FRP Duratec Turbo Project!

Do you have a Puma that is a project? Do you want to track the progress with your own thread? Feel free to do it here.

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FRP Duratec Turbo Project!

Postby red » Fri Aug 05, 2016 8:28 am

You can do it! :grin:
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FRP Duratec Turbo Project!

Postby Wild E. Coyote » Fri Aug 05, 2016 10:25 am

I guess the right way to say it should be: he did do it :wink:
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FRP Duratec Turbo Project!

Postby PumaNoob » Sat Aug 06, 2016 8:57 am

I'm pushing my luck a little, manifold and turbo are wrapped & bolted on, new EGT sensor fitted, & most of the downpipe is made.

Today's tasks are to finish the downpipe, plumb the external wastegate into the downpipe, fit the coolant lines to the turbo, extend the intercooler hose, make a new oil return, and fit induction hoses.

Fingers crossed I'll make it, even if I have to work through the night to get it done :lol:
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FRP Duratec Turbo Project!

Postby Wild E. Coyote » Sat Aug 06, 2016 10:16 am

If I were any closer, I'd give you a hand and do the catering for you so you don't run out of steam yourself
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FRP Duratec Turbo Project!

Postby PumaNoob » Sat Aug 06, 2016 1:23 pm

Thanks Sinisa, I know there would be a LOT of help if people were closer!

I'm cutting it fine, found out my intercooler pipe was too short as I've moved the position of the turbo, so having the hard pipe extended :?

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While I'm at it, might as well get the downpipe welded up! Spent the morning getting the V-band for the wastegate positioned properly, so once welded up, I've just got to go home and wrap the downpipe, fit it and the wastegate, and fit the water lines, then make an oil return from whatever I can find in my garage :?

Then try and get it cleaned! Soooo close!!
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FRP Duratec Turbo Project!

Postby Wild E. Coyote » Sat Aug 06, 2016 5:07 pm

If I see correctly, that is TIG welding going on, isn't it?
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FRP Duratec Turbo Project!

Postby Dal » Sat Aug 06, 2016 8:30 pm

PumaNoob wrote:Source of the post Then try and get it cleaned! Soooo close!!


Sod the cleaning - get it on stand tomorrow and I'll clean if for you!!! :thumbs: :thumbs: :thumbs: :thumbs:
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FRP Duratec Turbo Project!

Postby PumaNoob » Sat Aug 06, 2016 9:17 pm

Wild E. Coyote wrote:If I see correctly, that is TIG welding going on, isn't it?

It is indeed mate!

Dal wrote:Sod the cleaning - get it on stand tomorrow and I'll clean if for you!!! :thumbs: :thumbs: :thumbs: :thumbs:
:lol: :lol: I'll hold you to that mate!

Well, I'm pleased to say, I've just finished, feels like I've been at it for months!! I still need to take it for a test drive, but it's all back together & ive given it a quick clean!

Ford fair here we come!!
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FRP Duratec Turbo Project!

Postby tuonokid » Sun Aug 07, 2016 11:40 pm

Congrats on making it Errol :-)
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FRP Duratec Turbo Project!

Postby Lord B » Mon Aug 08, 2016 5:32 pm

Was good to see this car in the flesh.... Credit to you mate
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Postby PumaNoob » Mon Aug 08, 2016 7:01 pm

Thanks guys, the car drove faultless to and from the show, although I had to rewire the rad fan as the standard ECU wasn't switching the fan on and I didn't want to get caught out in traffic.

Just an update for those that don't know, the night before Fordfair, when I thought the car was ready, I was a little off on that one :oops:

I took it for a test drive at 11pm to make sure all was well, it felt great, powerful and drove as it should. But on accelerating hard, I noticed a trail of smoke behind me! I looked under the car and the oil return pipe had melted! The pipe I used wasn't heat resistant, so now all the oil being pumped into the turbo, was just draining onto the floor. I checked the oil, and there was none on the dip stick. Luckily the oil light had not come on yet so nothing had run dry, but I didn't want to risk driving it home. I was 2 miles from home so had to run home, get some oil & and a new oil return pipe, and ride my pushbike back to the car. I was working on it until 3am, but I was not going to miss ford fair!!
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FRP Duratec Turbo Project!

