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Discussion Starter #62
Engine build is at a standstill as Tech1 Performance have been allowed a holiday

We have a slightly "issue" so trying to sort the out

In the meantime I commissioned (asked a mate for a few beers) the below stickers, I think the middle one is best ;)

 

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My fault, I skipped the important part.

Unfortunately it's because the hpfp can't flow the fuel to the injectors in the first place. On 93 the limit of the hpfp's flow is ~350whp. To get beyond that you need to supplement the fueling somehow, and the best way to do that is to split the flow just prior to the hpfp, and route it to additional injectors mounted post throttle body.
Cool, thanks for the explanation.
 

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Discussion Starter #64
So there is good news and not so good news and good news again

Good news is the engine build is on its way, i got very excited and finally thought we'd get things moving and done and i could drive the car. However, we fitted the rods and pistons to the engine and.........see below



Something didnt look right, the pistons were not sitting right in the block. As first we thought possibly that being a GDI engine the pistons sat lower but i called Speedperf6rmanc3 in the USA and turns out that i accidentally ordered the 2.3 Ecoboost rods and not the 2.0 ones.......



Bugger. However the ever helpful Marshall suggested a quicker fix than returning the rods, a 2.3 crank........a stroke of genius (pun intended) and they had just received a set of std 2.3 cranks which are forged and...i stopped him there and ordered one.....as a favour they even keyed and then balanced the crank for me........tops guys

Next issue will be customs clearance and Tech1 finding a slot to build the engine

Problem i have now is the GTX2867 will be on its last legs at 8000rpm, so a GTX3076R would be better, then i can have 550bhp and can tell everyone in the pub. If the wife finds my bills i am dead, although she has a new kitchen we still have the Tartan carpet a year after moving......
 

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Awesome build!
 

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Discussion Starter #66 (Edited)



These just arrived too so I am happy with that


Also the 2.3l crank has arrived, the joyous moment. The last piece (hopefully and may of said that before) of the puzzle




I was so happy when I dropped it off at Tech1, but Paul wasn't as chuffed. He is normally smiling when I drop something off and his body language was terrible. Long of the short is he and his business partner have decided to part ways and he will be closing the work shop

Bollocks

Good news is he will build the engine for me, this I didn't want to take elsewhere and he has a workshop at home and will finish this. When, was the next question and Paul smiled.

So I now have to find someone stupid, sorry enthusiastic, enough to take on a project half done. I may of found someone but if anyone local knows of anyone (I don't) I would appreciate it.

I'd like to do it myself but don't have the time, or the mechanical know how to make the engine mounts and so on.

I think someone is trying to tell me something, and I think its don't give up ;)
 

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Discussion Starter #68
Some more goodies have arrived courtesy of Speedp3rform6nce, cant praise these guys enough for their support and knowledge

This time its the auxiliary fueling systems, i did want the JM manifold but its taking too long and as i am only going for 450bhp SP advised this kit would be simpler, easier and perfect for what i need. Apparently the std inlet flows pretty well and its also light.

Sounds complicated but Specialist Components already have the software to run both port and direct injection already (so i wont need the additional controller), and most High Power GDI engines, like the Mercs, run both port and direct.

Issue will be with the mapping but i will send the engine back to Specialist Components as they have probably the most experience on these engines in the UK, so need to get an exhaust manifold making and hoping Maniflo in Salisbury can help.

I have also found someone stupid enough to take on the engine mounts, and they are local ish, so having a ready mapped engine will make their and my life easier.

The Complete Kit


The Inlet adaptor


FoMoCo Injector, which is a bosch item


Additional Controller that i dont need
 

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Discussion Starter #70
So progress at last, Engine builder got a new job (after needing a break) and engine was in one place and tools in another

Anyway a month later the three of them got re-united and the engine is being built (again)

Issue i had was the Main Bearing studs, the OEM items are stretch bolts and once used you need to measure the stretch and then change the torque accordingly, so i rang Speedperf6manc3 and asked what this should be. The ever helpful, if busy, Pablo explained that i needed to fit ARP bolts.

Next problem was searching for the correct bolts, ARP catalogue number came up at £270 and no one in the UK had any, and they were 6 weeks delivery. Rang Pablo again, and asked him to ship some. Turns out the ARP bolts for the 2.3MPS DISI engine are the same as the ECOBOOST, and £175 ! Luckily i found a supplier in the UK, who also sent sweets with the delivery.....





