Building a budget zetec turbo, advise please.

[Reid]

Hello again lads, been a while since ive been on here but ive kept up to date with a few of your projects, some phenomenal cars kicking about!

So again ive started on my own wee project, a ka turbo. Some of you might remember i started one a fair while back but lost my job soon after and had to start selling bits meaning it was never completed. Now ive got a secure job, and the time to do it.

So, options were an efi turbo lump from a fiesta (which i fitted the last time no probs) but now after speakibg to a fella that does the engineering work for my boss im considering a ZT.

He reckons he could safely skim std zetec pistons enough to run 8psi or so of boost, what do you guys think? I know about the decomp plate option, but im not too keen on that.

With a zetec, what manifolds are used? I know the frst ones can be used if you get the head tapped, but what about focus rs exhaust and the rover turbo inlet?

Could it be run safely on ofab managenent?

Im not looking for alot of power, 150atw with a turbi should be enough of a laugh in a ka!

Cheers guys.

[DALSY]

watch out for a set of focus Rs pistons and rods, these will fit into a silver top or black top engine no worries

you can run OFAB management no worries upto 18psi, and about 220bhp @ the wheels

if i was building a budget zetec turbo engine thats the route id take

[Reid]

[DALSY]

youd pay about 150 - 200 quid for a set of pistons with rods, but make sure theyre a matched set, and theyll fit in no probs to

c20 let pistons means rebores machine work etc,,,,,,,,,,,, and probably around 400+ quid at a machine shop

[Reid]

Thats brilliant mate, cheers!

[mikeymikeyp]

http://www.ebay.co.uk/itm/IAN-HOWELL-AR ... 4ab0a272c9

couple of cheap bits for you kid

[peterRST]

hi Reid

if you are going for FRS pistons and rods ensure you get ones with new piston rings as they are unique to them and you can't buy them individually for them anymore.

std zetec pistons can be skimmed but make sure the setup is spot on as the skimming will weaken them a bit and keep the boost below$ 1bar. if you use a blacktop zetec these already have a small bowl in the piston so when they are skimmed you end up with a flat top piston, they also use a rear mounted starter which would help with the ka gearbox rear mount.

ST170 pistons and rods will do 300bhp and you can get the piston rings sent from mahle in germany... and they're strong enough to have a skim taken off them

If you want to keep standard pistons but don't like the decomp plate option, companies like ferriday can make up head gaskets to various thicknesses to lower the comp ratio.

An frst inlet can be used with conversion plates (ferriday/oddkid ect) but the ports will take a bit of matching, but it will bolt straight on.
a zetec efi one is o/e but you'll need to redrill it to fit the throttle body and make a fuel rail to suit the end feed injectors.
black plastic zetec inlet can be turbo'd but you'd need to check for space in the ka 'bay, likewise a rover inlet - this would also need a conversion plate but the ports line up and it uses bosch end feed injectors.

you can use a Escort RST exhaust manifold, either drill and tap the head or use a conversion plate, a focus rs exh will bolt straight on but its for a gt-series turbo so you'll either need one of those or adapt the outlet bolt pattern to suit.

hope some of that helps and get some pictures of the project when its going

Pete

[Reid]

Pete, that is an absolutely phenomenal reply fella, its much appreciated!

To get the car on the road ive just bought back my old efi turbo engine that wad RR'd at 202bhp ATF. Rather than messing about with ancient ofab looms im picking up a megasquirt loom/ecu at the end of the month. That was when i build my new engine there will be no probs changing it over.

Ive also bought a spacer plate, so plans now are to get this engine in and running, while finding an st170 engine to turbo (unless a set of frs pistons come up cheap first) I'll maybe need to modify astandard manifold due to problems with space in the ka engine bay, or go for a bonnet scoop!!

Cheers again for the help fellas.

Infact, while we're here and just out of curiosity... Running a supercharger, where would the drive for it come from, the aux drive belt ir its own belt, is there much else involved or is it just fitting the unit itself and plumbing it into the inlet, then going for the same injectors/management you would with a turbo?

Cheers for the help fellas.