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Thread: Escort Sigma 1600 Race Car

  1. #161
    Pit Crew Decade Plus User TepiTheFinn's Avatar

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    Re: Race Escort Zetec SE (engine build)

    Cheers, Tepi

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    Re: Race Escort Zetec SE (engine build)

    very nice build look forward to updates

  3. #163
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by TepiTheFinn View Post

    Yes.
    It is the native choice for engine management.

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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Moggy View Post
    Which ECU is that you are using matey?

    Hi moggy

    As Tepi above noticed it is a Finnish ECU called Tatech.
    www.tatech.fi (also in english)
    This latest T6 Pro involves all the functions I need and many more for future updates.

    They have a great chrismas sale. And beeing a total greenhorn in engine managements It felt good to go with a native ECU.
    When (not if) problems occur I can call directly to the man who invented the whole system.
    I can also have the engine mapped by the same guy.

  5. #165
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by dobuy View Post
    one wire at a time, it will all make sense.... eventually

    Thanks.
    I'm fortunate to have a car electrician as a mechanic in my team so hopefully I'll have help.

  6. #166
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Some DIY exhaust manifold bits.
    The flange should arrive in few days.
    Now I have the DIY exhaust manifold bits ordered so when I can't work on wiring I'll do the manifold.
    Cant wait to get these two bits done... then its only plumping the fuel,oil and water lines.

    Click image for larger version Name:	Laippa.jpg Views:	707 Size:	14.5 KB ID:	39949

  7. #167
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    Re: Race Escort Zetec SE (engine build)

    where do you get so much citric acid from?

    is it just a battery charger you use for providing the current?

  8. #168
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Dazzabhoy View Post
    where do you get so much citric acid from?

    is it just a battery charger you use for providing the current?
    From the local apotechary. Sold in 100g powder bags.
    The bags cost approx. 2 € a piece. I use 2-3% solution so two to three bags for every 10 liters of water.

    I use a car battery and a normal battery charger just to support the battery. Propably unnecessary tough.

    The part you need to de-rust needs to be wired negative and the other misc. metal object you need in the bucket needs to be positive. Object wired positive will corrupt and disolve so do not use anything of value.

    Make sure the two wired matals do not get in contact. This obviously will short circuit the battery and it could start a fire.

    Safer way is to just use a stronger 3-4% solution with out current. Just takes longer. I prefer this one whenever I have enough time.
    Last edited by Roadsport; 17-12-2009 at 07:33.

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  10. #169
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    Re: Race Escort Zetec SE (engine build)

    I bought 99% citric acid from local Agrimarket.
    Pig farmers give it to pigs suffering from diarrhea
    5 kilos of powder cost something near 20 euros.
    Cheers, Tepi

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    Re: Race Escort Zetec SE (engine build)

    thank you,

    looking to dip some parts as sand/soda blasting is messy and can be damaging

    also it is a very cheap way of stripping parts, would this disolve paint or would it jus tbe rust?

  12. #171
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Dazzabhoy View Post
    thank you,

    looking to dip some parts as sand/soda blasting is messy and can be damaging

    also it is a very cheap way of stripping parts, would this disolve paint or would it jus tbe rust?
    It certaily will remove any loose paint.

  13. #172
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    Re: Race Escort Zetec SE (engine build)

    what would you recommend to clean up a pair of webers?

    could i use a dip? or is it a case of some elbow grease and some wire wool?

  14. #173
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Dazzabhoy View Post
    what would you recommend to clean up a pair of webers?

    could i use a dip? or is it a case of some elbow grease and some wire wool?
    Don't know the remedy for that one. Maybe a total disassemblying and some king or blasting.

  15. #174
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    That's my new exhaust manifold

    Click image for larger version Name:	Primääri putket 002.jpg Views:	6 Size:	614.5 KB ID:	40021

    The flange has not arrived yet. But when it does I'll have a go of some cutting and welding.

    I was advised to do 800 or 900 mm long primary pipes. But I do not know what are these measurements based on.
    Any thoughs? Anyone?

  16. #175
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Roadsport View Post
    That's my new exhaust manifold

    Attachment 40021

    The flange has not arrived yet. But when it does I'll have a go of some cutting and welding.

    I was advised to do 800 or 900 mm long primary pipes. But I do not know what are these measurements based on.
    Any thoughs? Anyone?
    these tubes good good, where did you get emm, how much £££ and whats sizes pleeseeeee

  17. #176
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by graham bahr View Post
    these tubes good good, where did you get emm, how much £££ and whats sizes pleeseeeee
    Got them from Martelius Exhaust from Finland.
    www.martelius.com (also in english)

    They were not too expensive 74 euros per set of eight.
    These tubes are 41,5mm outer diameter with 1,5 mm wall thickness so 40mm inner dia. 180 degrees within 80mm bend.

    38mm and 44,5mm outer dia tubes available too. Also available with tighter 180 deg. in 70mm bends.

