Mk1 Focus RS powered Puma, now going RWD, JWRC

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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moondustka
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Mk1 Focus RS powered Puma, now going RWD, JWRC

Postby moondustka » Sun May 20, 2012 8:02 pm

Hi guys, thought I would share this..

This is my puma, I bought it February last year after my Ka came to an end. I finished it once last year in July and had it mapped at a place called TDI in Lakeside, Thurrock.

It made 244.5hp and 277 lbs of torque at the hubs, so guessing around 280 at the fly.

Unfortunately, I took very few photos, in fact it might as well have been none (which I regret for my own benefit).

The car then came off the road for an overhaul of everything around it as cooling was a massive issue, with water, oil and the air charge temps.

Again, this time I still didn't take many photos - doh!

Here are the few I did take. Most are self explanatory.

Shortly after I bought the car with my brothers wheels:
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Rear Wiper removed:
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Engine is in and lined up - the making of the timing end engine mount:

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The vibra techincs competition mount as well:
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Top gearbox mount, vibra technics - again competition.
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Underneath work, waxoyl, heatshields, fuel tank etc.
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And how it was before it came off the road last October. Some of you may have seen it at Ford Fair last year:
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Will do the next photos of what I have been doing in the next post!
Last edited by moondustka on Sun Feb 12, 2017 2:01 pm, edited 2 times in total.
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Re: Puma RS

Postby moondustka » Sun May 20, 2012 8:25 pm

Forgot this one.. On the hub dyno July last year:
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Not really in order of when but:

Welded in two spouts to the radiator. I chose a cosworth rad.
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I modded the oil cooler/warmer to get the spout in the right direction, however, it's in a totally different place now, you will see why shortly:
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Rear arch work to rust etc. This includes trying out 3M sprayable sealer - it's amazing!!

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Power Steering Mounting bracket I made:

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Modified power steering pipe... These are made standard from some sort of steel. The only way you can adapt it is to use a sleeve and silver solder joints. You need a blow torch and some sort of heat bricks (I used storage heater blocks) to get it to 650 C to do it!

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Peek of custom intercooler, loosely based on the RS500 style cosworth intercooler

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Old intercooler core vs new - a cheap core vs a proper one!

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Aluminium boost pipe I made to fit over the left side of the engine - previously all my pipework came from the right

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I then had a tubular manifold made, this came due to not be able to fit everything at the front and I needed more room for fans. This seemed the obvious route.

I had to mod it though slightly:
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New filter, nice and small, but apparently can flow up to 509hp!

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Evyerbody knows the dishwasher is an amazing parts washer! (I went to buy new but Ford don't do this one with the slide fitment at the back)

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The down pipe I've made (finished now but not in the photos)

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I've finished this down pipe now and it's heat wrapped - I had to cut it in half and put a v band clamp on to make it easier to fit!

I'll get some more photos soon. It's coming along and it's nearly ready to start again.

I'm gutted I don't have any photos of the engine bay as it was last year to compare as it's so different now.

The aim this time is to make everything as efficient as possible and hopefully get the 300hp at the hubs I'm after.

Ben
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Re: Puma RS

Postby Flying Scotsman » Sun May 20, 2012 8:39 pm

............................. What's your address........ I want that car!!!!!

UBER JEALOUS!!!

Seriously amazing job there.... I want PB to drop an RS engine into mine but they said it was out=dated so find another engine... Instead im building my own Puma RS out of the exsisting engine... they way it should have been done.
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Re: Puma RS

Postby Ginger Tom » Mon May 21, 2012 12:19 am

Mate that build looks mint...... Need to see her when she's done :pose2:
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Re: Puma RS

Postby d170sam » Mon May 21, 2012 7:18 am

Are you running the standard puma gearbox then? Epic build, great workmanship too!
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Re: Puma RS

Postby Sparx » Mon May 21, 2012 7:34 am

I remember you at FF last year- you came with all the Ka's, saw you in tescos car park when I heard the turbo chatter :lol:
Great build mate keep it up :ok:
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Re: Puma RS

Postby Flying Scotsman » Mon May 21, 2012 1:43 pm

Is that this Puma.... I remember that one.....
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Re: Puma RS

Postby moondustka » Mon May 21, 2012 9:47 pm

Sparx wrote:I remember you at FF last year- you came with all the Ka's, saw you in tescos car park when I heard the turbo chatter :lol:
Great build mate keep it up :ok:


That's right - I was with them as it was previously in a Ka..

I look back now and think it wasn't that nice last year at for fair :( It's getting a respray before this one, as it looks like it's been dragged through a hedge a few times!

