FRP 591, FRP replica, plus turbo conversion project

Hi guys, bit of a step forward over this weekend, first of all i hired a van and went up to Essex to collect my engine - 700 mile round trip in a day!, landed at Lightning Motorsport HQ where i was treated to a nice cup of tea and a good chin wag about engines/cars/karting etc with the Bosses dad


my steed for the weekend - good fun to drive too!



the main man himself Mr Newton showing off his handy work



all strapped down for the return journey


got the beasty home ok







anyway, no rest for the wicked, lots too do now, so today i stripped my gearbox for the new ATB diff to be fitted plus im getting the box casing stripped and painted


yes that is a wheel barrow im using





all stripped ready for rebuilding

Nice! Can't see the exhaust manifold properly, is that a twin scroll turbo?

BTW, excellent idea for cleaning;it never occured to me to do it like that althogh I have the equipment :!:

It's not a twin scroll manifold unfortunately

The old wheel barrow was great, all the oil collected underneath the board

That looks like a very nice engine build.

Simply "WOW!!" is all i'll say... :clap:

Thanks guys, busy day today, dropped of the gear box shell for vapor blasting, exhaust manifold dropped of to have the mounting plates 'faced' and a couple of parts for sand blasting/ powder coating, should be getting it in for a full exhaust in the next week or two also going for a full 3" system from the turbo back

Bit more work done over the last couple of days, test fitted my alloy radiator so i can get the intercooler brackets made and mount the oil cooler, I've decided that i'm going to completely strip the front end, pain all the chassis legs and engine bay, whilst getting the subframe and wishbones powder coated, anyway, i also got round to making a start on mounting the new uprated fuel sytem.....

stripped front end





New rad next to the old crappy one



Direnza list this as a Fiesta Mk 6 Rad! anyway after studying the pics of it i thought they made a mistake, so i ordered it and now im pleasantly supprised - even has mount to hold the A/C rad (not that im having A/C but handy to know!) also whilst i was there i fitted some new standard drop links and some new EBC front pads



fitted to its new home





I taught my neighbours some new swear words!!



Im liking the lack of number plate! gave it wash after the tinkering





Last few pics of the start of the fuel system install





for all those interested - thats a forge swirl tank, a Escort Cosworth fuel filter and a Bosch '044' motorsport fuel pump

This is getting better and better per update! Good to hear that the Direnza rad also holds the A/C! Handy info for me

Few more parts have arrived and a bit more work done today:

Picked up some new Ford bits: anti-freeze, coil pack, oil filter, Cam and Crank sensors



New Ford coil pack looks pretty cool



Fitted



Some special break-in engine oil and Quaife approved gearbox oil



Parts for new exhaust system have arrived: Sports CAT, centre and back box, as well as 4x 3" V-Band connectors (il now be running a full 3" stainless system from the turbo back



started making up some of the fuel lines, here is a little how to guide:

wrap them in masking tape and cut through with a 0.8mm cutting disc



assembly tools and parts ready



disassemble the fitting



push on one end



put the olive on the tool and jam it in the end of the hose







Push in the other end as far as it can go



ta-daa!!



Here are the hoses fitted roughly in their final positions in the boot (still need to drill holes for the bulkhead fittings to run the hoses under the car and to the fuel tank but you'll get the rough idea)

hands down one of the best pumas .........ever! k:

You need a NSFW in the title for this!

Your inspiring me to get cracking with my own turbo build now!

Are you gonna be running standard fuel tank?

Haha! Thanks guys, Jay - il be using standard tank and pump to lift fuel to the swirl pot, then the system above will supply the fuel rail

Sounds good, I was trying to decide whether to go with a fuel cell in the boot or stick with the standard tank and run a system similair/same as what you are planning.

I'm a whore for shiny things, so I had to go boot mounted lol

Got my gearbox mount and gearbox shell back from vapour blasting, mmmmmmm shiny!



I got on and did the most scary part so far today, I cut vents in the bonnet, there is something very sickening about sinking an angke grinder in to a carbon bonnet... anyway it turned out pretty good!

Made a little template for my Escort RS turbo vents



Some highly technical marking out going on here





After a lot of moving around and checking positions, i finaly settled on the final position, marked out on the bonnet, ready to cut



Cut a little test hole to see how the cutting disc felt and how the edges looked



Past the point of no return now...



after lots of sanding of edges we have a reasonable fit



I put a little guide coat of satin black on to see how they looked, i still need to make some proper mounts underneath but il leave that for the weekend now

Lovely update! Gotta love a clean and fresh gearbox.

Looks Mean! Good job!

I imagine you had to have a brave pill before cutting into that bonnet. Vents are something I've considered but I dunno if I can bring myself to chop into my carbon bonnet :-(

Two hard days of graft on my own done, doesnt look much but i have removed the front end panels (hood, wings, bumper) pulled out the current engine and gearbox, and today i have removed the wishbones, subframe and steering rack, it takes a whole lot longer when you don't have any air tools or an engine hoist!

stage one, get the panels off





stage two, pull the engine and box, radiator, hoses





small selection of now superfluous parts



stage three, remove fuel lines, EVAP system wishbones and subframes and steering rack, I also made a start on removing the now redundant engine sensors





next stage: finish removing engine sensors then power wash the bay. After that i can make a start masking stuff up to paint it, meanwhile il drop off the subframes, wishbones and various other parts for powder coating and send the rack off for an overhaul

Great start!! Looks scary like that, bet you can't wait to see it start going back together!