Mk1 Focus RS powered Puma, now going RWD, JWRC

So all of my efforts were wasted in taking the steel sump pan off to re-seal because this wasn't where the leak was coming from.

Before I assumed it was ok I went under the car to check the sealant. The rear corner at the timing end was oily. I decided to trace the oil and now I could see the leak was coming from higher up. It looks like the crankshaft seal on the oil pump :-(

So, with that found, I'm taking the car back to the engine builders. They will sort it, but I have to leave the car with them, which is slightly annoying because it's 40ish miles away.

On the up side, I've got the old front discs and pads off which explains the poor braking ability.





The discs are nowhere near minimum thickness but have worn very badly. I stupidly put new pads (and still have all the meat left) on these discs but it's not worth risking trying to re-use them as they have sort of worn into the old discs. New pads should be coming in the next couple of hours.

What are you going to do with those old (new) pads?

Might seem cowboy but can you not skim the pads in some fashion? Whack some p40 on a block of wood and plane them off?

I did look up about skimming the pads, but couldn't find any info in it.

Here's the comparison



So, not sure what I'm doing with them. I bought new because I wanted to see how good the brakes can be, so I've replaced all round, fully. But if I can save the pads by skimming them somehow, I may try. Unless you want them, Tom?

I am tempted by them, I need to get better pads at some point and would have gone for Redstuff if buying new, but if they're going cheap then I'd be foolish to say no.

Hi Tom,

Interestingly, Redstuff pads are cheaper :?

Anyway, I'll let them go for £30 if you're interested, otherwise I may as well keep them. You're not going to Ford Fair are you?

Ben

moondustka said:

[post]353690[/post]

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Damn that engine! Looks so big. Also very complicated. Good to see you have it all back man. I'd love to hear the sound this puma makes!
Did I spot another puma there in ur workspace? :wink: Got 2 of them?

The MTX75 gearbox is a fair bit bigger than the IB5 too. I find the engine quite simple and easy to work on. The 1.7 looks complicated to me :lol: just what you're used to.

The other puma is Dan's! ----> http://www.projectpuma.com/viewtopic.php?f=64&t=28350

Yes but it's not only the engine itself you have to be able to make the whole function as it should which doesn't look that easy to me tbh, but then i'm also not a wizard in mechanics like you. I'll just start by rebuilding my zetec once the car is offroad lol. Other Puma looks great, will check it out in detail later.

So, I've done all my running in mileage now - final mapping tomorrow :grin:

Had some hiccups along the way. Namely the power steering pump started leaking from the inlet union I'd tapped. It never tapped a deep thread so it was a bit loose and not tight enough for the aluminium union. I went the proper route and bought a helicoil kit for M16 x1.5 which wasn't cheap, but gets the job done properly and will last.













Fixed, and sealed with thread sealant



It's now leak free and all this mileage is definitely the most I've driven the car in a short period of time. It's actually more more enjoyable than I'd thought. The brakes are now better than I'd expected, it's like I've gone from having no brakes to brakes! The temperatures have been stable and the car has been reliable. I did have a hub nut come loose from 290nm which is worrying, but I'll keep checking them.

I also replaced the cabin filter:



The engine sounds very smooth and quiet after the re-build so finger crossed for a good result tomorrow after the check over and final map.

Good luck with the mapping tomorrow Ben, the first time the new engine will see the red line?
Barry

What a massive anti-climax.. :evil:



Drove it no problem in the heat yesterday afternoon to TDI, parked up and walked in. They take the car into the dyno cell, prep the car and bolt it to the hub dyno, meanwhile the radiator decides 'I don't like you' and feebly wees onto the floor. So didn't get very far with that one, car is unloaded and I call the AA who once has a look, decides best not to try any sort of rad-weld and takes us home k:

It seems like the core has failed, cracked around a row of two at the end. Whilst waiting for the AA I phoned pro alloy about a new one, of which they were extremely accommodating to my tight time frame (I had already booked the car in again for 2 weeks time - cutting it fine!). I decided to waste no time and drove the old rad to them this morning so they could see what additions had been made to the otherwise alloy Escort Cosworth radiator. I'd also decided on the phone that I would sort out the mounting of the fans and this led to getting one of their fan kits perfectly suited for this rad.

And I left, £700 lighter

I'm really hoping I start running out of bad luck soon.

I am supposed to get the radiator on the 29th to allow me enough time to fit and check. Fingers crossed they meet the deadline.

Barry, yes it would have been its first full sweep, I've only had it to 4k

Oh oh.. Not good! Hopefully they will source you the radiator in time! Ford Fair is getting close now :lol:

Hi Ben
One of these days you might get some good luck, let's hope it's soon.
Barry

Brian' said:

[post]354537[/post] Oh oh.. Not good! Hopefully they will source you the radiator in time! Ford Fair is getting close now :lol:

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Very close - every year I've been with a car I've been rushing. I was in good time about 3 months ago before engine went :roll:

tuonokid said:

[post]354555[/post] Hi Ben
One of these days you might get some good luck, let's hope it's soon.
Barry

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I hope so Barry, probably not that much bad luck but it certainly feels that way.

Still, Monday was very hot for an engine anyway so maybe it'll be a bit cooler in 2 weeks time and get a better result

Crickey me.. expensive rad. ouwch

So I've had a strange clock ever since I put this engine in 5 years ago. I've gone through everything, and things have changed anyway as the car has evolved. Last thing to try was the lower arms so I bought I set of genuine Ford arms at a great expense to swap with mine which have a spherical bearing at the rear and an uprated rubber bush up front.

Here are the new ones..





Unfortnately, they clonking was/is still there so definitely not those then.. So these are now for sale (have done less than 10 miles), see for sale thread.

I had also got some new punch bolts, as well as a new bolt for the rear torque link/lower gearbox mount.






Next up, I picked up the new radiator from Pro Alloy on the way back from Lincoln last Thursday

And here we are..



Thanks to Dan for prepping the fan wiring and putting a new male Delphi plug on.





So all fitted, plumbed in and tested ok.. Although now my heater matrix has got air in it again and doesn't blow hot! It's also slightly thicker than my old one and so very close to the intercooler pipe at the bottom. I may remake the radiator brackets to give some adjustment and therefor clearance.

Next, I improved my oil separator pot. I welded a plate over the thread at the bottom as oil was seeping out.



Then I changed the plates inside. This way the air has to change direction many times and should cause the oil to separate away.



Dyno day tomorrow again, hopefully better luck this time!

And, how did it go?

Rubbish, just rubbish - well, power-wise anyway. Less power than before :roll: as far as I make out the short of it is, the engine is really built for a bigger turbo. All the flow work that's been done to the head is just making the turbo problem worse because the one I have is so small.

On with the good news, no leaks after nearly 4 hours on the dyno and all temps were fine. It's also nice to finally be able to drive on boost properly and use all the rev range. Although down on power it's still quite pokey.

Unfortunately, the next step will have to wait until 1, I pay back this round of bankruptcy and 2, get the funds to go for a new turbo, new inlet manifold, new injectors and nice new management with some active knock control.

The list is endless!

Also, might have found my knocking. Would be grateful is someone could get some photos of the drop links and anti-roll bar whilst the car is on the ground (preferably flat). I guess the photos would have to be from the front of the car to get access. Thanks!