Fury556
Member
Thought i'd make a quick thread up for you guys in regards to the Turbo project! Not a huge amount has happened yet as we are still rebuilding the engine and i need to watch my cash flow going into this project 
I have been writing a blog for a little while (http://karsturbo.blogspot.com) and have gotten myself around to signing up as a member here now that I have a Ka sorted. See below all my updated thus far. Next update is due soon when I get some better pictures of the Ka itself as it is in great shape for an S reg
So it begins..
Well I decided to start seeing as a little progress has been made.
Basically the idea is to take a Mk1 Ford Ka and turn it into a track toy. This would include stripping most, if not all of the standard interior and fitting it with a roll cage, bucket seats and the appropriate dials. It will remain road legal to get to track days with minimal hassle.
As of Saturday the 27th I have the engine from an Escort RS Turbo complete with T3 turbo and gearbox. The bottom end and turbo have both seen better days but it is far from a wreck. With plenty of help from my brother over at WayneAshfordRacing we began taking the engine apart to find the cause.
Once the pistons were out of their cylinders it became apparent what had went wrong. The main bearings had been mixed up and put at the wrong points along the crank which likely would have caused the crank to not run true. The bearings all had score marks with the ocassional small piece of copper bearing still floating around. The crank also has some light scoring which will be sorted before it all goes back together.
The gauze inside the oil return was also clogged with thick black sludge and pieces of bearing which would have caused poor oil pressure. I have spent today cleaning up the pistons, block and oil return before the block itself is hot washed.
I have no photos as of yet but will provide the ebay image to give a rough idea of what we're working with!
The engine will want to be converted to EFi so we can give it the Omex treatment for much greater flexibility.
That's about all I have to say that's interesting and will remember to take some pictures at my next opportunity!
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Small update...
Just a brief update today. Spent an hour at most just making final preparations to the engine before it goes for a clean. This wont happen until either A) I sell the Puma or B) I come into some money. The former is certainly more likely!
Basically a couple of bolts sheared while we were taking apart the drive pulley/timing pully which we heated up for a couple of minutes using a blow torch and then using grips to twist them out. We also took the water pump off and removed the headgasket.
Another task at some point is to take the head apart to examine the cam and likely give that a clean up too. I took a quick picture of the head today in it's current state - nothing terribly exciting but it makes the page look more interesting until the good stuff starts happening!
Basically you're looking at the rockers and valve springs. The cam pulley is toward the right of the picture (as is the water pump to the far right).
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Valvey Goodness
Another small update here. We took the cylinder head apart last night to see what sort of state it was in. Not good is the verdict. We removed the rockers, lifters, valve springs and finally the valves themselves. The lifters whilst looking fairly new - were very coarse around the bottom edge. The barrels/chambers they sit in were also scored (1 quite badly).
All the valves look fine and the stem seals will be replaced when it comes to piecing it back together. Unfortunately the cam also took a bit of a beating and some of the hardened outer has worn away - this will want replacing too.
We may require a new head (it's looking quite likely) though we will get a second opinion from Dave before we do so.
If we do get a new head then we will get an EFi version as this is the route we want to go down.
Valves all lined up after removal:
All in all it was a little disappointing but certainly not the end of the world!
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Minor Update
Time for another brief update. Well hopefully tomorrow evening the Puma is being picked up buy it's new owner which is good news. In the meantime I picked up a new head for the engine which is shown below. Its been lightly skimmed and pressure tested by the previous owner. Looks very clean and in much better condition for that matter. It needs a new cam which is on the shopping list anyway.
I'll let the pics do the rest of the talking. Hopefully the next update will include the Ka which will be used
I have been writing a blog for a little while (http://karsturbo.blogspot.com) and have gotten myself around to signing up as a member here now that I have a Ka sorted. See below all my updated thus far. Next update is due soon when I get some better pictures of the Ka itself as it is in great shape for an S reg
So it begins..
Well I decided to start seeing as a little progress has been made.
Basically the idea is to take a Mk1 Ford Ka and turn it into a track toy. This would include stripping most, if not all of the standard interior and fitting it with a roll cage, bucket seats and the appropriate dials. It will remain road legal to get to track days with minimal hassle.
As of Saturday the 27th I have the engine from an Escort RS Turbo complete with T3 turbo and gearbox. The bottom end and turbo have both seen better days but it is far from a wreck. With plenty of help from my brother over at WayneAshfordRacing we began taking the engine apart to find the cause.
Once the pistons were out of their cylinders it became apparent what had went wrong. The main bearings had been mixed up and put at the wrong points along the crank which likely would have caused the crank to not run true. The bearings all had score marks with the ocassional small piece of copper bearing still floating around. The crank also has some light scoring which will be sorted before it all goes back together.
The gauze inside the oil return was also clogged with thick black sludge and pieces of bearing which would have caused poor oil pressure. I have spent today cleaning up the pistons, block and oil return before the block itself is hot washed.
I have no photos as of yet but will provide the ebay image to give a rough idea of what we're working with!
The engine will want to be converted to EFi so we can give it the Omex treatment for much greater flexibility.
That's about all I have to say that's interesting and will remember to take some pictures at my next opportunity!
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Small update...
Just a brief update today. Spent an hour at most just making final preparations to the engine before it goes for a clean. This wont happen until either A) I sell the Puma or B) I come into some money. The former is certainly more likely!
Basically a couple of bolts sheared while we were taking apart the drive pulley/timing pully which we heated up for a couple of minutes using a blow torch and then using grips to twist them out. We also took the water pump off and removed the headgasket.
Another task at some point is to take the head apart to examine the cam and likely give that a clean up too. I took a quick picture of the head today in it's current state - nothing terribly exciting but it makes the page look more interesting until the good stuff starts happening!
Basically you're looking at the rockers and valve springs. The cam pulley is toward the right of the picture (as is the water pump to the far right).
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Valvey Goodness
Another small update here. We took the cylinder head apart last night to see what sort of state it was in. Not good is the verdict. We removed the rockers, lifters, valve springs and finally the valves themselves. The lifters whilst looking fairly new - were very coarse around the bottom edge. The barrels/chambers they sit in were also scored (1 quite badly).
All the valves look fine and the stem seals will be replaced when it comes to piecing it back together. Unfortunately the cam also took a bit of a beating and some of the hardened outer has worn away - this will want replacing too.
We may require a new head (it's looking quite likely) though we will get a second opinion from Dave before we do so.
If we do get a new head then we will get an EFi version as this is the route we want to go down.
Valves all lined up after removal:
All in all it was a little disappointing but certainly not the end of the world!
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Minor Update
Time for another brief update. Well hopefully tomorrow evening the Puma is being picked up buy it's new owner which is good news. In the meantime I picked up a new head for the engine which is shown below. Its been lightly skimmed and pressure tested by the previous owner. Looks very clean and in much better condition for that matter. It needs a new cam which is on the shopping list anyway.
I'll let the pics do the rest of the talking. Hopefully the next update will include the Ka which will be used
