FRP 591, FRP replica, plus turbo conversion 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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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Fri Sep 01, 2017 6:59 am

Totally, I enjoy the rebuild when fresh parts start going together, this is where it starts to be fun :)
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PumaJay
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FRP 591, FRP replica, plus turbo conversion project

Postby PumaJay » Fri Sep 01, 2017 8:44 am

Really looking forward to seeing it all go back together, your inspiring me to start buying parts that I dont need yet!
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Van_Dammesque
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FRP 591, FRP replica, plus turbo conversion project

Postby Van_Dammesque » Fri Sep 01, 2017 8:59 pm

Puma porn! :ok:
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Sun Sep 03, 2017 9:40 pm

You should definitely buy parts you don't need, just saying lol
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Wed Sep 06, 2017 8:11 pm

New parts arriving

New Hella fan

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Manifold has had its mounting faces skimmed

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Vibra-technics engine mount pressed in

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New track rod ends, wishbone ball joints, inner CV boots and rear wishbone bushes

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New OMP lower strut brace

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Also done some grafting, sanded back my bonnet, splitter and bonnet vents (they have now gone off for re-laquering and painting

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Also started getting rid on the now superfluous loom

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Picked up a couple new small gaskets from Mr Ford

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PumaJay
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FRP 591, FRP replica, plus turbo conversion project

Postby PumaJay » Thu Sep 07, 2017 7:41 am

I'd of thought you'd of gone with powerflex bushes in the wishbones to help tighten the handling up a bit more.

Manifold looks a nice bit of kit.
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Thu Sep 07, 2017 4:25 pm

I've got powerflex front wishbone bushes and ARB ones but I wasn't too fussed about the rears :)
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Thu Sep 07, 2017 7:06 pm

Got the gearbox rebuilt finally, i had the shell vapour blasted then i had it painted silver and the end cap powder coated black, I fitted the Quaife ATB differential after my mechanic friend pressed on the bearings for me, and fitted all new seals and gaskets, the box was brand new anyway so i didn't change the bearings, it was a bit tricky to get everything back where it should be but i'm pretty confident that its all as it should be

The parts:

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Diff in its new home

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lots of cogs

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All done and looking sweet

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Lots of things going on simultaneously at the moment, i also made a start on the engine bay masking up

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once that was done i got a first coat of etch primer on

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Also bolted on a couple of engine parts

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more updates very soon!!
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tuonokid
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FRP 591, FRP replica, plus turbo conversion project

Postby tuonokid » Thu Sep 07, 2017 8:03 pm

Hi Sam
If you haven't already done it now might be the time to grind off the lower inner wing flange to give more clearance for your front tyres.
Barry
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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.
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My Project Link - viewtopic.php?f=64&t=23509

d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Thu Sep 07, 2017 8:19 pm

Thanks for the tip dude, I hammered it flat a few years ago when I converted it to the wide body, it doesn't seem to have any clearance issues anymore :)
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Wild E. Coyote
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FRP 591, FRP replica, plus turbo conversion project

Postby Wild E. Coyote » Fri Sep 08, 2017 7:15 am

Nice work indeed! Speechless :thumbs: :thumbs:
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Simonavis
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FRP 591, FRP replica, plus turbo conversion project

Postby Simonavis » Fri Sep 08, 2017 8:59 am

Oh my god, I have just got a wet patch!!! :lol: :oops:
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Who knew owning a cat becomes and obsession!!

d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Fri Sep 08, 2017 2:54 pm

Thanks guys, il update where I can but it's got a whole load of bits to do over the next few weeks :)
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siju
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FRP 591, FRP replica, plus turbo conversion project

Postby siju » Fri Sep 08, 2017 5:29 pm

Hi Sam,
The turbo is garrett gt2560rs (ball bearing)? Very nice project!

