FASTdan
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| posted on 3/1/10 at 10:59 AM |
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Our 2.3 Duratec Indy Install
I thought I'd do a post to document the build and install of our 2.3 ranger lump.
This is the car (pinto powered) at elvington last summer:
Those pro sports photographers can really take a good pic!
The new Lump upside down:
So far we have bought the RWD motorsport Bellhousing for cable clutch, Lightened fly, Release arm, pin, bearing etc. and clutch (LUK).
We also have a set of ZX9R carbs (early so need a sensor retro fitting) that will go on to start with, combined with megajolt ignition (yet to
purchase).
Bellhousing trial fitted:
Cost so far for 2.3 engine, ZX9R's, various ancillaries from a broken 2.0 mondeo and all of the above approximately £1000. The only remaining
sizeable items to be bought (as far as i know) are thermostat, belt tensioner and megajolt.
First job is sorting the sump - ranger version is far too deep as Flakmonkey has said in the past but I have opted to chop it and extend to suit.
First thing was to chop off the excess 50mm or so, then measure its capacity. Following that I mocked up some cardboard side bits for the extension
and filled with sand to check the new volume was similar:
Turns out we will be down roughly a 1/4 litre on the standard capacity - who thinks this will be an issue? I think not, as the difference between max
and min on the dipstick will be more than this I suspect? So given that the oil will be changed every 3k and the level carefully monitored? I can, if
needed make up the difference by boxing out an extra bit.
Then chopped out the rest, and tacked in some side plates:
http://img.photobucket.com/albums/0703/FASTdan/DSCN2483.jpg
Next job is to make a windeage tray, and some baffles/gates - havent decided wether to go mild, stainless or ali on these yet (gates will def be
steel).
I also need to salvage the drain plug etc and weld that in.
Once the sump is done it can be fitted, which will then allow us to change the front cover from the ranger type (which has a spare stub shaft sticking
out, think this was for a viscous fan?) for the FWD type.
That'll do for now, progress will no doubt be slow (currently finishing off my XR2TT restoration too) but I will update as we go along......
[Edited on 3/1/10 by FASTdan]
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FASTdan
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| posted on 3/1/10 at 11:07 AM |
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A couple of pics of the manifold for the ZX9's:
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jacko
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| posted on 3/1/10 at 11:55 AM |
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Nice looking car
Keep the good work coming 
It's nice to see what others are doing to there cars
Jacko
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Stuart_B
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| posted on 3/1/10 at 03:38 PM |
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that is nice dan.
what power will it be as it is a 2.3, and on carbs?
cheers
stuart
black mk indy, 1.6pinto on cbr600 bike carb's.
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FASTdan
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| posted on 3/1/10 at 04:53 PM |
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Not sure really Stu, standard focus without VVT is 151bhp. So Without all the nonsense, and big'ish carbs I'm certain it will be over
170bhp and plenty of torque. And a nice weight saving too 
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FASTdan
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| posted on 3/1/10 at 05:54 PM |
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Pick up pipe mods
We sorted the pick up pipe today, chopped in 2 places to crank it back up towards the block, then 28mm taken out of the straight vertical section that
enters the strainer. Total reduction was 50mm, leaving the strainer 8mm clear of the bottom of the new sump. The braces were cut and welded to suit
(tacked with the MIG ready for TIG'ing):
Bit blurry that one...
We have decided to retain the original windage tray, albeit extended and with baffles welded to it, so that is this weeks challenge.
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flak monkey
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| posted on 3/1/10 at 05:59 PM |
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Looking good Dan keep it up!
Makes me wish I had the patience to learn to ali weld properly.
Sera
http://www.motosera.com
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FASTdan
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| posted on 3/1/10 at 09:53 PM |
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quote:
Originally posted by flak monkey
Looking good Dan keep it up!
Makes me wish I had the patience to learn to ali weld properly.
Cheers Give the ali a go, bit of practice and you'd get it.
Out of interest how come we have a traditional looking pick-up pipe whereas you have a more modern looking one that picks up in a different region of
the sump? is that the standard FWD item?
I was looking at your gates and thinking 'that gates going the wrong way'......till I realised the differences.
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flak monkey
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| posted on 3/1/10 at 09:56 PM |
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Yes the ranger pick up pipe is the metal one, as you have, and the standard mondeo/focus one is plastic like mine
I am keeping my eye out for a secondhand ac tig
Sera
http://www.motosera.com
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FASTdan
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| posted on 3/1/10 at 09:59 PM |
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quote:
I am keeping my eye out for a secondhand ac tig
I did that for quite some time, then bought new....then saw someone on here selling one a few days back - presume you saw that (cebora).
