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Author: Subject: Duratec install progress - sump construction underway
beaver34

posted on 30/7/09 at 09:02 PM Reply With Quote
hows it coming along?, im starting mine this month, hopefully picking a head up this weekend
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flak monkey

posted on 30/7/09 at 09:23 PM Reply With Quote
Slowly. Run out of time and money at the moment.

Sump is away being welded up by my mate.

Inlet manifold will be made next week as I am on holiday from work.

Also will be making a billet ali water pump pulley, just because I can really....

David





Sera

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flak monkey

posted on 17/8/09 at 07:38 PM Reply With Quote
Righto, back on the case, and things need to start moving.

Here are the fruits of tonights labours. From 5pm to now has made me this:

Inlet manifold 1
Inlet manifold 1


Inlet manifold 2
Inlet manifold 2


Inlet manifold 3
Inlet manifold 3


Inlet manifold 4
Inlet manifold 4


Sadly due to the position of the aux belt tensioner the runner for the fist throttle body can't be dead straight.

I havent trimmed it up inside yet either as it was still smoking when I took the pics. However its distroted more than I had hoped so need to try and straighten that out somehow. Any ideas?

I should also point out, although the tops of the tubes are a bit wobbly at the moment its going on the mill at work tomorrow to have them all skimmed nice and flat

David

[Edited on 17/8/09 by flak monkey]





Sera

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Stuart_B

posted on 22/8/09 at 03:49 PM Reply With Quote
hi david, glad to see it is coming along, i am looking at soem engines at the moment, have you got teh 145hp one or the 170hp one?

do you now what i would have to change to get to 170hp?

as well what throttle boddies are you using?

i was think a set of 1000cc bike throttle boddies.

cheers

stuart





black mk indy, 1.6pinto on cbr600 bike carb's.

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flak monkey

posted on 22/8/09 at 04:24 PM Reply With Quote
The ST170 engine is NOT a duratec engine. Its a zetec with VVT which needs to be controlled by the ECU. It just has a duratec badge, other than that its all zetec.

Mine is a 150bhp one from mondeo/st150 etc etc.

The throttle odies are GSXR750 which are 42mm, exactly the same size as GSXR1000 but you usually pay less for the 750s





Sera

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flak monkey

posted on 23/8/09 at 02:25 PM Reply With Quote
Engine out and new water pump pulley made

Took the pinto out yesterday and it was collected in the afternoon, so all in a good days work so to speak! No major hiccups other than throwing gearbox oil everywhere! Forgot about it pouring out of the prop end!

Also finished off my shiney new ali water pump pulley this morning. Slightly underdrive (about 5%) compared to the old one. But also about half the weight, and I reckon it will look nicer too

Water pump pulley 3
Water pump pulley 3


Water pump pulley 2
Water pump pulley 2


Also just finished fettling the inlet manifold. Just need to get it skimmed front and back to completely finish it off.

David





Sera

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flak monkey

posted on 24/8/09 at 07:29 PM Reply With Quote
Fitted all the blanking plugs to the throttle bodies so they are now ready to fit.

I am as of yet undecided whether to machine off the old injector fixings. I might leave them as they could come in handy for fixing things too.



What I need to do now is work out how to make a positive retainer to hold the throttle bodies to the manifold. I really dont want them dropping off, or indeed blowing off when the supercharger is fitted....





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Stuart_B

posted on 25/8/09 at 05:54 PM Reply With Quote
that pulley looks nice.

where baouts did you get the bellhousing from, or ehich search words should i use to look on ebay?

i have my duartec engine now





black mk indy, 1.6pinto on cbr600 bike carb's.

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flak monkey

posted on 25/8/09 at 06:02 PM Reply With Quote
The bellhousing came off ebay. I paid 120 for it. They do come up every now and again. Sometimes listed under mk2 escort parts.

I assume you got a HE duratec and not a zetec duratec? lol





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Stuart_B

posted on 25/8/09 at 06:27 PM Reply With Quote
yep a he 2.0 duartec engine, mine cost 205.

i need a starter and a flywheel, i read on your website a 1.8 flywheel, what size stater or are they the same?

stuart

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flak monkey

posted on 25/8/09 at 06:57 PM Reply With Quote
Starters are the same. Some 1.8s still have a dual mass flywheel.

I'll have a look at mine and get the part number off it, if you then go into a ford dealer they will be able to tell you what models it was fitted to exactly.

David





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beaver34

posted on 25/8/09 at 09:29 PM Reply With Quote
if you need any ford parts info drop me a u2u, its all i do all day
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flak monkey

posted on 26/8/09 at 09:21 PM Reply With Quote
Flywheel part number Rescued attachment m_P1000390.jpg
Rescued attachment m_P1000390.jpg






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flak monkey

posted on 27/8/09 at 07:07 PM Reply With Quote
This is the water pump pulley fitted

New water pump pulley fitted
New water pump pulley fitted






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goaty

posted on 30/8/09 at 08:45 AM Reply With Quote
has anyone heard anything about oil pump failures on duratecs??
I got told about two yesterday and am now wondering which would be the best route, or just uprate the pump....
Dont think there would be much room for a dry sump set up.....