Thanks for comments :)

d170sam wrote:Are you running the standard puma gearbox then? Epic build, great workmanship too!


The gearbox is quite a hybrid...

The front half (bell housing with starter opening) is a Ka, the back half is puma to retain standard puma mountings. I rebuilt it around 8-10k miles ago with all new ford bearings etc. with a Quaife ATB diff, fiesta ST 1-4th and Ka 5th.

It's been brilliant so far, but everyone I've come across with 300 or more hp has broken them. However, they've all been boxes not quite the same. I'm hoping with good mapping we can make the torque and power progressive so that it will be kind to the box.

The key is regular oil changes. I change it when I do the engine oil, which I will admit I do change (some might say) excessively (every 3-4k)
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Re: Puma RS

Postby d170sam » Mon May 21, 2012 10:21 pm

That's good advice, il keep that in mind for my turbo build
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Re: Puma RS

Postby PumaNoob » Tue May 29, 2012 6:01 pm

The bearings in the fiesta ST box are supposed to be stronger, hence the IB5 + name. And if you can get the power progressive rather then all in 1 shot, and dont continuously do hard launches, you might be ok with 300 bhp, torque is the real killer. What is that bush you have in the gearbox mount, it looks bigger then standard? Intercooler cores look very well designed, a lot more surface area contact for cooling, what were your intake charge temperatures with the old intercooler and at what boost levels? And what sort of drop are you expecting with the new cooler?
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Re: Puma RS

Postby moondustka » Tue May 29, 2012 9:36 pm

PumaNoob wrote:The bearings in the fiesta ST box are supposed to be stronger, hence the IB5 + name. And if you can get the power progressive rather then all in 1 shot, and dont continuously do hard launches, you might be ok with 300 bhp, torque is the real killer. What is that bush you have in the gearbox mount, it looks bigger then standard? Intercooler cores look very well designed, a lot more surface area contact for cooling, what were your intake charge temperatures with the old intercooler and at what boost levels? And what sort of drop are you expecting with the new cooler?


The power will be more progressive - the boost solenoid is now linked to omex, so the omex will control it. I had around 280-290hp before (244.5 was measured at the hubs - flywheel is estimated)

The gearbox mount is a vibra technics competition mount.

Old intercooler was awful to be honest. Can't believe it even made the power it did. Inlet temps were around 55 degrees on full chat at 20 psi.

I'm hoping for inlet temps around ambient with the changes I've made. I've also moved the air filter. It was just sitting in the bay before sucking up a load of hot air!
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Re: Puma RS

Postby moondustka » Tue May 29, 2012 9:58 pm

Some progress and almost completed...

Top of wrapped down pipe - sprayed with thermo-tec copper spray.

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Up the back of the engine - you can see the v-band join i've put in.

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Gauges for monitoring - a pretty penny!!

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Half size filter with oil cooler bolted to the block

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Air filter & duct

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I want to try and box this in to the bumper to enclose it and duct some fresh air to it from the front.

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I started it and no leaks except water - from the rad where the welded the 16mm spout is. So took it out and got it re-done and TIG welded. Will go back in the car this weekend and try again! Happy there's no oil or power steering leaks, as I've modded a lot.

MOT is booked for next week and mapping for the week after so not long now! I need to get it back on wheels and check everything now.
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Re: Puma RS

Postby PumaNoob » Wed May 30, 2012 4:58 am

Was that on a cold day or a hot day you got those readings, do you know what the air temp was before the cooler and before the turbo? Im only asking because i want to know how my intercooler is performing. I took mine out on a hot day, 20+ degrees, and ran 20psi. My intake charge on my datalog peaked at 50 degrees. But from reading other threads, thats a pretty good figure, considering the air entering the turbo is 20 degrees, but the air leaving the turbo will be around 100 degrees celsius, because compressing the air that much aswell as passing through a glowing hot turbo will increae it a hell of a lot.

I used this calculator to do the calculations http://www.rbracing-rsr.com/intercoolers.htm

You will never get a 100% efficient intercooler that will cool the charge down the outside air temps, but ill be watching with interest to see what sort of efficiency you get, definitely a few horses and safer conditions to be had.
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Re: Puma RS

Postby moondustka » Wed May 30, 2012 10:30 pm

I can't remember what the other temps were..

I know I got it mapped in July and it was less than 20 degrees C that day. It was also stuck in front of a wind funnel that could generate 140mph winds - you struggle to move in front of it!

I remember the intercooler not being that cold on the exit - in fact it was warm. We tried move boost but no extra power was produced due to the heat build up. I remember them saying that at 60-65 degrees it starts getting risky for detonation, especially as I could have taken it out on hotter days. This is another reason for going to 70mm boost hoses to all help in reducing the inlet temps. Good hp gains can be had just from making the induction system as efficient as possible.

