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Thread: My mad Duratec 2.5 instalation - Cortina Mk1

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    My mad Duratec 2.5 instalation - Cortina Mk1

    You've probably seen a lot of projects where V8's replace a 4 pot. Well, how about a 4 pot replacing a V8! Yes - you may think I'm mad, but there is method to my madness. The V8 is a Rover (TVR flavour - no less), and the car is my extremely long term project Mk1 Cortina. I've had this for over 20 years now, and one day it WILL be finished.

    I did the V8 conversion some time ago, and the project kind of stalled. Its been in storage waiting, and waiting....

    Well, with the dust blown off, I've taken a close look and decided I would rather the lightness and balance of a Duratec. I know the Rover V8 isn't too heavy at around 150kg, but I think the Duratec is 95kg, and in its 2.5L form can be made to pump out some good power (especially if I go with a turbo or supercharger).



    Colour is Ford Ermine white with a pearl green stripe.







    I spent quite a bit of time dressing the TVR (Rover) V8. Looks the business, but now it will have to go into another project.





    Tubbed to accept some serious rubber.









    There's a full space frame under there. Very little of the original Cortina remains. The engine mount brackets were all designed for the V8, but I'll have to cut these out now. The front wings, and front panel are a homemade GRP, made with the help of a book I got from the library.




    This is the place where the Duratec 2.5 will eventually sit.






    I made the bonnet too and incorporated a bulge to clear theV8's air cleaner. This won't be needed now, and I was never really that keen on it. I'd like to keep it fairly stock looking on the outside.





    Steering rack is from a Mk2 Escort.



    Space frame has backbone tunnel - like a TVR.





    I'll keep the pictures coming as I progress.

    It would be nice to hear from anyone with experience of tuning, a 2.5 Duratec - especially anyone running a turbo or supercharger.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1


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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Looking forward to seeing your progress with this
    Keep her lit

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Nice looking project look forward to watching it come together

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    You be better turbocharging 2.0 duratec I've done 2.5 it vibrates a lot with the ballance weights out makes good power but not a smooth engine

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    amazing work..looks mint...cheers mark

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by Lmr025 View Post
    You be better turbocharging 2.0 duratec I've done 2.5 it vibrates a lot with the ballance weights out makes good power but not a smooth engine
    There's quite a bit of controversy about the balance weights. Some say it makes no difference. Others say Ford put it there for a reason. I don't think there's a balance weight in the 2.0 or 2.3, which makes me think its only there for the longer stroke of the 2.5.

    What were you revving to with your 2.5 turbo? I wonder if its just a case of having the bottom end dynamically balanced?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Bottom end was balanced and the gear was shaved down it revved to 7700 rpm made 335hp at wheels at 8lbs of boost had rods and pistons made in America , just had a 2.4 duratec sbd motor na with forged crank and that's not smooth either so not sure if it's the big gear what drives the ballance weights even tried softer engine mounts

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by Lmr025 View Post
    Bottom end was balanced and the gear was shaved down it revved to 7700 rpm made 335hp at wheels at 8lbs of boost had rods and pistons made in America , just had a 2.4 duratec sbd motor na with forged crank and that's not smooth either so not sure if it's the big gear what drives the ballance weights even tried softer engine mounts
    The 2.4 SBD motor sound interesting. I would have thought the forged crank would eliminate all balance issues. I can't use the standard weight balance - even if I wanted to it will interfere with the RWD sump.

    Does it vibrate at the top end only or throughout the rev range? What pistons and rods did you use from America?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    all through the range rods are crower and pistons are cp 9.0 compression ratio

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Some more progress - picked up a brand new 2.5 crate motor courtesy of Dave at RetroFord.





    Dave also supplied some engine mounting hardware.




    A new GRP bonnet from Old Ford Auto's.



    Picking these two bits up myself saved me more than enough to pay for the van hire... and my lunch... and a coffee...

    Now I've got everything I need to get that new engine mocked up in place.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Stunning work

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Love this build

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Ecoboost

    I will be putting a 1.6 ecoboost in a 3dr Sierra as they make good power
    With next to no money spent and it's light
    ( it's just a sigma se engine )

    You could use a 2.0 ecoboost which I am led to
    Be leave is a turbocharged duratec
    But with respectable internals?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    beeRS any idea where that water outlet on the engine came from? I need one for my duratec build in my mgb

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by Lacey View Post
    Ecoboost

    I will be putting a 1.6 ecoboost in a 3dr Sierra as they make good power
    With next to no money spent and it's light
    ( it's just a sigma se engine )

    You could use a 2.0 ecoboost which I am led to
    Be leave is a turbocharged duratec
    But with respectable internals?
    Good idea. I've seen pics of the 2.0 ecoboost and the block does look like a Duratec.

