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Black Top Zetec to MK1 RS Focus Spec with turbo
DixieTheKid - 26/7/11 at 09:35 AM

Hello People,

I'm toying with the idea to turbo my brand new Black top by doing the following:

Replace pistons and rods with new standard MK1 RS Focus to strenghten and lower compresion
New manifold or Escort RST
New/recon T2 Turbo. Tee off othe oil pressure switch and return into sump to lub it up
Fiester XR2/RS Turbo Flywheel for EFI sensor
EFI Inlet manifold with adaptor plate and EFI management

My questions are:

Will a Fiester XR2/RST flywheel mate to a MT75 gearbox & what cluch will be needed?
Will the Plenum and cross over pipe fit under the bonnet?
Where am i going to put the intercooler?

Thoughts please =) Oh and i should mention that this is going into a GBS Zero.

skippad - 26/7/11 at 09:58 AM

Oh and i should mention that this is going into a GBS Zero.









What a waste.....

DixieTheKid - 26/7/11 at 10:02 AM

Why? Its my first build and thier cheap?

big_wasa - 26/7/11 at 10:38 AM

Will a Fiester XR2/RST flywheel mate to a MT75 gearbox & what cluch will be needed?

Lots of options on the clutch but the flywheel will need the ignition pick up or you can run a trigger wheel on the crank.

Will the Plenum and cross over pipe fit under the bonnet?

not a chance. You need the engine as high as you can get it. Just run the boost pipe work around the engine.

Where am i going to put the intercooler?

infront of the rad is where others have put it. Most are custom alloy and not cheap.

As for sticking it in a zero, why not ?

DixieTheKid - 26/7/11 at 10:45 AM

Thanks, need to rethink the plenum and inlet manifold! Going to have to make one up or see if i can modify another.

DixieTheKid - 26/7/11 at 11:10 AM

Does anyone know if the Focus RS Mk1 exhaust Manifold will fit a Zetec E blacktop?

[Edited on 26/7/11 by DixieTheKid]

AndyW - 26/7/11 at 12:08 PM

quote:
Originally posted by skippad
Oh and i should mention that this is going into a GBS Zero.









What a waste.....



And to back up your statement?

mrwibble - 26/7/11 at 12:35 PM

cant help but think if you want an rs spec zetec, find one written off in scrap yard?

djtom - 26/7/11 at 01:07 PM

quote:

Replace pistons and rods with new standard MK1 RS Focus to strenghten and lower compresion

Not sure how much you can get RS Focus rods and pistons for, but unless they are very cheap either keep the standard rods and pistons and use a decompression plate, or use proper forged pistons and steel rods. The RS Focus ones are not very strong.

quote:

New manifold or Escort RST

ERST will fit, but needs the head studs redrilling and one of them breaks into an oilway. It's also a T3 fitment so your T2 turbo won't fit.


quote:

New/recon T2 Turbo. Tee off othe oil pressure switch and return into sump to lub it up

T2 is too small for a 2l engine. T25 minimum, T3 or bigger preferred. Your lubrication suggestion is ok though, that's how I've done it.

quote:

Fiester XR2/RS Turbo Flywheel for EFI sensor

Just get a 1.8l zetec flywheel and a mk1 1.8 mondeo clutch, this will fit the MT75. Not sure why you want to use a fiesta flywheel?

quote:

EFI Inlet manifold with adaptor plate and EFI management

Manifold OK, I wouldn't use EFI management for a turbo application though, you'll need a decent mappable ECU to get the fuel and spark maps right and to ensure it lasts longer than a few minutes before it melts holes in the pistons... I used Megasquirt, which is fine if you are happy building it yourself and tak ing the time to learn how to map it, otherwise you're looking at several hundred quid for an Emerald, Omex, DTA or similar and some rolling road sessions to tune it

quote:

My questions are:

Will a Fiester XR2/RST flywheel mate to a MT75 gearbox & what cluch will be needed?

See above

quote:

Will the Plenum and cross over pipe fit under the bonnet?

Almost certainly not

quote:

Where am i going to put the intercooler?

Somewhere where it gets some air! In front of the rad?

There are a whole host of other things that you'll also need to consider to turbo it, heat management is a major issue in a seven, you'll also need bigger injectors, a fuel pump capable of delivering enough fuel, a boost-referenced fuel pressure regulator, a dump valve, charge piping, cooler running spark plugs etc etc. Been there, done that, don't underestimate the headaches and sheer amount of work it takes in getting it to be a reliable setup.

Having said that, it's fun when it does work!

Tom

DixieTheKid - 26/7/11 at 02:01 PM

quote:
Originally posted by mrwibble
cant help but think if you want an rs spec zetec, find one written off in scrap yard?


Good Luck trying to find one!

DixieTheKid - 26/7/11 at 02:37 PM

CheeRS Tom thats good info, more than helpful.

I meant T3 i have no idea why i put T2???

Standard rods & pistons are cheap as chips for the MK1 RS. Im not looking for massive BHP, its not needed in such a light car. I understand you can get a a de-comprestion plate, but thats two head gaskets and twice a much to go wrong! Plus because my engine is new i can leave the head as it is.

I've just been reading up that 820i rover inlet manifold would fit with a conversion plate, that way i could run the boost pipes around the engine which makes more sense as apposed to over the top!

What plugs do you recommend, cossie plugs wouldnt fit would they?

Ive got a new cossie fuel pump and regulator left over from my S2 RST which i never fitted (somewhere).