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    Re: Race Escort Zetec SE (engine build)

    41.5mm OD with 1.5mm thickness gives 38.5mm ID
    always look forward to updates on this, i'm planning a zetec se conversion on my fiesta at some point.

  19. #178
    World Champion Decade Plus User alladdin's Avatar

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    Re: Race Escort Zetec SE (engine build)

    great thread.
    if you cant get citric acid you can use a carbonate of soda solution (as i have done in past).
    to make carbonate of soda, first make a solution of bicarbonate of soda in a saucepan (3 table spoons from memory) any bicarb / baking soda from asda etc. then boil it. the bubbles coming off are 1 of the carbonates (carbon dioxide?) anyway it leaves a carbonate of soda solution which you mix into a large bucket of water and start the electrolysis with battery etc.

  20. #179
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Kee View Post
    41.5mm OD with 1.5mm thickness gives 38.5mm ID
    always look forward to updates on this, i'm planning a zetec se conversion on my fiesta at some point.

    Good point!I was only assuming the wall thickness. I'll have to do some measuring.

    Thanks for the compliments Kee. I'll try to keep the updates coming.

  21. #180
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by alladdin View Post
    great thread.
    if you cant get citric acid you can use a carbonate of soda solution (as i have done in past).
    to make carbonate of soda, first make a solution of bicarbonate of soda in a saucepan (3 table spoons from memory) any bicarb / baking soda from asda etc. then boil it. the bubbles coming off are 1 of the carbonates (carbon dioxide?) anyway it leaves a carbonate of soda solution which you mix into a large bucket of water and start the electrolysis with battery etc.

    Thanks Alladin

    My patience is running low with this project! I want to get it running allready!

    But just need to keep my head cool and consentrate on the task at hand. There's still plenty to do.

  22. #181
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Haven't got much done lately. At this point the progress has seemingly slowed down. Just soo many loose ends.

    I spent the whole day in the garage today. And by the looks of things I was only standing around with hands in my pockets. Seems like I really got nothing done.

    But I managed to remove most of the old wiring. Could not start to install the new loom since I did not have big enough grommet for it. And did not want to risk damaging any wires.

    Sorted out the route for the clutch cable too. Only need to drill the hole for the cable bigger in the bell housing. Only, I do not have a 17.5mm drill bit . But all and all was fun to find out that I can use something old. The Transit van clutch cable was just long enough for this conversion. See this new bellhousing is made in the U.K so the clutch release arm is on the opposite side to my former Pinto and X-flow.

    Fitted the oil filter blanking plate today too. It too had to be modified,obviously, to fit the Titan Motorsport sanwich plate. Got it back from the machine shop and now it fits nicely and clears the steering coupling. Now I need to sort the place and plumbing for the remote filter head.

    Hope the exhaust manifold flange arrives before christmas so I could start making the manifold during holidays.
    Had a look at it today and it looked difficult but possible.
    The J- bent pipes fit nicely to the collector I have so thats good news.
    Last edited by Roadsport; 20-12-2009 at 21:19.

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    Re: Race Escort Zetec SE (engine build)

    If you ever get fed up of the project, and want to get it done quickly, then stop, come on here and have a look at grahams fiesta.

    Then get back to taking your time and doing a proper job of it.
    If i had the patience to build cars to this level id be a very happy man.
    Id also be happy if i had off street parking but thats a different story

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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Roadsport View Post
    Haven't got much done lately. At this point the progress has seemingly slowed down. Just soo many loose ends.

    I spent the whole day in the garage today. And by the looks of things I was only standing around with hands in my pockets. Seems like I really got nothing done.
    I too have days like that. Just dont lose sight of the target.

  25. #184
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Yes. Things are looking up again. Gathered some items for the wiring today. Bought the ignition modules needed with this Tatech ECU. And some alloy plate to mount the ECU and ignition modules. Also got the larger grommets today and the protecting "pipes" for the loom.

    So as soon as Santa leaves our house I'll rush to the garage and start mounting the ecu and installing the loom

    Click image for larger version Name:	hotelli 001.jpg Views:	5 Size:	910.4 KB ID:	40057

  26. #185
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    Re: Race Escort Zetec SE (engine build)

    Made the bed for the ECU today.
    Cut a hole in to the transmission tunnel and covered it up again with a alloy plate.
    The idea is to let the air flow cool the alloy plate down.
    The heat from the ignition modules is transferred to the large alloy plate and on to the outside air.
    The ECU will be mounted using rubber to insulate it from the body vibrations.
    This is not ideal considdering the cooling but I think the overheating is not an issue with the Tatech ECU since the big current is run through the ign. modules. Added bonus in this location is the slight angle of the ECU. This allows any water to flow off the connector rather than laying around it.

    Sorted out the loom a bit too. It is quite ready now to be pulled to the bay.






    Last edited by Roadsport; 27-12-2009 at 19:14.

