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Thread: MK1 Duratec

  1. #81
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    Re: MK1 Duratec

    hi Eric nice strong looking g/box is H pattern or sequential ? looks alot bigger then type 9 !! thats going to be one tidy engine bay when you get it finished
    All the best for 2015 Happy track days
    Gerry

  2. #82

    Re: MK1 Duratec

    Quote Originally Posted by v6gerry View Post
    hi Eric nice strong looking g/box is H pattern or sequential ? looks alot bigger then type 9 !! thats going to be one tidy engine bay when you get it finished
    All the best for 2015 Happy track days
    Gerry
    Hi Gerry its a 6 speed sequential, looking forward to those track days

  3. #83
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    Re: MK1 Duratec

    Gosh you have throw your cheque book at it LOL ! 2 more gears to play with should just keep pulling and pulling , can you change ratio if need be ? keep up the outstanding work i'll catch up for a looksy next time i'm down lynns .

  4. #84
    Part of the furniture Decade Plus User trig's Avatar

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    Re: MK1 Duratec

    Vids on YouTube search Trig bishop.

  5. #85
    Part of the furniture Decade Plus User trig's Avatar

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  6. #86

    Re: MK1 Duratec

    Nice driving and the 60g looks good

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  8. #87

    Re: MK1 Duratec

    Small update, had to cutup trigs gearbox mount to suit my tunnel and wait to for the replacement mounts to turn up from Bradley Motorsport, these turned up Friday so sorted out the final alignment for the tunnel brackets so the all main alignment is sorted, finally think the escort is getting somewhere now.









    One of my sons xmas present to me nice bit of wrapping




  9. #88
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    Re: MK1 Duratec

    Quote Originally Posted by eric View Post
    I know the duratec needs a tank with a min 5ltrs capacity and one with decent internals to get the air out of the oil. also looking to cut a recess in the o/s inner wing for a neat fit Ralloy do just the thing 1.5 gallon with a curved plate but its the size of a dustbin.
    Oil tank next to exhaust? thats kinda asking for fire, why not mount it in the boot?

  10. #89
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    Re: MK1 Duratec

    Mounting it the boot make the pump work harder.

    I was told by Pace to mount a oil tank as close to the engine as you can.

    Passenger footwell i suggest
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    Re: MK1 Duratec

    Quote Originally Posted by Andrew@ALD View Post
    Mounting it the boot make the pump work harder.

    I was told by Pace to mount a oil tank as close to the engine as you can.

    Passenger footwell i suggest
    It shouldnt make the pump work harder once the system is primed, passenger footwell is tricky for scrutineering, i dont think your allowed fluid tanks inside the car.
    Most works cars have the oil tank in the boot.

  12. #91
    Racer Decade Plus User wildo105e's Avatar

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    Re: MK1 Duratec

    great progress and some great work. There was some chat years ago on here about under bonnet or boot etc. Some like HT racing like them under the bonnet but i think it came down to packaging issue rather than performance. How many cars have boot fitted tanks and are fine ? A custom tank under the bonnet saves a shed load of cost on the pipe work.

    I think you just pick your option and go with it.

    keep the updates coming.

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    Re: MK1 Duratec

    In the bay for me
    A.L. Developments Fabrication and Engineering
    Cylinder head ported and polish work for
    Ford Zetec, ST170, CVH, 2.0/2.3 Duratec, I4, Volvo Modular head I'E Focus ST/RS 2.5, N/A YB
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  14. #93
    Racer Decade Plus User wildo105e's Avatar

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    Re: MK1 Duratec

    Quote Originally Posted by Andrew@ALD View Post
    In the bay for me
    if i was doing it i would put in the engine bay

    I think the thread was on mk1gaz and his n/a cossy install like i say a good few years ago but a search may find it. May help the decision either way.

