

    Helix 4 Paddle Clutch kit


    designed for the Puma, but as far as i can see (i've test fitted the plate on the gearbox spline and measured the cover plate against the standard) it fits the Duratec :thumbsup:

    Gonna fit it along with the Helix clutch release bearing (to replace the current 4k one, lol) and it seems to be made better than the ford item (alloy instead of plastic)

    Have also been collecting parts for my braking system:

    10m brand new braided hose (i have another 10m in bits of used hose)


    Assortment of Fittings (new and used) and a bias valve:


    Another bias valve (i need one for each rear line):


    Also, been looking at mountings...
    this is a puma gearbox (same as fiesta mk4/5)


    and this is the ST150 box:


    looks pretty close to me! if anyone has one of the brackets that bolts to the top of the gearbox in this area from a mk4/mk5/puma could i please have it? just want to confirm it all fits.

    My Project... Fiesta D-TEC

  29. #29
    Spanner Monkey tarmac terriost's Avatar

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    Re: Fiesta D-TEC

    nice little project you have going there
    should be a stealth stormer 200bhp duratec lump hmm
    very nice

    where did you get the clutch kit from
    also the tbs and inlet manifold ?
    mrk 2 mondeo ghia saloon
    17" tsw reflexs bomz kit
    fast road cams/obx pulleys
    drop 30mm eibach springs mongoose catback exhaust
    4.1 ceramic coat exhaust manifold
    custom down pipe/highflow cat

    list to do :-
    st bodykit 300mm disc conversion+rear disc
    underdrive pulley custom management 45mm throttle bodies gasflown big valve head
    comp ratio increased 11:1


    looking for a mint 4x4 rouse motorsport 304r sapphire running std (260bhp) or stage 3 set up

  30. #30
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Quote Originally Posted by tarmac terriost View Post
    nice little project you have going there
    should be a stealth stormer 200bhp duratec lump hmm
    very nice

    where did you get the clutch kit from
    also the tbs and inlet manifold ?
    thanks

    as for the parts you've mentioned, i have a friend in the trade who sourced the t/b's from lumenition (made by jenvey, stamped by jenvey but cheaper)

    inlet manifold was from raceline

    trumpets are from titan

    clutch is a full helix kit which i bought new and unused from a friend who is now putting a cossie engine in his fiesta, so had no use for this.

    My Project... Fiesta D-TEC

  31. #31
    Racer Decade Plus User Graham_S1's Avatar

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    Re: Fiesta D-TEC

    very nice.

    gonna be a little monster.

  32. #32
    Racer Decade Plus User Adam B's Avatar

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    Re: Fiesta D-TEC

    Right, bit of an update, as i cant remember when i did my last one...

    coolant hoses are in place, and throttle bodies are in!!!

    i'll let the pics do the talking...






    My Project... Fiesta D-TEC

  33. #33
    Pole Position Decade Plus User
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    Re: Fiesta D-TEC

    that should be well fookin fast once its done.
    tommy 2000

  34. #34
    World Champion Decade Plus User RChambers's Avatar

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    Re: Fiesta D-TEC

    Wow how did I miss this one! Nice project will be a flyer for sure

    She's built like a Steakhouse, but handles like a Bistro

  35. #35
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Fiesta D-TEC

    Just spotted this


    Amazin work bud (next will be turning the engine around the right way ).

  36. #36
    Pit Crew

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    Re: Fiesta D-TEC

    Blood nice job, doncha just love those Duratec's

    www.gulfpetrolheads.com

  37. #37
    Bodger edrush05's Avatar

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    Re: Fiesta D-TEC

    top job mate some well spent money there!!!

  38. #38
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    Re: Fiesta D-TEC

    that is one hell of a set up you have mate.

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  40. #39
    Bodger

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    Re: Fiesta D-TEC

    Cracking installation

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    Bodger Daniel83's Avatar

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    Re: Fiesta D-TEC


    What a nice clean Job, sure you could eat from that engine...

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