Problem with a lot of them is the 3phase thing, though some manufacturers put in a jumper facility to convert.
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FASTdan
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| posted on 10/2/10 at 10:01 PM |
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Quick update then....
The sump and windage tray is now complete. We went for a mild steel extension of the existing windage, with baffles and gates hanging from this -
making it a removable and servicable item if needed. Mounted on threaded spacer bars using binx nuts (metal locking) to ensure security. The drain
plug and its boss were salvaged from the cut off section too, and a fitting included for the oil temp sender.
I also tacked on a sacrificial skid plate from checkerplate that can be easily ground off if it takes a beating at any point:
Prior to fitting the sump we removed each big end bearing cap and inspected - replacing the bolts with ARP's as we went.The sump is now fitted
to the engine and the next job is to swap out the ranger front chain cover for a FWD one.
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RK
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| posted on 10/2/10 at 10:18 PM |
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you're doing a great job there! Such talented people on here, and sadly for me, so far away.
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FASTdan
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| posted on 22/2/10 at 10:23 PM |
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Pinto sold and removed on saturday morning, and the duratec dropped in for a measure up:
It's very tight fitting under the bonnet, but the ground clearance the chopped sump provided is at least as good as we had with the pinto (that
was chopped too). The sump sits flush with the bellhousing underside.
Also designed and had CNC'd a nice bling oil take-off plate for the remote filter:
Will hopefully get the engine mounts finalised this week, whip the engine back out to fit the clutch and front cover/pulley/belt and then it can go in
properly......
Slow but steady progress.
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tul214
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| posted on 22/2/10 at 11:03 PM |
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Just noticed this thread and recognised your car from Elvington. Do you have any footage from the 19th Sept last year. I am sure you followed me for a
while and it would be great to see it
Cheers,
Mark
1.6 Raw Super6 sold
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FASTdan
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| posted on 7/3/10 at 09:55 PM |
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So the alternator is mounted, front cover on, all pulleys in place, and engine is in properly now:
Those V8 engine mounts are excellent, very rigid!
We are halfway through modifying the MK pinto exhaust manifold:
Really need to buy the megajolt next and get the plumbing done (silicone is all on order).
Its coming together nicely
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speedystew
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| posted on 7/3/10 at 10:34 PM |
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hi dan,just noticed your in bradford,i am just about to put a 2L duratec in my sprint car (u2u sent)
stew
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FASTdan
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| posted on 21/3/10 at 09:32 PM |
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Me and pops have been busy over the last week or so. The exhaust manifold is now complete and the entire system has been refitted with some minor
tweeks to the rear silencer mount.
The bonnet has been modified to suit the new header positions - they have ended up approx 2" further back than with the pinto. It is quite
surprising how much shorter in length this engine is compared to the old boat anchor.
Most of the plumbing is sorted, and the megajolt has been bought, we just need to get our heads around the wiring.
We also trial fitted the new ZX9R carbs on the nearly finished manifold:
Water rail components (not quite finished):
Aluminium bracket for mounting the Ford coilpack on the end of the head:
If the water rail components work I will hopefully be offering a kit of parts in the future, watch this space.....
I reckon we're on track for a start up next weekend
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karlak
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| posted on 21/3/10 at 09:48 PM |
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Nice one Dan - Looking good - I will be along to buy it this time next year when you upgrade ?
Got the Boat Anchor installed today 
Runs soooo much better than the other Lump. Have a couple of snags to sort out, but cant wait to get her out on the road.
Cheers Si,,
MK Indy - 2litre Duratec - Omex 600 - Jenvey throttle bodies - ETB DigiDash2
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flak monkey
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| posted on 21/3/10 at 10:04 PM |
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Looking good Dan keep up the good work.
Its good to see a few other Duratec engined cars springing up now.
Sera
http://www.motosera.com
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FASTdan
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| posted on 13/4/10 at 09:19 PM |
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Couple of finished engine bay pics:
vid to follow if i can get it uploaded...
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FASTdan
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| posted on 13/4/10 at 09:22 PM |
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vid if it works....
http://smg.photobucket.com/albums/0703/FASTdan/?action=view¤t=10042010016.flv
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karlak
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| posted on 13/4/10 at 09:25 PM |
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Excellent
Looking and SOUNDING good Dan
MK Indy - 2litre Duratec - Omex 600 - Jenvey throttle bodies - ETB DigiDash2
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beaver34
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| posted on 13/4/10 at 09:25 PM |
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very good!
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Stuart_B
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| posted on 14/4/10 at 03:11 PM |
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looking good
stuart
black mk indy, 1.6pinto on cbr600 bike carb's.
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