Right then, its still winter so the mods still count
i have a Luego Viento with a zetec blacktop and jenvey (the red ones) ITB's with fast road cams currently sitting at 700kg and 185BHP and revs to
7500
what i am considering is turbocharging using the jenveys, i have seen it done before and jenvey actually make a plenum for it(but too much dolla for
me).
im considering using a GTIR nissan pulsar intake plenum and an adapter plate to bolt to the jenvey side
the cars running an omex 200 (think the basically rebadged megajolt i think it was)
not yet found the manifold or turbo parts yet but from bailey performance and others that have turbo'd a zetec im understanding approx 11psi and
240-250 bhp is about the limit for standard internals (that will be for now, then forged in the future)
type 9 gearbox im hoping to leave for a bit but understand this is a bit risky
the brakes are standard sierras with green stuffs and vented/grooved so if they are good enough for a car weighing twice mine it should be ok.
ill head back to standard cams and modify the sump, and coolant lines for the turbo
has anyone any experience with this or see any major issues?
cheers, Rob
Any chance of some photos of the Zetec in the Viento please ?
I have just bought a Viento but am 75% through turbo charging a Zetec in an mk Indy. ( not finished as I keep changing the spec ). I keep having
thoughts of raiding it for parts for the Viento but keep thinking of more displacement.
Ohhhhh i like the sound of this thread!!! Do you have room to house the turbo?
Turbo is the easy bit. Inlet is a bit harder and charge cooling the biggest pita and getting it all plumbed neatly together in a standard 7.
My current spec,
Engine is a St170 / blacktop hybrid. 9:1 Cr.
Turbo, I have a few but I’ve settled on the Impreza Td04.
Exhaust manifold is a reworked ford manifold.
Inlet, I have a few but I’ve settled on the Mk1 Focus Rs, has 440cc injectors.
Engine management is the mk1 Focus Rs.
Cooling, I am more concerned about this than anything else. Coolex rad and intercooler.
[Edited on 7/1/20 by big_wasa]
I've just more or less finished exactly that, Zetec turbo using jenveys and a gtir plenum, but in a stylus, if you want I'll take a piccy
of the install at the weekend
Shooter
A vid of you blipping the throttle would be even better 
quote:
Originally posted by big_wasa
A vid of you blipping the throttle would be even better
The throttle response on Itb’s should be really crisp.
I’ve also modified a Gbs plenum but I am un sure what boost it will hold.
I know my focus manifold will stand up as it’s tried and tested.
https://youtu.be/afwiOZWXQKk
[Edited on 7/1/20 by big_wasa]
Sell the jenveys and go for a single throttle body and remove a massive load of headache as well as having slightly fuller wallet.
quote:
Originally posted by Robbaa
the cars running an omex 200 (think the basically rebadged megajolt i think it was)
Wasa happy to send photos if you feel like PMing my your email (makes it easier).
my plan has gone somewhat up the swanny as the guy selling the plenum is ghosting me suddenly and DANST engineering said he could happily make me the
adapter plate and then suddenly put his price up on that piece as soon as i showed interest so out of principle ill want to go somewhere else now
the viento has tonnes of room in the engine bay and it looks like no problem whatsoever with fitting
You have pm
quote:
Originally posted by big_wasa
You have pm
As mentioned above getting the turbo running well is easy. Not that cheap but good value for money for the bhp increase
So I had a zetec conversion using a modified jenvey plenham which was good. My issues came from heat heat heat
So after several failed trackdays due to heat issues here are my thoughts
Big arse charge coolers work well but restrict the rad working well so use one but give it some room behind the rad.
A big arse radiator. On trackdays mine would stay stable under 100 if I removed my mesh grill off the westfield.
Bigger expansion tank was needed due to rad size but my bottle caps wouldn't last too long. I think I needed one without the pressure limit but
unsure never solved that one but the tops cost me a few quid
Hoses near the turbo didn't fair well at all so try use metal around here main ones are the turbo the silicone braided ones burnt up pretty
quick
Resolved this with the turbo blankets which also saved my bonnet which used to change colour on trackdays from yellow to orange and eventually
stained.