  27. #186
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    Re: Race Escort Zetec SE (engine build)

    Fantastic work so far , and fantastic attention to detail in having it look right too . You'll be swamped in the paddock every race!
    By any chance would you know how much lighter the Zetec SE is than the Crossflow?

  28. #187
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Tristan View Post
    Fantastic work so far , and fantastic attention to detail in having it look right too . You'll be swamped in the paddock every race!
    By any chance would you know how much lighter the Zetec SE is than the Crossflow?
    Thank you Tristan
    But 11 years of racing has left little marks on the body and it could use a little ra-spray allready. Its rust free tough, only marks and cover up paints here and there.

    I guess the std Sigma would be about thirty to forty kilograms lighter than the std X-flow engine.

    On the first page of the Zetec SE topic in the Zetec installations section the Sigma is quoted to weight 82kg's.
    But is that with ancilleries or only the long motor?
    But in race trim the Sigma would loose weight still even if it is an ultralight engine to begin with. Forged high compression pistons weight the same as the OE ones. And the forged H-beam cons are a bit heavier than the original ones. But lighter flywheel, alloy racing clutch, alloy vernier pulleys and smaller alternator would all give good weight saves. Dry sump would add to this occasion. Loosing the windage tray, removing the oil from the sump and the sump itself would save some weight too. I guess all of these would count for 10kg's or so.
    But then again if the original afore mentioned 82 kg's is with power steering pump and A/C compressor the the full race version of it would be even 15 kgs lighter.

  29. #188
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Speaking of weight saving, the small oval hole exhaust flange arrived today.
    Made out of two millimeter thinner iron than the original 10mm thick one (below in the pic). And we left out the heat shield mounts too.
    This should give some weight saving. The areas marked in black may still be drilled for extra weight saving. I think the holes are originally meant to cool down the cylinder head. Everything counts .


  30. #189
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    Re: Race Escort Zetec SE (engine build)

    I am in awe of your patience!

  31. #190
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    The electrics finally made their way to the engine bay today. Ecu is now bolted on as are the ignition modules.
    This electronics bit is not my favorite part of this built. Hope to get it over with and back to the more mechanic bits. Building the exhaust manifold. Still a lot to do with the wiring tough. But it really seemed to take a step forward today.



  32. #191
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Could not work on the loom today so I started making the exhaust manifold.
    The flange lines perfectly with the exhaust ports. Very happy with it.
    Made these 2" long oval tubes to mimic the shape and size of the exhaust port. Not perfect but came pretty close.
    That's the start. Next step is to make the primary tubes and weld them over these smaller "take off" tubes.









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    Re: Race Escort Zetec SE (engine build)

    looks neat , and with the new pipes welded on over those stubs , you should have no issues with gas reversion . What are you making it out of? Will you be getting it coated?

  34. #193
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    I've been making it out of plain cheap iron.

    I will be getting it coated. I'm not a fan of the rusty look you get so fast with iron without propper finishing.
    Originally thought of spraying it myself with black satin but
    the fella who coated my pistons volunteered to coat it with some sort of ceramic coating. Acting much like the Thermotec heat wrap.
    Last edited by Roadsport; 02-01-2010 at 20:45.

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    Re: Race Escort Zetec SE (engine build)

    It keeps just getting better mate! well done buster.

  36. #195
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Moggy View Post
    It keeps just getting better mate! well done buster.
    Thank's Rich!
    I really need get things happening now. In only six months I need to be in a starting grid.
    Everything is quite well sorted except the gearbox issue.
    Last edited by Roadsport; 02-01-2010 at 21:44.

  37. #196
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    One down (almost, still need to turn it left a little to align with the exhaust pipe) three to go.
    The position of the collector is not ideal as sits a bit below the x-member level and is the lowest point of the car .
    So I need to stay between the white lines (little more) from now on...


  38. #197
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    Re: Race Escort Zetec SE (engine build)

    looking good mate, this is always a cracking thread to read

  39. #198
    Racer Decade Plus User Roadsport's Avatar
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Dazzabhoy View Post
    looking good mate, this is always a cracking thread to read
    Thanks D. I'm pleased with the progress too. So far.
    Last edited by Roadsport; 04-01-2010 at 21:23.

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    Re: Race Escort Zetec SE (engine build)

    There's so much time measuring and tweaking and thinking in exhausts isn't there? I made a few and you would just wonder where the hours go..

  41. #200
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    Re: Race Escort Zetec SE (engine build)

    Quote Originally Posted by Tristan View Post
    There's so much time measuring and tweaking and thinking in exhausts isn't there? I made a few and you would just wonder where the hours go..
    So far the exhaust system has gone fluently. But I've now only done the easy bits.
    The following three primary pipes should be more challenging.

    This project has been the most time consuming build yet. There are now off the self solutions for this one so very much customisation needed. Luckily most of the engine parts were available on order or off the shelf.

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