Postby FRPCurn » Mon Aug 08, 2016 7:32 pm

Fair play to you. Its an awesome car and you sound like nothing was going to stop you making Ford fair :ok:
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FRP Duratec Turbo Project!

Postby ArtfulHussy » Mon Aug 08, 2016 10:12 pm

What a hero. :lol: I wish I had been there to see it after such a determined effort!
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Postby red » Tue Aug 09, 2016 8:31 am

:grin: that's a great story, very glad you made it... see I told you you could do it!
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Postby moondustka » Tue Aug 09, 2016 7:55 pm

Absolute dedication :thumbs:
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FRP Duratec Turbo Project!

Postby Puma Lee » Tue Aug 09, 2016 8:28 pm

car looked amazing, just a fantastic effort
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FRP Duratec Turbo Project!

Postby McCloud 85 » Tue Aug 09, 2016 9:31 pm

You didn't mention that on Sunday! Top effort. Glad you made it!
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Postby XAF » Tue Aug 09, 2016 10:50 pm

Awesome Errol!
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FRP Duratec Turbo Project!

Postby PumaNoob » Mon Aug 29, 2016 4:57 pm

Ok, so for those that have not seen my puma in its natural habitat, here it is:

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It's been at least 2 years since its been on a recovery truck so it must have been feeling a little home sick! I was on the M1 northbound to Leeds, and there was a HUGE white cloud behind me. It seems that the head gasket around cylinder number 4 decided the grass was greener on the other side so abandoned ship. Cylinder 4 full of coolant :oops:

I removed the plugs and they also look like they are holding a white flag begging for mercy :Image

On has the ceramic completely missing, the other is half missing!

So if anyone has any ideas of a good spark plug and head gasket combo that can take 550hp,I'm open to suggestions. The head gasket is cometic and the spark plugs are denso iridium it16
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FRP Duratec Turbo Project!

Postby tuonokid » Mon Aug 29, 2016 8:17 pm

Hi Errol
Try SBD, they do a lot of work on Duratecs and if it results in a sale of a gasket for them they might offer some good advice.
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2001 ColOrado red Puma 1.7, work in progress.
Westfield SEIW 1800 Zetec.
Building Westfield SEI 2.0 Zetec Blacktop on TBs.
Fiesta Style 1.25
Aprilia Tuono Factory.
1975 Yamaha TY80
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My Project Link - viewtopic.php?f=64&t=23509

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Postby PumaNoob » Mon Aug 29, 2016 8:53 pm

Excellent, I'll give them a go, thanks Barry.
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Postby red » Tue Aug 30, 2016 9:12 am

Ahhh not off the road again!!
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Postby PumaNoob » Tue Aug 30, 2016 10:32 am

:cry: unfortunately so mate, it could be as simple as a head gasket, but I had a horrible feeling this morning that perhaps the bore liner could have split :? I was warned not to push the engine too far, but me being the idiot that I am, I may have just pushed too hard. I made a few more modifications and the mid range was so much stronger, too strong perhaps. I'm sure Ian Howells duratec had the corner split off the block at around 450hp?? My software estimated figures were more then 100hp above that so I may have found the limit to the duratec engine! I will remove the head as soon as I get a chance, meanwhile when I get home tonight I'll get my snake can down the bore and see if I can see any cylinder wall damage.
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Postby Wild E. Coyote » Tue Aug 30, 2016 7:45 pm

Ouch! That is not the best of news, I am affraid. So sorry for you!
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Postby warrenpenalver » Tue Aug 30, 2016 9:53 pm

look at cossies for plugs. They seem to be able to find plugs for that kind of power level and running conditions. Cant imagine they will last long whatever you find though - you arent on 123bhp any more!!
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