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

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Davedrave

Member
Joined
Apr 2, 2012
Messages
256
Location
Essex
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.
 
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.
 
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.
 
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/Lightning-Motorsport/358411514189964?ref=ts&fref=ts" onclick="window.open(this.href);return false;, 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.
 
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!
 
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.
 
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.
 
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/showthread.php?t=1863001" onclick="window.open(this.href);return false;
 
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.
 
Davedrave said:
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 ?
 
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.
 
IMG_0536_zpsfe49d80a.jpg


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:
 
The old fella is looking very tidy! And I see you've got good taste in wheels.... Look like gloss black?
 
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!
 
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?
 
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.
 
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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