Rwd Zetec Mini

[steve w]

Already posted some pics of the car (and thought about selling it more than once!) But thought I'd put them into a build diary now, as Ive re-ignited the build!

It is a 2.0l Zetec Blacktop engine, fitted with a Tubular exhaust manifold, K&N, and Typhoon management.

The front end has a Cox gtm fuel tank, converted for fuel injection. Focus Alloy cored Radiator, and header tank

Ive gone for KAD 4 pot front brakes with vented discs and KAD pedal box.
Although these are soon going to be switched in favour of a home made willwood/KAD/custom disc setup

a few pics

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1594.JPG

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1596.JPG

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1595.JPG

Front end 1 part of a carbon 2 piece front, with a Prepreg carbon Mk1 Bonnet

A-panels are also Prepreg Carbon, Roof is Fibreglass, as is Bootlid.

I cut the inside out of the doors and have fitted slightly tinted Perspex windows

Wheels are now Force Racing 3 piece split rims, in black (The only Significant part of the car that isnt Second hand I think!)


This week Ive just finished converting a set of Pulsar GTIR ITB's to fit the Inlet side of the Zetec head, all going according to plan tomorrow, I'll post some pics up Monday!

[philster]

we need pics with the bonnet off! :D

just read again, is it mid engined? still need pics :p

[steve w]

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1099.JPG

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-204.JPG

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1449.JPG

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-1447.JPG

[kcchan]

I remember reading build diaries for this but they disappeared? Lots of carbon I seem to remember.

[miron]

rwd mid engine is the way to go!

[steve w]

throttle body adaptor plate finished. fitted it with mini wheel studs, countersunk from the rear.

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2448.JPG

Got these twin throttle bodies from a Nissan Sunny GTIR

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2449.JPG

had to mod them slightly with a bandsaw, to make them sit slightly closer together.

and this is them together

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2450.JPG

Just got to mod the injector rail, and port the adaptor plate slightly (5mm in width per port) to match the sunny and zetec spacings

Then need to make up a trumpet and clamp plate, and there you go, a £50 46mm itb conversion!

[steve w]

Got a bit of work done.

painted the roof, seems to have come out very flat, think it may have been far too hot yesterday.
http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2454.JPG
Colour is a bit bright, but im blaming my brother-in-law as it was his idea!

Also switched the high pressure side of the fuel line to braided hose. Although it was already high pressure injection hose, figured it was best to make sure.

Thought it was best to do alot of pre-fitting on the front, as its just not sitting right, and is pushing the rad back towards the tank one side. Finally got round to bonding the arches on with carbon fibre aswell.

Got the old driveshafts out today, new ones are in progress, but im having to get the snapped ones repaired before Avon.

[steve w]

Been a while since the last update.

I've been arranging a new engine, and the focus Rs engine has just arrived.

I have a Primary Designs manifold on it's way, aswell as a hybrid Gt25 turbo. All this should see me with around 315-330 bhp.

Hoping to get it in by February, and get it mapped before the good weather arrives, so I can get testing when the weather allows.

[philster]

I have a Primary Designs manifold on it's way, aswell as a hybrid Gt25 turbo. All this should see me with around 315-330 bhp.


That's gonna shift! is it the T5 engine or the eariler ford variety?

[steve w]

The earlier, it's basically a renamed, low comp, zetec with a reworked head!

[matt]

Looks good. :cool:
How does it handle is it predictable? Bad understeer, oversteer?

[steve w]

Looks good. :cool:
How does it handle is it predictable? Bad understeer, oversteer?

To be honest, not too sure yet! It went really well in straight line with 140bhp. Well, when I didn't have snapped driveshafts, or had messed up the map! Which has meant I haven't even managed a complete run up the strip yet. Spent money in the right places this year, so will find out as soon as the snow leaves us!

[caveman]

Coulor looks great mate be nice too see the red roof flying down the strip :D

[kcchan]

The red roof might help spectators keep track of it!

[miron]

any progress steve??

[steve w]

Bit cold out in the garage, so I've been getting on with other stuff. Primary designs exhaust manifold has arrived.
Decat is here, and is now sporting some black Heatwrap
I've been switching all the engine cover panels from ally to carbon, to stop the vibrations.
Also nearly finished the plenum, and have started installing an uprated, alloy, top mount intercooler into the rear.

.

[P17NTR]

I like the rear suspension arms, where did you get them?

[steve w]

Z-cars. Got a rear beam, both arms, hubs bearings, and brakes. Although I have had to fit them upside down to make the engine fit.

[steve w]

Finally got round to taking some pics,
http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2669.JPG
Decat, as mentioned, its heatwrapped

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2668.JPG
Adjustable fuel pressure regulator has arrived, also got an adaptor to convert the fuel rail to use it

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2666.JPG
Ive shortened the Fuel rail to match the next throttle body spacing, its been TIG'd back together, and just needs a bit of paint

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2667.JPG
Heres the Manifold, its a work of art!

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2665.JPG
Made these for a few of my mates lately, so thought I'd treat myself to one. Cutout was because a mate wanted to see his verniers. But as the engine mount has to be removed to remove the cover, it will be handy for adjusting the timing!

[apbellamy]

That's a bit cheeky. Sticking your pictures on turbominis, but not actually contributing to the forum. That's what flickr/photobucket is for.

[kcchan]

I'd always thought about posting a build thread on there but I don't have much to show and plus its not an A series.

Very resourceful though

[apbellamy]

We like minis with turbos. We're don't discriminate if you choose a different engine.

[steve w]

That's a bit cheeky. Sticking your pictures on turbominis, but not actually contributing to the forum. That's what flickr/photobucket is for.

Never really given it much thought tbh! Always uploaded there from when I had a build thread on it. Fair do's though, I'll paypal some over today!!

[steve w]

I'd always thought about posting a build thread on there but I don't have much to show and plus its not an A series.

Very resourceful though

It's not just about a-series, my most valuable info has come from turbominis members!

[apbellamy]

I didn't mean to financially contribute, more to be an active member. Stick a build thread on there, that kind of thing.

[kcchan]

It's not just about a-series, my most valuable info has come from turbominis members!

Same actually.

I will eventually pop a build thread on there but there isn't much progress to show.

[steve w]

Quick update.

The old 2.0l Zetec engine is now sat in the middle of the garage, next to the new engine.

I've started swapping bits over, and bolting the new bits onto the turbo engine.

Found one problem so far. The nice new £75 throttle bodies, are taking up a load of the room where the standard ford alternator used to fit. I cant see any other way out than to buy a Denso one, and fabricate a new mount. There are solutions available from other companies to do this but they're expensive, and I'm still not sure they will work with my throttle bodies.

I'm nearly at the point where the engine is all done and in need of the gearbox off the old engine, but I havent built up the stomach to fork out for a Focus RS clutch yet!

Pics to follow when the weather isn't so shocking.

[steve w]

Heres the Pics so far

http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2736.JPG
http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2737.JPG

and I'm in the middle of changing the parcel shelf/firewall to carbon, as the ally rattled and vibrated like hell!
http://www.turbominis.co.uk/uploads/i/wh530-oe1-at1/chargedzetec-2738.JPG

I do have an issue with the driveshafts, as on the only real run I managed with the old 130bhp engine they snapped after changing out of 1st gear. So as much as my wallet isnt going to like it im going to have try to source new custom ones to cope with the expected 330-350 bhp!??