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

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.

Moderator: Moderators

User avatar
moondustka
Project Petrol Head!
Project Petrol Head!
Posts: 1255
Joined: Sun Mar 27, 2011 10:49 pm
Model: Turbo
Location: Surrey

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

Post by moondustka » Thu Jun 16, 2016 6:48 pm

Agree with Sinisa.. And a proper multi-point cage will help also, as well as for safety!
0 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Thu Jun 16, 2016 6:52 pm

Have had a read of this: http://www.fiestaturbo.com/feature-cars ... iesta-evo/ and bloody hell it looks the nuts! Running an RS transfer box and rear diff and thats 720bhp!! I wouldn't want that much power because ultimately it will still be a road car, just a f'ing quick one!

Can anyone shed any light on why the 6 speed boxes are worse than the 5 speed?
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
moondustka
Project Petrol Head!
Project Petrol Head!
Posts: 1255
Joined: Sun Mar 27, 2011 10:49 pm
Model: Turbo
Location: Surrey

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

Post by moondustka » Thu Jun 16, 2016 7:50 pm

Oh yes, forgot about DJM, they can some or all of it for you. Only ever heard really good things about them. They made a 4WD Ka also.

So, if you've got deep pockets, they will fabricate and install all that Evo stuff for you.
0 x

McCloud 85
Adolescent
Adolescent
Posts: 157
Joined: Wed May 13, 2015 10:28 pm
Model: Cosworth

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

Post by McCloud 85 » Thu Jun 16, 2016 11:18 pm

Supposedly DJM are the company that fabricated my cosworth Puma. It was done to a good standard, and the car drives well without any oddities with it being a converted car. Pretty pleased with that work on the car.
0 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Fri Jun 17, 2016 12:16 am

Yeah I have heard about them before. The company I have mentioned before, MDVse are just down the road from me and have built a 900bhp Pike's Peak RS200 and a Cossie RWD white Focus RS Mk1.. They've expressed large interest in doing the conversion for me. I know it's new tech as opposed to old tech but just can't decide if I want to go down the cossie route or EVO route!

All the gear kits I can find for EVO gearboxes are dog boxes and I know I don't want one of those. Maybe the standard internals once they've been shot peened and super finished might be alright but probably would be better off asking the guys at MDV about it.
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
moondustka
Project Petrol Head!
Project Petrol Head!
Posts: 1255
Joined: Sun Mar 27, 2011 10:49 pm
Model: Turbo
Location: Surrey

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

Post by moondustka » Fri Jun 17, 2016 9:32 am

Shot peening makes a big difference to the strength of gears and is a relatively simple process. I would be surprised if the gears themselves were still the weakest link afterwards.

Be interested to know what they would charge for 4wd conversion. Must into 10s of thousands I would have thought, complete.
You can usually get the shell converted for a few thousand.
0 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Fri Jun 17, 2016 9:37 am

I would probably just buy a standard box and have the gears shot peened and then see how an RS rear diff fairs up. I'm only having UP TO 500bhp, most of the time it would be run at a lesser boost level but would be nice to know all the parts will have the strength there when a track day comes up etc.

I'd imagine I'm probably looking at around the £20k mark at least for all the work to be carried out, would also want to redo my brake setup, pedal box is actually quite a nice touch and I feel comfortable with it but without the ABS its rather tricky to say the least!

Just dreaming aloud here and of course if money was no object as I'd probably be looking for £10k+ on parts alone..
Anyone fancy seeing a Nissan GTR converted puma :P VR38DETT up front, GR6 gearbox at the back, would make weight distribution perfect and provided all supporting mods had been done to the shell, with the extra weight, 600bhp should be lovely :lol: :lol:
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
moondustka
Project Petrol Head!
Project Petrol Head!
Posts: 1255
Joined: Sun Mar 27, 2011 10:49 pm
Model: Turbo
Location: Surrey

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

Post by moondustka » Fri Jun 17, 2016 10:06 pm

Well, if you do ever get rid of your engine, first dibs on the inlet manifold :P

Be very interesting, whatever route you take.
0 x

McCloud 85
Adolescent
Adolescent
Posts: 157
Joined: Wed May 13, 2015 10:28 pm
Model: Cosworth

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

Post by McCloud 85 » Sat Jun 18, 2016 10:48 am

Anything is possible and people have done bonkers things to prove just that.

What you must remember is builds like this can and will cost 10's of thousands to get built by companies, it wouldn't surprise me if a total build by a decent company would be in the region of 40-50 thousand by the time you're done. Parts are expensive when you start pushing big power to make it reliable and give you the drive yore after.

This is I'm sure why so many projects are started with great intentions but the cost of them puts an end to them before they are anywhere near finished.

Make sure you do you budget justice and allow a large contingency!!

But if you see it through you will have something not far of epic!
0 x

ArtfulHussy
Project Petrol Head!
Project Petrol Head!
Posts: 1097
Joined: Wed Feb 06, 2013 2:13 pm
Model: 1.7

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

Post by ArtfulHussy » Sun Jun 19, 2016 11:34 am

Sorry to hijack slightly, but does anyone know if that DJM place has a website? I Google but couldn't find them and would like a lookie.

