The Build P6

Quote: jimmyesh on Mon Nov 24, 2008 7:35 pm

Hi everyone, got bored in my lunch break today so thought I'd tackle a niggly power steering issue πŸ™‚

As you know, I have the PAS pump which is standard fitment on 1.8/2.0 Duratec Mondeos, 1.8/2.0 Duratec Focus and Fiesta ST (That's the one I have). The problem is that the Fiesta Si high-pressure PAS pipe won't fit the PAS pump of the Duratec and the Duratec pipe wont fit the PAS rack of the MK3.5 fiesta! :oooh:

The Mondeo MK3 rack high-pressure inlet connection is just a "push-in" type that has a plate which bolts it on to the rack, the fiesta one is a more conventional swivel-ended screw type that screws into the rack.

Therefore I carefully cut the Mondeo push-fit end off that pipe, (keeping the flat "collar" that's on the pipe to allow for a stronger base to weld to) did the same with the Fiesta screw-fit end from the Fez pipe, cleaned the faces up then carefully welded the Fiesta end to the Mondeo Pipe. A small bar was inserted into the pipe to keep alignment correct throughout.

The finished article - later on I painted any exposed metal as the pipe is steel and I want it to last at least a year! :rolleyes:
Fits a treat too :Q

Not the most exciting update I know but it's one of those crappy little jobs that I didn't want to do at the end.

Quote: jimmyesh on Thu Nov 27, 2008 6:03 pm

Bit of progress today πŸ˜€ Got my sump back from my mate, Frenchie, at work who's kindly TIG welded my -10 turbo and -6 oil catch-tank oil returns which I bought from Earls hoses. The sump was cleaned of swarf and rubbed down, followed by a couple of coats of gloss black engine enamel. Sump and dipstic were fitted this afternoon πŸ™‚

He also fitted some new brackets that I made for the GRS intercooler (the old ones had seen better days...)

Another niggly problem - The EGR valve needed removing as I'm not intending on routing exhaust gasses back into my inlet to save the planet! :rolleyes: (Looks awful too!) Here's the offending item...

Using the old gasket as a template I made a blanking plate out of aluminium, here it is shown before I cleaned the mating faces and fitted a new gasket, along with some shorter bolts.

Still waiting on my turbo manifold - it's been nearly 2 months now and I need that all fitted before I dummy-fit the engine :rolleyes:

Bye for now! πŸ™‚
Quote:Β jimmyesh on Fri Nov 28, 2008 9:20 pm


Excursion kindly told me that my EGR blanking-plate is too thin and has to be at least 10mm thick (when made with Ally) - Something else to crack on with next week.

Also I'm tring to blag a trolley from work that I can place my engine on whilst fitting the flywheel & clutch, before fitting the transmission. That way I can move it all easily to the other end of the workshop where the crane and ramps are for dummy fitting over Christmas leave.

Come on Pumaspeed, hurry up with my manifold!! :aaah:

Quote:Β jimmyesh on Sun Nov 30, 2008 5:15 pm

Hey everyone, good news! πŸ˜€

Got lucky on Ebay today and bought a Focus RS Gearbox (so much for not touching the Christmas spends! :rolleyes: )

As most of you know, the Focus RS Gearbox already has a Quaife ATB Diff fitted as standard, along with shot-peened gears and stronger bearings. Seeing as the Quaife is Β£520 + Vat (so more like Β£600) new on its own I've basically paid half price for it and it comes with an uprated gearbox too! :aviator:

07 focus rs box
08 focus rs box
I'm aiming to collect it on Friday, once in the workshop I'll take the FRS "Zetec" MTX75 bellhousing off and swap it for my mondeo "Duratec" MTX75 bellhousing. I'll fit the flywheel, clutch and gearbox to the engine the following week when I'm on leave again.

Bye for now!

Quote: jimmyesh on Fri Dec 05, 2008 5:29 pm

Turbo Manifold arrived today, made me very happy despite having "man-flu"! πŸ™‚

I'll be collecting my gearbox on Monday too, so stand by for a plethora of updates next week (and a big chunk of my budget blown on Beecham's powders! :rolleyes: :aaah: )

Quote: jimmyesh on Mon Dec 08, 2008 6:04 pm

Had a bloody mind-numbing 320-mile round trip today to collect the FRS 'box, but at least I used work transport and fuel! πŸ˜€

Here's my new exhaust manifold resting on the studs at the moment (will be covering in heat wrap and fitting the turbo soon). As you can see it's not a funky "bunch-of-bananas" & equal length primaries affair, instead it's just cast steel and compact but perfectly adequate for my power needs πŸ™‚

The couple of pics below are a useful reference if buying a 2nd-hand FRS 'box (just in case some uscrupulous scum bag tries passing off a normal MTX as an FRS item :rolleyes: )

Here's the standard MTX 75 Open Diff (services no longer required!)

Compare and contrast with this, the MTX 75 Quaife ATB Diff :Q

Here's a quick pic of the two different bellhousings, firstly the FRS Zetec/standard Ford bolt pattern:

...and here's the Duratec (Mazda) bolt pattern, vastly different:

Just in case anyone was in any doubt, the Mondeo MK3 Duratec uses the same gearshift setup as the FRS so that can all stay put (confirmed by Ford TIS too so there! :bonkers: )

Tomorrow I'll be swapping the bellhousings over and fitting the turbo if time allows :aviator:

Quote: jimmyesh on Tue Dec 09, 2008 6:16 pm

Hi readers, BIG update today! πŸ˜€

Firstly I added the "Turbo" to the Duratec so I now have a "Duratec-Turbo" πŸ™‚

Here's where problems arose... 😑 :rolleyes: I stripped the bellhousings of both the FRS 'box and the Mondy MK3 Duratec 'box, as you can see the bolt pattern on the "gearbox side" is slighly different even though they're both MTX 75 'boxes! 😑

It became a bit more obvious when I attempted to fit the Mondy MK3 bellhousing to the FRS 'box - not very oil-tight! :aaah:

Resorting to plan B I removed the standard "open" diff from the Mondy 'box...

...and replaced it with the Quaife ATB from the FRS 'box, along with new diff bearings.

Mondy MK3 Duratec bellhousing was then re-fitted, along with the SPEC hydraulic release bearing.

Quaife ATB now resident in the Mondy 'box.

Check out the difference in size between the FRS & standard Focus 2.0 Inner CV Joint housing! :oooh:

Flywheel & bolts ready for fitting...

...and fitted!

Spec stage3 6-paddle clutch all fitted.

Lastly, I also had a modified MTX gearbox mount made today at work - just as I did with the "Manj". Basically the "tower" part of it (that bolts up through the mount) has been move inboard about 2" - this gives me some much-needed room to fit the gearbox mounting point to the n/s inner wing. It's very strong and has worked fine for me in the past, so hopefully it'll be ok this time!

Bye for now I'm bloody knackered! :rolleyes: πŸ˜‰