I'll run the laptop while driving and see what omex says - the sensor is at the end of purple pipe where it connects to the silicone, so fairly close.
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Re: Puma RS

Postby moondustka » Tue Jun 12, 2012 6:49 pm

Bit of an update:

New boost vents

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Finally got the car out, but a bit dirty!

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Made an airbox for my filter:

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Drilled a pattern of holes for airflow

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Although now that it's been mapped, I might core some holes through it as the 3mm holes aren't brilliant for airflow I'll admit.

And yesterday, had mapping on it! Couple of pics..

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That's at around 5,500rpm, full boost.

Result:

Hp at the hubs: 281
Torque at the hubs: 286 lbs ft

They estimated the power at the fly to be a good 350hp - Though I'm not sure myself.

Power delivery has a really good curve, making 260hp at the hubs at around 4,400 rpm and rising to 280, holding all the way to the limiter.

So a pretty good result. They have advised I get the manifold coated for obvious reasons, and put reflective tape under the bonnet!

Cooling is good - struggling to keep the engine at 85.. but much easier to make something warmer than colder!

Had a few minor issues, a coolant hose blew off, but they sorted that,and put my throttle bottle on a lathe to provide a lip for the silicone to bite onto (after it blew off!) And I have a power steering leak from one of my silver soldered joins :-( It had sealed for a few journeys and then let go, I just plugged it with load of super steel glue for the mapping and ordered some more silver solder to do it properly at the weekend.

Didn't really get to try the power on the way home, weather is so bad and it was raining all day yesterday. It feels really strong though!

Won't be coming out until a dry day now - I never plan to be out in it when it's raining or wet, especially after it's re-sprayed!
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Re: Puma RS

Postby ScubaSteve » Tue Jun 12, 2012 7:03 pm

deffo needs large holes cant see those 3mm holes providing anything really lol
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Re: Puma RS

Postby Flying Scotsman » Tue Jun 12, 2012 7:06 pm

Damn this car is f***ing awesome!!
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Re: Puma RS

Postby moondustka » Tue Jun 12, 2012 10:52 pm

ScubaSteve wrote:deffo needs large holes cant see those 3mm holes providing anything really lol



I know :lol: I plan to holesaw some larger ones in!


Flying Scotsman wrote:Damn this car is f***ing awesome!!



Thanks! Should look the part at Ford Fair as it's going for a full re-spray 1st July :)
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Re: Puma RS

Postby Flying Scotsman » Wed Jun 13, 2012 5:42 am

moondustka wrote:
ScubaSteve wrote:deffo needs large holes cant see those 3mm holes providing anything really lol



I know :lol: I plan to holesaw some larger ones in!


Flying Scotsman wrote:Damn this car is f***ing awesome!!



Thanks! Should look the part at Ford Fair as it's going for a full re-spray 1st July :)


What colour will the re-spray be?
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Re: Puma RS

Postby moondustka » Wed Jun 13, 2012 12:04 pm

Same, in black. The paintwork is shocking at the moment! As some rust on one of the arches and boot lid.
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Re: Puma RS

Postby JordyBoy » Wed Jun 13, 2012 12:22 pm

Is this the puma I saw at a meet in Brighton marina a while back? Had a little chat with you.... Sure it was this one as Puma Rs' are few and far between lol! Especially with those wheels and the front intercooler... :)
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Re: Puma RS

Postby Pixie » Wed Jun 13, 2012 1:41 pm

Can I have first dibbs on this when you are bored of it :) ( if that ever happens)
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Re: Puma RS

Postby moondustka » Wed Jun 13, 2012 8:29 pm

JordyBoy wrote:Is this the puma I saw at a meet in Brighton marina a while back? Had a little chat with you.... Sure it was this one as Puma Rs' are few and far between lol! Especially with those wheels and the front intercooler... :)


Yea it is, I remember. Was completely different when you saw it!
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Re: Puma RS

Postby moondustka » Wed Jun 13, 2012 8:30 pm

Pixie wrote:Can I have first dibbs on this when you are bored of it :) ( if that ever happens)


I think I would sell for the right price! but my right price is a lot more than anyone would pay :lol:
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Re: Puma RS

Postby Flying Scotsman » Thu Jun 14, 2012 12:39 am

moondustka wrote:
Pixie wrote:Can I have first dibbs on this when you are bored of it :) ( if that ever happens)


I think I would sell for the right price! but my right price is a lot more than anyone would pay :lol:


Don't be so sure..... lol
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