Never mind I think I just found it...!
0 x

User avatar
moondustka
Project Petrol Head!
Project Petrol Head!
Posts: 1255
Joined: Sun Mar 27, 2011 10:49 pm
Model: Turbo
Location: Surrey

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

Post by moondustka » Sun Jun 19, 2016 11:37 am

Hi Emma,

It's here: http://www.djm-motorsport.co.uk

Ben
1 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Wed Jan 25, 2017 5:53 pm

Time to kick start this thread back up again in 2017.

Hope you all had a great Christmas '16 and New Year.

We are actively looking for a company who will conduct some work on the Puma and subsequently look after from there after. Preferably local but we are open to all suggestions. Work that needs doing on the car stands at;

- there is a nasty oil and water leak that needs sorting
- seriously bad running issues believed to be more than just a software issue as have had it all checked and apparently all okay with mapping side of things, what the potential hardware problems are I have no idea
- at some stage, needs a larger inter cooler fitted along with a custom 3" down pipe fitted

If anyone has any recommendations let us know! Look forward to getting stuck into this again and hopefully bringing the old chap out of his garage this year and fingers crossed up to ford fair finally running some decent power.
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
Bentleya
Project Petrol Head!
Project Petrol Head!
Posts: 1321
Joined: Tue Oct 12, 2010 7:28 pm
Model: FRP
Location: Chelmsford, Essex

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

Post by Bentleya » Wed Jan 25, 2017 8:52 pm

You will often find a lot of companies are reluctant to touch engine which have been built by others, as it can be a big can of worms for them and i can imagine the majority would prefer to sell you a new engine built by them.

Obviously you're unable to go back to Chris and I believe you've been to see Ollie Clarke at some point last year?

Dunnell Engines in Suffolk have a good history with building strong and quick Zetec engines.
Scholar Engines, again in Suffolk, also have a good history with building Zetec engines.
Harris Performance Engines, in Kent, built a 2.0 litre Zetec for one of my work colleagues for his mk2 Escort.
0 x

CeReD
Adolescent
Adolescent
Posts: 66
Joined: Tue Jun 19, 2012 1:23 pm
Model: 1.7

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

Post by CeReD » Fri Jan 27, 2017 12:07 am

amazing project and sounds like a Group B rally car, hope it gets sorted!
0 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Sun Jan 29, 2017 10:07 pm

Thank you very much for the response there with those companies. It's currently booked in at Redline Tuning to find out once and for all what is wrong with the car and where we can go getting it sorted as I do really miss driving the car.

Also, thanks for the nice words! Love the noise of the beast
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
PumaJay
Guru!
Guru!
Posts: 2170
Joined: Sun May 25, 2008 6:00 pm
Model: 1.7
Location: under the bonnet
Contact:

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

Post by PumaJay » Mon Jan 30, 2017 11:33 pm

Great to see this being revived.

In terms of your exhaust requirements I can't recommend this guy strongly enough http://www.schubandautoworks.com/ he is a master at his craft. Specialises in Honda's but will take on all work.
0 x

Lodgy
Newbie
Newbie
Posts: 2
Joined: Sat Jan 28, 2017 8:29 pm
Model: 1.7

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

Post by Lodgy » Thu Feb 02, 2017 5:07 pm

Just read this all what a build!
0 x

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Sun Jan 07, 2018 7:42 pm

Yet again we start the thread off in the new year. Happy 2017 to all those who have been following this thread.

Nothing but good news to share with you all over the coming few days. Last year we managed to get the car sorted briefly, found out that when the last ‘rebuild’ at LMS was taken place the fuel pressure pump wasn’t configured properly? Looks like it had been purposely dialled down and thus, wouldn’t get fuel into the engine to start.

So we got that simple thing fixed amongst a couple of other tiny things and the car was back in action! ...until we blew it up again.

This time there was some head damage and block damage and now we are on engine no. 3. The car has been with Redline Tuning since May 5th ‘17 and we should be picking it up now running a 2.0 BLACK top engine with new head and sump etc and lots and lots of things out right - things that we didn’t even know were a problem!

I will post some pictures and a much more in depth update this week once we have picked the car up ready to run the new engine in!

From Dan and I, we look forward to seeing you all out and about during the year at shows.

Dave
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

gingerdave
Project Petrol Head!
Project Petrol Head!
Posts: 687
Joined: Tue Feb 12, 2013 9:00 am
Model: Millennium
Location: essex boy ...in worcestershire

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

Post by gingerdave » Sun Jan 07, 2018 10:49 pm

Is it still running same turbo?
0 x
Puma millennium x2
2.3 diesel Sierra mine all it’s life
Bemani Exige 275 bhp and just 900 kilos so 305 bhp/ton😍
Escort Mk2 which is slow
S1 FHC E Type 1966
Ford Ka 1996
Escort mk 1 which is not slow
Shagged out Peugeot 405
Citroen BX which is busted
Mobylette 1962 now registered on UK plate!
Puch maxi
And a Grey Fergie 1949 which is very very slow very

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Mon Jan 08, 2018 9:23 pm

It certainly is, GTX3067R
0 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Tue Feb 20, 2018 1:13 am

The car is still down at Redline Tuning having some bits done to it. We recently found out that when it was initially built it had N/A spec cams in it that we had no idea about? Would explain the strong tapping noise we used to get.