Pauls managed to fit them this week and cams are next



Cams are on lifters as per the Duratec but they are not shimmable, instead the buckets come pre-sized. Great idea but Paul needs to fit the cams check the gaps and then order some buckets.......more delays ffs

Good news on the cams, i decided to fit the full blown 12mm lift cams capable of 650bhp and 8000rpm........just need a bigger turbo, chargecooler, radiator, bigger tyres, more cooling and the head porting.........hmmmmm
 

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Discussion Starter #71
Well its Christmas soon.......

Engine progress is slow, the last (please for the love of god) challenge is the cam followers. Ford in their wisdom made the ecoboost (like the duratec) with mechanical followers. They then made cam followers "un-shimmable" so you have to buy the correct followers shimmed accordingly.

Luckily i only need three, and these have been ordered direct with Ford

Then the engine needs building and dressing, flywheel, clutch and gearbox then ship it off to get a manifold made then off to get dyno'd




#nevergiveup
 

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Discussion Starter #72
Well New Year, New Engine !

Its finally been built, well almost the flywheel, clutch and box need to go on and the gearbox.

Engine with the external oil filter bracket and PCV delete and breather



Without the inlet fitted



With the new auxillary fuel manifold, basically a spacer with ports for 630cc injectors and ports for meth injection ;)




Engine Fully built




I then need to make an exhaust manifold adapter (engine has on internal exhaust manifold) which needs to have an external wastegate as the USA is the only place to get them and they only sell them as kits with upgraded turbos ffs

Worst still Garrett have released a GEN II GTX2867R which would be perfect for this engine, the current GTX2867 will run out of puff above 7500rpm.........and the internals are not interchangeable

However good and bad news, the tartan carpet has gone and we now have Brimstone :)

 

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Discussion Starter #74
Tobad you can just swap to the FRPP head that has individual exhaust ports.

Sent from another garage.
They are hard to find over here, i had a good look and looked at costs. As i would need a custom exhaust manifold and buy the head (which is similar cost to a second hand engine over here) i deemed it a no go

As i am not going for big big power the std head will also flow enough

If i go silly power, then the head needs to be ported and bigger valves so may go FRPP head then
 

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Discussion Starter #75
Had a mad thought today as i realised i havent fitted the custom flywheel, helix clutch (Rover T series) and gearbox (PG1 but C4 u spec) all together

Good news is it all fits, gearbox input shaft meshes with the clutch friction plate and everything seems to be ok

Obviously wont know its all perfect until its in and i have pressure on the clutch. But the signs are good

Good news is the engine is now pencilled in for the dyno with specialist components, and i have found a nice man to make the turbo adaptor. Plan is to have one made in stainless steel, to the best guess, get the engine dyno'd and hope it fits when the engine goes in. Then make one out of inconel for the long term.




 

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Discussion Starter #76 (Edited)
Today is a good day

Custom dash is nearly ready and i was asked if i wanted a custom screen so i got a pen and a fag packet and drew, like a 5 year old, what i'd like on the back.

a few weeks later and this is what has been done, at startup the 111ST logo is shown on boot up (not for long but if first boot it takes a few moments longer i am told), at the redline the welsh dragon appears in the middle (something the designer and I share heritage from so seemed apt and its a dragon !!) and the third and last screen is as per my request. 1st is copy of std dash, for road use but all the parameters shown on 3rd screen (track screen) can be show also on the 1st screen.

Oil pressure gauge is duplicated a few times but will be replaced with air temp, battery voltage and something else.

Its all plug and play with the analogue inputs, fuel etc and plugs directly to my ECU and will show all parameters it does.

Could not be happier, and i cant thank Alec enough for doing this


 

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Discussion Starter #80
So today i have the, first production dash fitted to the car and wow....just wow....i mean like wow

First off was the box


Then the contents, the dash on the top and the wiring below




I've spoken to Alec about how to control, and whilst you can use the trip reset and indicators he asked if i would like a small joystick for moving around the dash, i said yes a small discreet one with a push button so he supplied this. Idea is to have it mounted on the dash or just use it when you need it and plug it in



Next was fitting it to the standard mount


The original dash was taken out a few months ago and sent to Alec so fitting the new dash took about 30 mins




Fit and finish are pretty damn good and the graphics are awesome, the dash can take up to 6 screen designs (one of which i designed myself and Alec made for me), and then the 7th is the data logger


Took some photos, from afar, sun light was straight ahead but not direct sunlight but the dash was more than bright enough






Overall very very happy and it has more features that you can shake a stick at, everything was plug and play and worked

However i dont have an engine in the car, so couldnt test drive it
 
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