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flak monkey

posted on 6/9/09 at 08:24 AM Reply With Quote
quote:
Originally posted by goaty
has anyone heard anything about oil pump failures on duratecs??
I got told about two yesterday and am now wondering which would be the best route, or just uprate the pump....
Dont think there would be much room for a dry sump set up.....


Not heard specifically of oil ump failures. But sadly I dont think anyone is making an uprated aftermarket pump yet, seems drysump kits have taken over.

Like you I dont have room for all the dry sump gubbins. Having said that, someone (maybe cosworth) make a drysump for the duratec where the scavenge pump is in the actual sump pan rather than a seperate bit which you need to find a home for. May be more suitable for a locost install?





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goaty

posted on 6/9/09 at 06:53 PM Reply With Quote
possible, i have just picked my Titan one up but i think iwill be able to squeeze it all in. Tank is the main issue i think.
Luckily the bloke i bought it off works for Caterham developments team and this is the same things he does. Bought an ap friction plate for 40 too. But he said get in touch whenever for help as they just made one and got 330bhp.
So it can fit and shoudl go well
Will be interesting to see how the different builds turn out....cant wait.
all the best

ps, he said that they haven't had any oil pump failures as yet though.

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Breaker

posted on 6/9/09 at 08:52 PM Reply With Quote
quote:
Originally posted by flak monkey
This is the water pump pulley fitted

New water pump pulley fitted
New water pump pulley fitted



Any particular reason you want the water pump to run slower (larger pulley) ?

BTW: Duratecs with aircon have a double crankshaft pulley. 1pulley for the water pump and alternator and the other pulley for the aircon. Perhaps you can use the second one for your supercharger ?

[Edited on 6/9/09 by Breaker]

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flak monkey

posted on 7/9/09 at 07:02 AM Reply With Quote
quote:
Originally posted by Breaker
Any particular reason you want the water pump to run slower (larger pulley) ?

BTW: Duratecs with aircon have a double crankshaft pulley. 1pulley for the water pump and alternator and the other pulley for the aircon. Perhaps you can use the second one for your supercharger ?




Thanks for that, I knew some had a double pulley but wasnt sure which it was. I would like to retain the single pulley if poss though.

The thoughs behind running the pump slower? Not much really other than upping the red line a bit and by increasing the pulley diameter a bit will stop it going over its design speed. Will have to see what effect it has on cooling at lower speed. If I run into problems, then I may end up fitting an electric water pump anyway.

David





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FASTdan

posted on 7/9/09 at 02:11 PM Reply With Quote
what are you doing in terms of the oil filter? I've seen stuff about replacing the standard housing with an aftermarket one to fit a traditional filter that sticks off the block sideways - presumably to eliminate ground clearance issues? I've not assembled ours yet to see how low the standard housing hangs.

Did you look at using the RWD sump (ranger) at all? just wondering what thats like in terms of ground clearance etc as thats what we have. We were planning to baffle that sump.

you may have mentioned it somewhere and I've missed it so apologies if thats the case.

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flak monkey

posted on 7/9/09 at 02:19 PM Reply With Quote
quote:
Originally posted by FASTdan
what are you doing in terms of the oil filter? I've seen stuff about replacing the standard housing with an aftermarket one to fit a traditional filter that sticks off the block sideways - presumably to eliminate ground clearance issues? I've not assembled ours yet to see how low the standard housing hangs.

Did you look at using the RWD sump (ranger) at all? just wondering what thats like in terms of ground clearance etc as thats what we have. We were planning to baffle that sump.

you may have mentioned it somewhere and I've missed it so apologies if thats the case.


The ranger sump is very deep, I did have one but it required so much chopping about I decided to make my own. My sump design is only 75mm deep in total and this is the total depth you have available to make the sump level with the bottom of the after market bellhousings.

WRT the oil filter. I am as of yet undecided. I have a take off block for a remote filter (basically a milled aluminium block) which I may use. Or I might splash out on a proper block from raceline to mount the filter on the side of the engine. This will basically all come down to the amount of space I have next to the engine.

I do know the std filter will hang way too low.

David





Sera

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FASTdan

posted on 7/9/09 at 03:30 PM Reply With Quote
quote:
Originally posted by flak monkey
My sump design is only 75mm deep in total and this is the total depth you have available to make the sump level with the bottom of the after market bellhousings.


David


how does the height of the aftermarket bellhousing compare to the standard pinto one?

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flak monkey

posted on 11/9/09 at 04:20 PM Reply With Quote
Tried the supercharger up to the block the other day.

Looks like it will fit nicely, still may need to move the steering column though.











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goaty

posted on 11/9/09 at 04:22 PM Reply With Quote
looking very good, can you get to the oil lines ok?? what about running the air hoses from it??
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flak monkey

posted on 11/9/09 at 04:27 PM Reply With Quote
quote:
Originally posted by goaty
looking very good, can you get to the oil lines ok?? what about running the air hoses from it??


Yeah the oil hoses are on banjo fittings so can be close to the body.

Oulet hose might be an issue. But until I get it in the car I wont really know

All I do know is that to the edge of the supercharger outlet (which needs turning around) is 2" less than to the edge of the alternator on the other side of the engine bay.

I will be keeping it all as close to the block as poss to avoid any potential issues with hoses.





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