Then came getting the heat out. I've seen people like Dave binns and others cutting the sides off and putting the side vent carbon bits on. I
didn't want to do that but in hindsight probably would have been easier than all the messing I had to do to get the temps down.
Then came oil temp even adding the raceline sump didn't help too much needed to add a oil cooler which I placed on its side near the front
wishbones getting cool air from the gaps there. Got them under 100 most of the time so happy.
Then the hose from the rad coming past the turbo needed moving or recovering as that got so hot it melted the cable ties about a foot away from the
turbo so this was moved to the bottom of the chassis rail.
So this took me about 6 or 7 trackdays just to solve these issues but after this never over boiled anymore. I used the big expansion tank off the mini
the round one but only filled up to 10 percent and when hot would be 80 percent full so a big expansion space needed.
Car ran for about another 6 trackdays without engine issues then the crank started knocking at angelsey which I think was oil related and my fault. So
we replaced the crank another standard one and new ARP bolts and also the head skimming as the heat issues caused some serious warping and was fine
again until I sold it.
Final numbers after reducing boost to 18psi I think. 269hp with td04 turbo and 625 Siemans Daka injectors
Best of luck with the build. Also keep a bit of distance between the back of the thermostat and the chassis mine was too close and smashed the
thermostat housing if I used launch control.
We tried to keep it back to give more room for the charge cooler but was about 15mm and meant that it moved on the mounts a little and would spew hot
water everywhere under the scuttle.
Final step I did was removed one of the 2 charge cooler rads to improve rad temps which apart from hot trackdays then sat pretty happy at 85 with the
new fan I bought from VHS hydraulics that was the best mod to finally resolve the issues I had.
Newpicdavej
[Edited on 12/1/20 by jossey]
quote:
Originally posted by jossey
As mentioned above getting the turbo running well is easy. Not that cheap but good value for money for the bhp increase
So I had a zetec conversion using a modified jenvey plenham which was good. My issues came from heat heat heat
So after several failed trackdays due to heat issues here are my thoughts
Big arse charge coolers work well but restrict the rad working well so use one but give it some room behind the rad.
A big arse radiator. On trackdays mine would stay stable under 100 if I removed my mesh grill off the westfield.
Bigger expansion tank was needed due to rad size but my bottle caps wouldn't last too long. I think I needed one without the pressure limit but unsure never solved that one but the tops cost me a few quid
Hoses near the turbo didn't fair well at all so try use metal around here main ones are the turbo the silicone braided ones burnt up pretty quick
Resolved this with the turbo blankets which also saved my bonnet which used to change colour on trackdays from yellow to orange and eventually stained.
Then came getting the heat out. I've seen people like Dave binns and others cutting the sides off and putting the side vent carbon bits on. I didn't want to do that but in hindsight probably would have been easier than all the messing I had to do to get the temps down.
Then came oil temp even adding the raceline sump didn't help too much needed to add a oil cooler which I placed on its side near the front wishbones getting cool air from the gaps there. Got them under 100 most of the time so happy.
Then the hose from the rad coming past the turbo needed moving or recovering as that got so hot it melted the cable ties about a foot away from the turbo so this was moved to the bottom of the chassis rail.
So this took me about 6 or 7 trackdays just to solve these issues but after this never over boiled anymore. I used the big expansion tank off the mini the round one but only filled up to 10 percent and when hot would be 80 percent full so a big expansion space needed.
Car ran for about another 6 trackdays without engine issues then the crank started knocking at angelsey which I think was oil related and my fault. So we replaced the crank another standard one and new ARP bolts and also the head skimming as the heat issues caused some serious warping and was fine again until I sold it.
Final numbers after reducing boost to 18psi I think. 269hp with td04 turbo and 625 Siemans Daka injectors
Best of luck with the build. Also keep a bit of distance between the back of the thermostat and the chassis mine was too close and smashed the thermostat housing if I used launch control.