Anyway, some new turbo spec cams have been ordered from Newman as we are now running a Blacktop Zetec engine.

The car has also been treated recently and we have ordered:
An AIRTEC RS500 Sierra intercooler which is absolutely enormous :lol: now we can get rid of the Toyosports piece of crap and turn the boost up
Also sent the Peron manifold that everyone loved back to them so we can get a 3” downpipe made up to suit which is nothing short of beautiful as would be expected from them
Also ordered an ITG cone filter for the car to get rid of the standard air box, I fancy a bit more turbo noise and I’m sure there will be some flow gains to be had from this also
And last but not least.. something I’m very excited about.. we have just purchased a Race Technology DASH2 digi dash! Something we’ve wanted for ages and now we have one so we can keep an eye on all temps, boost, pressures etc, and it’s going to look awesome! I’d like to try and get it mounted on some carbon if possible but we’ll see how that goes

Anyway, a full update will be here soon to explain what’s happened. Sadly not many photos as the rebuild has been going on since May last year and if I’m honest, I forgot all about this thread! I will get photos of the new toys and upload them and explain all what’s happened to the car and what was wrong with it!

Look forward to seeing some of you again this year. I can’t believe it was Ford Fair 2015 when it was last properly used and on show to people..
1 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

User avatar
red
Site Administrator
Site Administrator
Posts: 10836
Joined: Wed Oct 03, 2007 4:31 pm
Model: Other
Location: Cambridgeshire
Contact:

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

Post by red » Tue Feb 20, 2018 10:33 am

8-) 3 years is long enough.

You can just post photo's 'as is' and we'll be more than happy :grin:

Sounds like it's got some cool bits added to it recently, bet you can't wait to get out and use it properly.
1 x
FRP#0201 (2000) 2009-2011
Melina Blue (1999) 2006-2009
Moondust Silver (2000) 2006

User avatar
Davedrave
Project Regular
Project Regular
Posts: 245
Joined: Mon Apr 02, 2012 9:22 pm
Model: Millennium
Location: Essex

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

Post by Davedrave » Sun Jul 15, 2018 10:21 am

Another few months have passed since an update on the car.

It got finished, we had the car back and done almost 500 miles on the old chap running it in. New engine feels amazing, so much stronger than before, so many things have been changed and been rectified for the better thanks to Rich and his team @ Redline Tuning, they really have looked after us well and been a dream to work with. It's amazing what some communication can do for the bond between customer and tuner..

Anyway, the auxiliary belt decided it didn't want to stay on so has been back a few times for the pulley systems to be re aligned. There was so much tension on the belt it was bending brackets so one was put right and reinforced. We picked it up and was all happy days until it happened again only this time, it was the power steering pump bracket that has bent. Back to redline for them to fix it which they have done brilliantly and also picked up on something else to put right. They have found that the CV joint kept expanding and catching on the bodywork and would split and throw oil all over the engine bay :-( Not very nice but they have sorted this for us along with a whole host of things since they have had the car last year - I will update and give a full write up on what they have done. Sadly no really pictures of their work but I have invoices and info with what they have done for us.

Anyway, by this point the car had been road tested many times and was now over 500 miles and run in ready for a mapping session. All went well for 20 power runs, Rich had the car on the dyno for over 4 hours and it made 376bhp @1.6bar still using that tiny tiny intercooler :evil: and then.. as if anything else couldn't go wrong.. on the last power run, the car lost all boost..

Something is wrong with the turbo quite what it is we are unsure of yet but nevertheless we are still without car and are sending the turbo back to Owen Developments next week for further inspection. Rich thinks it was what happened last year when the engine blew up again they has caused some heat shock to the turbo and maybe something going through the turbine has caused the failure. It has taken this long to show up as it just wasn't run on any boost until now so these things happen and we were sort of expecting it after last years events.

We are hoping they can rebuild our turbo the GTX3067, it's a good turbo - GT28 compressor housing with a GT30 turbine housing, makes good power isn't too laggy and we like it! If they can't then we are making plans for a Gen2 GTX2867 with Tial housing to suit and fit with our rather gorgeous Peron manifold.

So thats' where we are.. still no car on the road but we are so so close!

My son now works for AIRTEC!! Which is amazing news because the car will be going to them for a full cooling package overhaul, custom intercooler, radiator, boost pipes, silicones and rad fans will all be new and finally up to spec of the car.

Looks like there is still interest in this build which is nice to know. More updates to follow soon.. we are close!
1 x
Millennium Edition Puma - The Yella' Fella'
2.1 Zetec Turbo build - CLICK HERE

Post Reply

Return to “ProjectPuma”