2.1 Zetec Turbo - The Yella' Fella' (Videos and Dyno pg7)

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2.1 Zetec Turbo - The Yella' Fella' (Videos and Dyno pg7)

Postby Davedrave » Sun Oct 12, 2014 7:23 pm

Hello everyone,

Decided to start a new thread now before I forget further down the line. Basically, heres the plan:

1. Take my Puma Millennium edition (a.k.a. The Yella' Fella')...
2. Drop in a 2.0 Zetec turbo engine and MTX75 gearbox...
3. Enjoy!

Obviously, it's not going to be as easy as this, but my son, Dan, works with Chris @ Lightning Motorsport whom you may have heard of, so it is safe hands.

Engine spec is to include the usual stuff - JE Pistons, Eagle long rods, LMS spec cams - a GT3076R turbo with LMS tubular manifold, TiAL waste gate and screamer pipe, 850cc injectors, JS Performance hoses and Jenvey inlet plenum, to name a few items from the list. Other stuff includes Emerald K6 ECU, a digital dash - to be confirmed - MTX75 gearbox from Mk1 Focus RS, Adjustable coilovers, Brembo 330mm front brake conversion, 280mm rear disc conversion, front splitter, decent mud flaps and a small spoiler.

Will update with a few pictures of the car as it currently is over the next few days. The work is going to be carried out on the week commencing Monday 27th October, so not too far away!

Look forward to hearing your thoughts and comments throughout the build, cheers guys.
Last edited by Davedrave on Thu Nov 19, 2015 4:01 pm, edited 2 times in total.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Glenn_ » Sun Oct 12, 2014 8:00 pm

Sounds good. Will be a handful too.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Mon Oct 13, 2014 2:12 pm

Will be a hell of a lot of fun though. The Puma is a good handling car so should be okay to take the power.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby PumaJay » Mon Oct 13, 2014 4:35 pm

Looking forward to seeing some pics of this one!

you planning on having it all done it one week?
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Tue Oct 14, 2014 7:52 am

I'll try and dig out some pictures of what it currently looks like today.

And, yes, the plan is to have it 95% complete in a week, the longest thing will be making the exhaust manifold from scratch and having it sent off to be ceramic coated.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby PumaJay » Tue Oct 14, 2014 8:39 am

Wow, that will be quite impressive if you get that lot done!
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Tue Oct 14, 2014 1:01 pm

Well, we shall soon see won't we! We are also looking to do a fast ford magazine feature in connection with Lightning Motorsport when its done. I urge you all to go and check them out on Facebook https://www.facebook.com/pages/Lightnin ... ts&fref=ts, they have a lot to offer for the Puma's: cams, remaps, custom inlet plenums, turbo conversions etc. My son also helps them out and has the joy of working on the car, so lucky him.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby PumaNoob » Thu Oct 16, 2014 6:01 pm

Wow that's a big ask in a week, I'm sure it can be done but the problems normally occur when you bump into unexpected issues and have to wait on delivery of custom parts! But then I suppose if they have done this before, they will know what's required and hopefully there will be no unexpected issues.

What driveshaft will you be using with the MTX gearbox, and what internals, ie focus, Mondeo etc?

Really looking forward to progress on this, its a pretty big spec!
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Thu Oct 16, 2014 11:01 pm

Yes I'm not sure if it's going to get done in a week but like I said I want to be around 80% there in the week at least! Going to have to make sure that all parts are ordered and stocked etc. by Lightning Motorsport so that we can crack straight on with it. The toughest bit will be engine mounts I expect.

We are having custom driveshafts made by a company Chris @ LMS uses, and managed to source a genuine Focus RS MTX 'box for the car! Been very lucky with that find.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 12:34 pm

So I'm pretty much decided that I'm going to fully respray the car to have it looking nice and fresh when the new engine goes in. Whilst it's being done, I figured I may as well fit the S1600 bodykit to make it look like it should have when it first left the factory all those yeas ago!! I absolutely love the S1600 bodykit, looks mint, love how wide it is too.

What is everyones thoughts on the F2 Spoiler? I heard that it was an actual Ford designed item that was designed to provide downforce instead of being just a cosmetic item? Some people don't like it, and I never used to, but I've come to like it a lot recently so want other peoples opinions of it. Also, what do you think the wide puma will look like in the Millennium Yellow - I'm not sure what the correct paint colour is called, zinc yellow I think?

Another idea I had is a custom 4" outward rolled centre exit exhaust system, proper race car style! Not sure how much room there is under there, will have to look when its up on the ramps in a few weeks time.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Bentleya » Fri Oct 17, 2014 1:05 pm

The S1600 spoiler is the only spolier which suits the Puma in my opinion and can really finish off the appearance when fitted with a decent set of alloys.

If you look at Erroll's FRP it looks incredablie mean with the Comps and S1600 spolier.

The S1600 is quite hard to come by unless your willing to spend £1,000 with Chris Birbeck. I should hopefully have some copies made in the new year if things all go to plan.

There was a Zinc yellow S1600 Puma in Fast Ford magazine, I wasn't able to grab a copy but I shared a staus with a photo of the car on my Facebook Page.

