OK so its been a few months now and I've finally got a day to update this! old 'Turbo Tubby' has had a few ups and downs over the last few months, its had a couple of teething issues and I've broke a few bits but its going well.
So i finally got it running after many a headache with the ECU, i had issues with a bad power supply and it kept draining the battery, in the end i redid the main power to the ECU which solved the problem but not before it killed the battery, replaced the old battery with a new shiny Bosch one and that cured a lot of the problems!
Its now been mapped up to 4K rpm and is currently running 8psi boost (whilst the engine is being run in) its now had a power run so i don't now what power its making though, pretty sure its well beyond standard as it pulls real hard on boost (even though its only running half the boost it will finally be running as well as only half the RPM range!) it still needs cold start mapping as its struggling to idle until its fully warmed up though, I'm up to around 750 miles on her now, the rest of the mapping will happen after she reaches 1000-1500 miles
Its run through two lots of competition 'running in' engine oil (Millers CRO 10/40) and original ford filters and now is currently running on its third lot of oil (now switched over to its long term oil - Millers 10/40 competition CFS oil)
Things I've/she's broke:
- Oil pressure gauge line burst at the oil sandwich plate (now replaced with a new one and working well)
- Second hand Vibratechnics gearbox mount shit itself and split in two, replaced temporarily with a cheap standard one, new
Vibratechnics one has arrived and I'm waiting to get it pressed in and fitted
- Vibratechnics torque link was a good 7+ years old and had quite a bit of play in it so i replaced it with a new one, much less
play now and feels more solid
- Turbo to down pipe bolts worked their way loose, now re-tightened
- Centre drive shaft bolts worked their way loose, now tightened and secure
- Secondary fuel pump died, likely due to poor feed from the swirl tank and the cold weather, fuel filter now moved to after
the pump and supply to pump increased from -6 hose to -8 hose, pump also replaced and running again fine
- Heat shielding applied to the HCV hoses as they are quite close to manifold
- Turbo oil drain melted during initial mapping, hose replaced and heat-shield applied (seems to be working well)
- Replaced a t-piece in vaccume lines that was blocked
- Steering rack blew a seal (after being overhauled!!!!) sent it back to be done again, then the hose failed, had smoke pouring
out from under the car as the PAS fluid was dripping on to exhaust! after a quick call to Lightning Motorsport i got a standard
second hand replacement from a fiesta Zetec-S (for non-AC cars) that now doesn't leak
Things I've had to finish off:
- Digital dash has had more parameters set up now, she has the odometer updated and now has both boost and water temp
values showing
- Engine bay wires tidied up and moved out of site/ziptied together for neatness
- Added a wideband Lambda from Emerald including a little flashing LED for exhaust gas temps
Anyway that sounds about where I'm up too, here's some pics as i know that's all you lot tune in for lol
Getting the tracking done and camber adjusted
Gearbox mount that turned out to be as tough as a richtea biscuit after one dip in a cuppa
Cheeky interior shot, think she makes a good Decepticon (note steering wheel centre cap) which is appropriate i think lol
Number plate relocated to increase airflow
Melted oil drain with its heatshielded replacement