Alex
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Fri Sep 08, 2017 8:32 pm

Close it's the gt2560r good for around the 300bhp mark I want to achieve :)
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Sun Sep 10, 2017 10:59 am

got my steering rack back from its overhaul, Pupper is doing me a help

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Also managed a quick 1st coat of matt black this morning

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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Fri Sep 15, 2017 5:00 pm

Bit more work done today, started fitting part back on, got the new wiring loom through to engine bay, also got the new heat shield fitted

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Also got to polishing some parts before refitting, also painted the inner CV housing and centre shaft

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Breather tank

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Lightning motorsport large bore throttle body added (powder coated and new bearings fitted by me)

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PumaJay
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FRP 591, FRP replica, plus turbo conversion project

Postby PumaJay » Sat Sep 16, 2017 7:47 am

More good progress, looks like its all moving in the right direction nice and smoothly.
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Mon Sep 18, 2017 8:40 pm

Lots more progress!!

Picked up the last lot of new parts from Ford: new ARB brackets, bonnet switch, gearbox speedo drive holder, all the bolts that hold the subframe, wishbones, rack ARB in situ

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Got all the parts back from the powder coaters, heres the subframe

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Wishbones (with new bushes pressed in, radiator/far support bar, upper strut brace ends as well as the FRP inlet support bracket and gearbox mount

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FRP carbon splitter sanded down and re-laquered

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Aux belt (non-aircon) fitted as well as the alternator

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Subframe now fitted

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ARB greaced up and fitted (with powerflex bushes)

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PAS rack in - note it has the adapter and Aeroquip fitting for the high pressure line from the pump

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All ready to go back in - its make or break time!!

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trust me i think i know what im doing.....

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just as i note i fitted the flywheel, clutch and gearbox too before i craned it in (sorry, no pic)

Aaaaaahhhhhhh yyyyeeeeaaaahhhhhhhh!!!!!!!!!!!!!!!!!!!!!!!1

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Engine and box in, rad and fan fitted

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Nice and shiney!! also you can see the other aeroquip fitting for the PAS pump (now located at the front of the engine now the A/C in deleted)

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Delighted with my efforts (i did all the above in one day on my own, with out power tools too!)

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she's now been loaded up ad taken away for exhaust fabrication as well as hard pipes for the intercooler and airfilter, should be back in 7-10 days for me to finish off the last bits before the first start up!!!

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sorry for the long post (been too busy to update lol)
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moondustka
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FRP 591, FRP replica, plus turbo conversion project

Postby moondustka » Mon Sep 18, 2017 10:58 pm

Nice parts on there and a lot of effort! :thumbs:
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XAF
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FRP 591, FRP replica, plus turbo conversion project

Postby XAF » Tue Sep 19, 2017 7:10 am

Amazing job! Love it
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Wild E. Coyote
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FRP 591, FRP replica, plus turbo conversion project

Postby Wild E. Coyote » Tue Sep 19, 2017 7:13 am

Speechless again. And as jealous as the dog in one of previous images.... :grin:
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siju
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FRP 591, FRP replica, plus turbo conversion project

Postby siju » Wed Sep 20, 2017 10:33 pm

Awesome work. Looking forward to the engine results!
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PumaJay
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FRP 591, FRP replica, plus turbo conversion project

Postby PumaJay » Thu Sep 21, 2017 3:06 pm

That really will be a super tidy engine bay when its complete, keep up the good work buddy.
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Postby d170sam » Fri Sep 22, 2017 7:01 pm

More progress achieved, the car is half way through getting its exhaust, hard boost pipes and inlet pipe fabricated up, i've also been inspired with my new horn button to call the car megatron lol

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anyway here are some exhaust pics, its a full 3" system from the turbo back including v-band connectors throughout, a sports cat and 2x silencers almost identical in dimensions to the ones that were on te car before (Piper stainless system)

down pipe

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flexi pipe and sports cat

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mid section

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first silencer

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over the rear beam

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back box

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should have the car back tuesday (26th) then its finish up the last bits of wiring and tidying
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