We tried to keep it back to give more room for the charge cooler but was about 15mm and meant that it moved on the mounts a little and would spew hot water everywhere under the scuttle.
Final step I did was removed one of the 2 charge cooler rads to improve rad temps which apart from hot trackdays then sat pretty happy at 85 with the new fan I bought from VHS hydraulics that was the best mod to finally resolve the issues I had.
Newpicdavej
[Edited on 12/1/20 by jossey]
I am thinking heat management may be a touch easier in the bigger Viento.
quote:
Originally posted by big_wasa
I am thinking heat management may be a touch easier in the bigger Viento.
You'll still struggle, never ending cycle of bigger intercoolers, oil coolers, water rads & fans.
Any tips ?
You have had a big power Zetec ?
As Jeff says it's forever cycle. My guide above got me 269hp and reliable temps but the engine was too far gone by that stage and I lost the love
after the rebuild so sold it.
My advise get an 1.6 EcoBoost it's designed for the turbo and cut big arse holes in ye sides and bonnet
quote:
Originally posted by big_wasa
Any tips ?
You have had a big power Zetec ?
Agree with all the above - getting the turbo installed, mapped and running well is the easy bit.
Heat management has been by far the biggest issue - I built my Zetec Turbo about 10 years ago and there are still improvements that I make every year
as I find the next weakest link in the system. It's been a long journey of melting things, replacing them, shielding them, uprating them,
increasing rad size and thickness, chopping holes in bodywork to better vent the hot air, etc etc.
I've ended up running the biggest rad that will physically fit in the nose, ducted so that every last bit of air goes through it, and a big oil
cooler, and a big chargecooler rad as well, with lots of vents chopped in the body to get rid of the hot air. It all gets a bit congested in the nose,
and there's a lot more piping and wiring to fit in and to protect than in a NA installation.
Having said that, it's hilariously quick, makes whooshy turbo noises, it finally seems to be reliable (crossed fingers!), and nothing much goes
past it on the average trackday.
On that note, be warned that having more usable power also then means that you'll quickly become aware of the limitations of your brakes, tyres
and handling in particular, and all of which you will then throw money at upgrading! Go into it with your eyes open. It is a lot of fun and I've
loved solving the engineering challenges at each step, but there's a strong argument for sticking with a nice tractable 175bhp NA engine and
spending the thousands that you'll save yourself on trackdays, driving tuition and just using the car more....
[Edited on 14/1/20 by djtom]
And, last but not least, if you get towards the power the Phoenix was making you will be rebuilding your highly expensive modified Type 9 (BGH E8,
Quaife etc etc) pretty often. A stock Type 9 will not cope with much over 200 ft lb torque. I ended up (after the 4th rebuild) going to a Quaife
60G with paddles which was an extra £10k+ once fitted/running.
The sweet spot on a Zetec is probable a ST170 or Blacktop, nice Neil Roper head, set of decent cams, arp crank bolts, Omex throttle bodies, Raceline
water rail and sump running via a nice TTV flywheel into a decent clutch. Put a BGH E8 on the back and fit Omex/Emerald etc management and it will be
a happy engine with little drama and make 210ish BHP while remaining reliable and useable on the roads. If the worse happens you take the expensive
bits off the old engine and put them all on a 2nd hand engine and start again.
Why is heat management so hard to sort out on our type of cars? I had a Renaultsport megane with only 225 bhp and never has an issue with heat. The turbo was standard but even after trackdays heat under the bonnet wasn't that bad and there was very little ducting for air to be released.
You have WAY more frontal area in a Megane than you do in a tiny se7en nosecone. That means that you can use rads with a much larger surface area, so
you get much better cooling.
That and the fact that Renault will have spent millions in CFD modelling the flow of air through the engine bay...
I’ve also got a Meg 225 and the intercooler is marginal if tuned over Oem.