    The think the 1.6 ecoboost is the same engine I had in my recent Fiesta ST. If so, it is a cracker. Should work well in your Sierra.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by itsawindupuk View Post
    beeRS any idea where that water outlet on the engine came from? I need one for my duratec build in my mgb
    The water outlet in the pic is actually what the 2.5 engine comes with as a crate engine. It comes up and over the exhaust ports. I need below the exhaust ports, so this one is redundant. If you want it let me know.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Ooh yes please!

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    .....now that is nice...great job

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Here comes the fun bit: with the engine mounted on a stand and a box full of goodies from Dunnell Engines its time for a dry build. This is just so I can sort out what goes where. I'll strip the engine down later for a performance build.



    Careful measuring means that I'm really tight for space heightwise. The Duratec is taller than the V8. This wouldn't normally be an issue in a Cortina, but this car is affectively channelled over its chassis.



    To gain an extra 25mm I've 'borrowed' a cam cover from a new MX5 (MX5 one shown on the right, and Ford one on the left). Its a little shallower and goes straight on. Its what Frontline use on their MGB recreations. I will probably put something that looks a lot sexier on eventually, but if I use this as a starting point at least the bonnet will shut. Both cam covers allow variable cam timing, but I'm still unsure if I'll use this.

    If anyone knows of any nice Duratec cam covers please let me know.



    There's nothing really wrong with the water outlet that came with the engine, but I'm going to use the Dunnell one which routes underneath the exhaust ports.



    The original outlet fits quite tight to the head - not bad for an OE part. Its not required - so off to a good home.



    Dunnell supplied alternator.


    Dunnell's water outlet kit.


    Dunnell's wet sump is designed for Escort RWD fitment.



    Removing the balance weight on the Duratec has shed a stone! Now I have something to prop open my garage door on windy days.



    Arrggghhh! When everything bolts straight on without drama you just know murphy will kick in with his stupid law. The Dunnell oil pickup pipe anchors on the wrong side. This must be a difference between the 2.0 and 2.5. Anyway Dunnell have said they'll modify this for me.











    I do like Dunnell's aluminium brackets. Pricey, but made really well.



    Measuring up for a new V-belt pulley with string.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    And a good home that water outlet went to thanks very much!
    That engine is looking good! Are you forging the insides? I used k1 rods and supertech pistons on mine with Kent cams and arp everything.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by itsawindupuk View Post
    And a good home that water outlet went to thanks very much!
    That engine is looking good! Are you forging the insides? I used k1 rods and supertech pistons on mine with Kent cams and arp everything.
    Hope its just what you needed

    Is your MGB registration RRP...? If so, I saw your YouTube video. It's a really tidy one and with that engine I bet it flies!

    If I do go with a Supercharger or Turbo I will certainly be using forged internals. Not sure what spec to build to at this stage.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    lots of nice info here

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Don't use the lightweight front pully mate mine vibrates really bad changed to big standard damper and now it's spot on

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Was it zero balanced with that lightweight pulley? Was there some heavy flywheel with it?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Rocker Cover:

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    BeeRS yeah that's mine. Took a bit of work but got there in the end. I'm now doing a full body restoration tho so won't be on the road for a while.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Stunning, I like it a lot

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    Clint, Who makes that cover? Its fantastic and also has mounts for cops which i Will use.

    Lähetetty minun D6503 laitteesta Tapatalkilla

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Quote Originally Posted by Lmr025 View Post
    Don't use the lightweight front pully mate mine vibrates really bad changed to big standard damper and now it's spot on
    The OE pulley would have been my preference, but it might be tight for space as it is so close to the steering rack.


    Quote Originally Posted by Clint View Post
    Rocker Cover:

    That cam cover looks fantastic - just what I want. Where does it come from?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Id take one as well

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    My mad Duratec 2.5 instalation - Cortina Mk1

    Me too, looks great

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Love the build, I'm doing a mk1 cortina duratec as well, where can I get one of those cam covers?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Somehow, I've managed to venture out into my freezing cold workshop to make some progress. Who knows, maybe I'll even finish this project within my own lifetime.



    Mocking up a cardboard bracket of how the oil pick-up bracket ought to be. I have no idea, why the 2.5 should be bracketed on the opposite side to the 2.0 or 2.3. Ford just seem to love making like difficult for us.