  15. #94

    Re: MK1 Duratec

    Getting closer to start the engine build 1st thing was to check the arp main stud to dry sump pan clearance, turns out mine is no exception the end of the studs foul the Titan dry sump internal baffle tray, 2mm is needed to remove with a 65 degree chamfer to finish off.








    Sorted

    I am going the tried and trusted way with a pace dry sump tank in the boot the only downside is the cost of the hardware, the inner wings are just to good to be cut up.

  16. #95
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    Re: MK1 Duratec

    Nice

    www.gulfpetrolheads.com

  17. #96

    Re: MK1 Duratec

    Quote Originally Posted by dobuy View Post
    Nice
    Thanks Neil yours ok?

  18. #97
    Part of the furniture Decade Plus User trig's Avatar

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    Re: MK1 Duratec

    I have that custom made oil tank here still buddy

  19. #98

    Re: MK1 Duratec

    Quote Originally Posted by trig View Post
    I have that custom made oil tank here still buddy
    Thanks Trig I've got 1/2 price pace tank from ebay the same as this one


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  21. #99

    Re: MK1 Duratec

    By kind permission of the wife the engine is being is built at home in the kitchen got a nice spot next to the radiator, got to keep the damp out of those bores

    Following the Caterham 260 build manual one of the 1st jobs was to de-burr the block

    So after hours deburring and cleaning the block it is all set up ready to start the build, been looking forward to starting this, has got to be one of the best jobs.







    Oil gallery rivets drilled out for cleaning and replaced with alloy bungs, the gallery's had some dirt build up so was worth the effort.





    Started with the checking the rings gaps, borrowed a nice ring gap tool( thanks steve) clamped this to the kitchen chopping board worked a treat 2-3 hours later and with help from one of my sons all sorted.







    Modified the old water pump and made a alloy plate to blank off the hole going electric water pump so not needed










  22. #100

    Re: MK1 Duratec

    Fitted the mains shells correct alignment is time consuming affair to get right, trail fitted the crank and all oil ways line up to the journals







    Need to add the block is now at 88mm all machining was done by Steve at Roland Alsop to very tight clearances, using Supertech pistons and Manley rods with the crank keyed to suit.

  23. #101
    World Champion Decade Plus User meXEco's Avatar

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    Re: MK1 Duratec

    Very nice.


    '68 1100 Deluxe-bog stock soon to be a twincam rep.


  24. #102

    Re: MK1 Duratec

    Quote Originally Posted by meXEco View Post
    Very nice.
    Thanks mate

  25. #103
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    Re: MK1 Duratec

    Engine coming together nice. Hope to see what power it makes when done.
    A.L. Developments Fabrication and Engineering
    Cylinder head ported and polish work for
    Ford Zetec, ST170, CVH, 2.0/2.3 Duratec, I4, Volvo Modular head I'E Focus ST/RS 2.5, N/A YB
    XE, Vag 1.8 20vT, Vag BJS/BML, Vag AGZ/AQN ,F4R730 172/182, C1J Turbo

  26. #104

    Re: MK1 Duratec

    Quote Originally Posted by Andrew@ALD View Post
    Engine coming together nice. Hope to see what power it makes when done.
    Would like to see 250bhp@8500rpm, its getting all the right parts so fingers crossed

  27. #105
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    Re: MK1 Duratec

    Nice build pics

    www.gulfpetrolheads.com

  28. #106

    Re: MK1 Duratec

    Few more pics of the work on the interior, all the holes in the floors welded up and the seat bars welded in next job is to get the rear glass removed to finish off the firewall. I will get this painted soon hopefully










  29. #107
    Part of the furniture Decade Plus User trig's Avatar

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    Re: MK1 Duratec

    Looking good buddy. Done anything with the box yet?

  30. #108

    Re: MK1 Duratec

    Quote Originally Posted by trig View Post
    Looking good buddy. Done anything with the box yet?
    Had a go sitting in the escort changing gear and making engine sounds apart from that not a lot

  31. #109
    Part of the furniture Decade Plus User trig's Avatar

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    Re: MK1 Duratec

    Lol I remember doing that too pmsl.