When I looked at doing a Duratec Turbo conversion on an FRP I liked the idea of having an exhaust system like the Ford Fiesta and Subaru Impreza rally cars and using the CAT as a back box at the rear of the exhaust system. http://forums.nasioc.com/forums/showthr ... ?t=1863001
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 2:11 pm

The S1600 Spoiler is what I'm referring too when I say F2 Spoiler, they are the same item IIRC. Errol's car does look really good and I have seen the pictures of it. The compomotives also look absolutely stunning but my car is going to be Zinc Yellow and not Imperial Blue so not sure how good they would look with the colour.

I already have the S1600 body kit sourced with a company near me who have independently developed a kit that moves the wheels and wishbones and suspension to fit in the new wider arches. Proper bit of kit.

I managed to buy that copy of Fast Ford because of the Puma and it does look awesome, just wanted some other people's opinion on what they think it will look like. That exhausts system also looks pretty cool too, may be an option to do something like that. Still want a centre exit exhaust too, properly done with custom fiberglass to blank off original hole to make it look factory fit.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Ziggy » Fri Oct 17, 2014 2:36 pm

Davedrave wrote:I already have the S1600 body kit sourced with a company near me who have independently developed a kit that moves the wheels and wishbones and suspension to fit in the new wider arches. Proper bit of kit.


Got any details ?
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 6:31 pm

Ziggy, if you want some more information then you need to talk to Peter Bennett @ MDV Specialist Engineering. I don't know much about the specifics of it, sorry!

IF we do decide to go with the bodykit then I can assure you all there will be lots and lots of pictures and specific details of everything.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 6:39 pm

Image

I hope this works, just created a photo bucket account which I'm not happy about. Really wanted to be able to upload pictures without using a file hosting site, but hey ho!

It should be a picture of my car as it stands at the moment, not a very good one but only one I can find on my laptop at the moment! Tiny tiny brakes behind the 17" Team Dynamics :cry:
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby CherryVimto » Fri Oct 17, 2014 8:21 pm

The old fella is looking very tidy! And I see you've got good taste in wheels.... Look like gloss black?
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 9:10 pm

Why thanks mate! Indeed they are gloss black, Team Dynamics Pro Race 1.2's :wink: they do look good on the car, hopefully they'll look even better when they're 8" wide with semi slicks and the S1600 kit on it!
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby RyanG » Fri Oct 17, 2014 10:05 pm

Hello mate, your build will be loads of fun i hope you don't have any major issues with it :)

Couple of little questions, what are you doing for oil pump as with the power im guessing your looking for its almost inevitable to break/shatter taking the engine with it?
Also ive now seen a couple of the jenvey inlets split wide open how come you have chose to go down that route?
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Fri Oct 17, 2014 10:17 pm

Thanks mate, lets hope we don't have any main issues hey!

With regards to that, I have absolutely no idea. I know we aren't going to be running too much boost and the rev limit will not be over 7500 so should be under too much stress.
Also, I haven't heard anything about the Jenvey plenum being broken so just going with what I've seen before mate.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby RyanG » Fri Oct 17, 2014 10:25 pm

Ok mate good luck with the whole build and i hope it gets some track action :)
What power are you hoping for?
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby grayfox » Sat Oct 18, 2014 9:07 am

RyanG wrote:Ok mate good luck with the whole build and i hope it gets some track action :)
What power are you hoping for?


440bhp I believe Ryan don't think a torque figures been mentioned tho.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Lord B » Sat Oct 18, 2014 9:48 am

sounds like fun, will be an interesting build, its just mapping to be drivable rather than a dyno queen, to many mappers just wind up the boost to give high peak power figure, even though the average power across the usable rev range is low (compared to what it could be), and little thought given to the gear ratios.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Sat Oct 18, 2014 5:26 pm

RyanG wrote:Ok mate good luck with the whole build and i hope it gets some track action :)
What power are you hoping for?


As stated above, 440bhp is the target power. Do you have any suggestions on what to do regarding the oil pump?

I'm sure it will get some track action next year some time, would like to see it along side your insane N/A puma and Errol's car too.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby Davedrave » Sat Oct 18, 2014 5:30 pm

With regard to the mapping, the main aspects that this build has to be are drivable, reliable and show standard - the power is quite simply just a figure to aim for. The spec on this build should easily pull 500bhp with maybe 1 or 2 slight adjustments but I don't want anywhere near that. The car will have 3 different maps to switch between and it will more than likely spend the majority of its life on the low boost map, but should still chuck out around 320/330 bhp which is more than enough to have a good time!

I want the engine to be able to produce its power as efficiently as possible, another reason for the Jenvey plenum. Going with a full race set up on the manifold too so it can spool as quick as possible and have nice derivability too it. At the end of the day, it will be what it will be and this is my first project car and I want it to last for as long as possible. I want to be able to pass it on to my son in a few years too, when I get too old for it and he has some decent driving experience. I will just be happy with whatever end result we get and it should be able to keep up with about 90% of the cars on the roads anyway.
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Re: 2.0 Zetec Turbo - The Yella' Fella'

Postby RyanG » Sun Oct 19, 2014 2:18 am

I thought there were billet gears available for the oil pump but i may be wrong, we have just dynoed a zetec turbo that gave 510bhp and that used an external oil pump which is a very good option rather then going dry sumped.

I understand your want for peak figures but you would be pushing the engine and turbo hard to make 500bhp, around 30psi of boost would be a must on your 30/76

In my opinion to build an engine like this just to make a peak figure then use it at 330bhp is pointless as you then have no need for the 500bhp turbo other then making the engine have a very small power band, sure you would be better having a more responsive 400odd bhp?
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