    With the bearing cradle removed from the block, you can see the big horrible drive on the crank (used for driving the weight balancer unit of the 2.5). I'm not sure whether I'll be keeping this crank or not - I'm not even sure there are any options available that keep it a 2.5 capacity? Many seem to use a 2.3 crank for better revving. Anyway - I'll worry about that another day.



    I sent the oil pick-up and bearing cradle back to Dunnells and they modified it for me. It might have been easier to do it myself, but they insisted it be brazed - not welded. I'm happy to MIG weld, but have not tried brazing yet, so it seemed simpler to let them take care of it.



    Brazed on bracket.




    Sorted .




    Could this be the worlds most expensive bellhousing? Reluctantly, I've gone for this item from Quad 4 Rods in the States. Its so expensive it makes my skin crawl. Just what you need at this time of year. The space frame chassis was designed around a T5 so I'm reluctant to swap it for something else now. There's a lot of chat on this forum about alternate gearboxes - Mazda MX5 box, RX8 box, Raceline's new box... but I've decided to stick with the T5 as I already have one (originally intended for the V8). This bellhousing is the only one I've found to mate a Duratec to a T5 box.









    I agonised about which sump to fit. I would really have loved to use a dry sump, but the shallowest one was still 50mm deep. Compared to 35mm at the front of Dunnells wet sump. In the end that extra 15mm is what swung it for me. It really is that tight for space (heightwise).






    Ready for a trial fit in the chassis? Not quiet - First, its time to get the angle grinder out...

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    brazing is much much less likely to crack than a mig weld

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    A friend of mine took a 1700 BDA to a reputable engine builder for a complete overhaul including new crank and rods. He presented him with a big wing alloy sump for a X Flow engine which no one had ever seen before. The oil pick up pipe was damaged and needed repairing. The engine builder did his nut when the owner asked him to repair the pipe. In the end he had to fork out another £1200 for a dry sump system or he would n't have built the engine.

    In the old days we would often modify or repair oil pick up pipes with either braze or mild steel, but then again the engines did n't stand us at a lot of money unlike today.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    in a similar vein i was talking to a customer about his engine and he was talking about shot peening his rods, to which i replied, yes in the old days when steel rods were exotic and affordable by 99.999% of customers it made sense, it didnt matter if it took someoen the best part of a day to draw file and polish the rods first, but today steel rods are so cheap why risk it?

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Despite the freezing cold I've made some progress...



    This is the complete GRP front end removed as one panel. It only weighs about 3kg, but its damn awkward to move about on my own. With it out of the way getting round the engine is going to be so much easier.




    The bonnet is propped here at exactly the correct height using a very high tech method (a piece of 2x2 sawed to length ).




    A bit of bracing tack welded into place before I begin cutting away the V8's engine mounts and the cross member.




    Even got some help from my 11 year old son. Start them early - I say.








    Further bracing of the suspension towers before I cut away the cross-member. This will tie the towers into the upper frame. I'll box this later.



    For the record- this is not the way to build a car. I would not recommend you spend weeks making engine brackets, then get the car painted before cutting it up. Best to just figure out what engine you want from day one. Oh well - live and learn.

    The new cross member will have to sit a little lower to make sure the Duratec fits without the need for a bonnet bulge. I'm trying to keep this looking fairly stock on the outside.









    Just a temporary coat of zinc primer. Now I'm ready for the engine at last.





    Well pleased with that .








    Looks so much smaller at this stage than the V8 I had before.



    With the Mazda cam cover in place I've got the engine sitting at exactly the right height within the chassis. I probably won't use this cam cover in the end, but at least I know it'll fit with this one as a fall-back.




    Sitting as far back in the engine bay as I dare go. That's 5mm clearance.




    Sometimes it doesn't matter how many times you measure something, until you put it into practice you never know for sure. I was convinced that the OE Ford crankshaft pulley would foul the steering rack. Well here's some good news - I've got plenty of space to spare.

    Next step engine and gearbox mounts.

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    What did you end up doing for the T5 Pilot bushing/bearing? I had a 19mm OD oilite bushing bored out to .688" to fit the V8 input shaft. If you have a I4 input shaft for that t5 you could use the factory Duratec bearing. You could also turn down the input shaft but then you've got to pull the tranny half way apart and you're going to cut through the case hard on the shaft.

  46. #40
    Tyre Wall Terry Decade Plus User 4parajon's Avatar

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    Re: My mad Duratec 2.5 instalation - Cortina Mk1

    Enjoying the build fella
    Was making the front end difficult then??
    What was the book called you used as a guide??

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