  32. #110
    Spanner Monkey Turbosport Subscriber Jimmythedimmy's Avatar

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    Re: MK1 Duratec

    nice project, engine is coming along nicely

  33. #111
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    Re: MK1 Duratec

    metal work looks great

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  34. #112
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    Re: MK1 Duratec

    Good progress and nice box for it. I have waiting 69g in my room for future projects You will be driving this way before I drive my mk1 duratec, keep it up

    BTW, one question regarding ARP studs. Have you honed the crankshaft bore with ARP studs tightened to correct torque? I intend to use those also in my engine buildup, but will be honing the crankshaft bore at the machinist shop to get it round, pretty sure it will be out of round little bit with the studs and bigger clamping force. And I read somewhere that you should use extra wide washers for the nuts to prevent alloy distortion, they are pretty small when you look the oem bolt flange.
    Last edited by Sultzi; 25-03-2015 at 10:14.

  35. #113

    Re: MK1 Duratec

    one question regarding ARP studs. Have you honed the crankshaft bore with ARP studs tightened to correct torque? I intend to use those also in my engine buildup, but will be honing the crankshaft bore at the machinist shop to get it round, pretty sure it will be out of round little bit with the studs and bigger clamping force.

    Yes I did install the arp studs before the block was honed not sure if it is realy required to be honest.

  36. #114

    Re: MK1 Duratec

    Quote Originally Posted by dobuy View Post
    metal work looks great
    Thanks Neil, my son did the posh welding

  37. #115
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    Re: MK1 Duratec

    Quote Originally Posted by eric View Post
    Yes I did install the arp studs before the block was honed not sure if it is realy required to be honest.
    Was crankshaft bore honed? Or are we just talking about cylinder bore honing?

  38. #116

    Re: MK1 Duratec

    Quote Originally Posted by Sultzi View Post
    Was crankshaft bore honed? Or are we just talking about cylinder bore honing?
    Just the cylinder bores the crankshaft journals was left untouched

  39. #117
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    Re: MK1 Duratec

    Would have been good to hone also that crankshaft bore in the block. I'm pretty sure it will go out of round when you tighten those arp studs, because that different clamping force they give. And due also from that different kind of washer in them. I always hone that crankshaft bore when bolts have changed from original ones. Also I think why people are saying don't put arp on the studs is because of this, they don't hone the bore like it should be done. I just wan't to make sure your engine stays fine. If that would be my block, I would take it back to machinist for that honing to be done. Strange that your machinist shop didn't say about this?

    Maybe it isn't much out of round, but just to be sure I would do it. Expesially with all alloy block.
    Last edited by Sultzi; 25-03-2015 at 20:44.

  40. #118

    Re: MK1 Duratec

    Quote Originally Posted by Sultzi View Post
    Would have been good to hone also that crankshaft bore in the block. I'm pretty sure it will go out of round when you tighten those arp studs, because that different clamping force they give. And due also from that different kind of washer in them. I always hone that crankshaft bore when bolts have changed from original ones. Also I think why people are saying don't put arp on the studs is because of this, they don't hone the bore like it should be done. I just wan't to make sure your engine stays fine. If that would be my block, I would take it back to machinist for that honing to be done. Strange that your machinist shop didn't say about this?

    Maybe it isn't much out of round, but just to be sure I would do it. Expesially with all alloy block.
    What tolerance change have you seen when using arp main stud kit over std?

  41. #119
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    Re: MK1 Duratec

    Never heard of anyone "having" to hone the crank bore, that includes a couple of professional Duratec engine builders on pretty big bhp engines. The Duratec crank bore is pretty stable with its caged design

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  42. #120

    Re: MK1 Duratec

    I dont know of any cases where the arp main stud kit has caused the journals to go out of tolerance to a extent where machining would be required

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