beaver34
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| posted on 30/7/09 at 09:02 PM |
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hows it coming along?, im starting mine this month, hopefully picking a head up this weekend
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flak monkey
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| posted on 30/7/09 at 09:23 PM |
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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
http://www.motosera.com
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flak monkey
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| posted on 17/8/09 at 07:38 PM |
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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 2
 
Inlet manifold 3
 
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
http://www.motosera.com
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Stuart_B
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| posted on 22/8/09 at 03:49 PM |
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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
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| posted on 22/8/09 at 04:24 PM |
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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
http://www.motosera.com
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flak monkey
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| posted on 23/8/09 at 02:25 PM |
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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 2
Also just finished fettling the inlet manifold. Just need to get it skimmed front and back to completely finish it off.
David
Sera
http://www.motosera.com
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flak monkey
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| posted on 24/8/09 at 07:29 PM |
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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....
Sera
http://www.motosera.com
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Stuart_B
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| posted on 25/8/09 at 05:54 PM |
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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
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| posted on 25/8/09 at 06:02 PM |
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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
Sera
http://www.motosera.com
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Stuart_B
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| posted on 25/8/09 at 06:27 PM |
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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
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| posted on 25/8/09 at 06:57 PM |
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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
Sera
http://www.motosera.com
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beaver34
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| posted on 25/8/09 at 09:29 PM |
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if you need any ford parts info drop me a u2u, its all i do all day
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flak monkey
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| posted on 26/8/09 at 09:21 PM |
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Flywheel part number
 
Rescued attachment m_P1000390.jpg
Sera
http://www.motosera.com
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flak monkey
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| posted on 27/8/09 at 07:07 PM |
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This is the water pump pulley fitted
 
New water pump pulley fitted
Sera
http://www.motosera.com
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goaty
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| posted on 30/8/09 at 08:45 AM |
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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
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| posted on 6/9/09 at 08:24 AM |
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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?
Sera
http://www.motosera.com
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goaty
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| posted on 6/9/09 at 06:53 PM |
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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
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| posted on 6/9/09 at 08:52 PM |
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quote:
Originally posted by flak monkey
This is the 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
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| posted on 7/9/09 at 07:02 AM |
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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
Sera
http://www.motosera.com
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FASTdan
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| posted on 7/9/09 at 02:11 PM |
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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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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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flak monkey
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| posted on 7/9/09 at 02:19 PM |
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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
http://www.motosera.com
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FASTdan
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| posted on 7/9/09 at 03:30 PM |
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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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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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flak monkey
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| posted on 11/9/09 at 04:20 PM |
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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.
 
 
Sera
http://www.motosera.com
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goaty
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| posted on 11/9/09 at 04:22 PM |
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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
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| posted on 11/9/09 at 04:27 PM |
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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.
Sera
http://www.motosera.com
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