FRP 591, FRP replica, plus turbo conversion project

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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Van_Dammesque
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FRP 591, FRP replica, plus turbo conversion project

Post by Van_Dammesque » Fri Sep 22, 2017 8:29 pm

When I win the lottery your going to do the same to my car! :lol:
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Fri Sep 22, 2017 9:51 pm

No probs ;)
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Simonavis
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FRP 591, FRP replica, plus turbo conversion project

Post by Simonavis » Sat Sep 23, 2017 8:56 am

Maybe Ford should be in touch with you to discuss the blueprints for the design and the launch of the new Puma!!!? :grin: 8-)

Totally jealous and mindblowingly beautiful, I am in awe...can I have a go when it's finished!!! :lol:
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Sat Sep 23, 2017 1:26 pm

Haha thanks dude, ive had to make a list of people now who are keen for a ride, il add your name ;)
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Sat Sep 23, 2017 1:40 pm

Picked up the bonnet from the body shop, looks nice and shiny now, the vent were gloss black but unfortunately the paint reacted when drying, so they got redone in matt black, i'm pretty happy with it, also had half hour free this AM so i cut and stuck on some heat shield material

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Post by PumaJay » Mon Sep 25, 2017 8:14 am

Nice to see the RST vents being used over the Focus RS ones everyone seems to be fitting at the moment. Bonnet looks uber shiney as well. I may have to see about doing mine as its started fading quite a bit.
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Mon Sep 25, 2017 7:27 pm

I love these vents now they are fitted! The bonnet is quite easy to sand down - I used a random orbital sander with some 240 paper, took a couple of hours and around a dozen pads, cuts through the faded top coat nicely, I did this 2 years ago but the UV light fades the lacquer over time :(
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Post by PH03NIX » Fri Oct 20, 2017 1:11 am

Now this is a project of inspiration... Loving the vents!! :clap:
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Sun Mar 11, 2018 5:09 pm

OK so its been a few months now and I've finally got a day to update this! old 'Turbo Tubby' has had a few ups and downs over the last few months, its had a couple of teething issues and I've broke a few bits but its going well.

So i finally got it running after many a headache with the ECU, i had issues with a bad power supply and it kept draining the battery, in the end i redid the main power to the ECU which solved the problem but not before it killed the battery, replaced the old battery with a new shiny Bosch one and that cured a lot of the problems!

Its now been mapped up to 4K rpm and is currently running 8psi boost (whilst the engine is being run in) its now had a power run so i don't now what power its making though, pretty sure its well beyond standard as it pulls real hard on boost (even though its only running half the boost it will finally be running as well as only half the RPM range!) it still needs cold start mapping as its struggling to idle until its fully warmed up though, I'm up to around 750 miles on her now, the rest of the mapping will happen after she reaches 1000-1500 miles

Its run through two lots of competition 'running in' engine oil (Millers CRO 10/40) and original ford filters and now is currently running on its third lot of oil (now switched over to its long term oil - Millers 10/40 competition CFS oil)

Things I've/she's broke:
- Oil pressure gauge line burst at the oil sandwich plate (now replaced with a new one and working well)
- Second hand Vibratechnics gearbox mount shit itself and split in two, replaced temporarily with a cheap standard one, new
Vibratechnics one has arrived and I'm waiting to get it pressed in and fitted
- Vibratechnics torque link was a good 7+ years old and had quite a bit of play in it so i replaced it with a new one, much less
play now and feels more solid
- Turbo to down pipe bolts worked their way loose, now re-tightened
- Centre drive shaft bolts worked their way loose, now tightened and secure
- Secondary fuel pump died, likely due to poor feed from the swirl tank and the cold weather, fuel filter now moved to after
the pump and supply to pump increased from -6 hose to -8 hose, pump also replaced and running again fine
- Heat shielding applied to the HCV hoses as they are quite close to manifold
- Turbo oil drain melted during initial mapping, hose replaced and heat-shield applied (seems to be working well)
- Replaced a t-piece in vaccume lines that was blocked
- Steering rack blew a seal (after being overhauled!!!!) sent it back to be done again, then the hose failed, had smoke pouring
out from under the car as the PAS fluid was dripping on to exhaust! after a quick call to Lightning Motorsport i got a standard
second hand replacement from a fiesta Zetec-S (for non-AC cars) that now doesn't leak :)

Things I've had to finish off:
- Digital dash has had more parameters set up now, she has the odometer updated and now has both boost and water temp
values showing
- Engine bay wires tidied up and moved out of site/ziptied together for neatness
- Added a wideband Lambda from Emerald including a little flashing LED for exhaust gas temps

Anyway that sounds about where I'm up too, here's some pics as i know that's all you lot tune in for lol

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Getting the tracking done and camber adjusted

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Gearbox mount that turned out to be as tough as a richtea biscuit after one dip in a cuppa

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Cheeky interior shot, think she makes a good Decepticon (note steering wheel centre cap) which is appropriate i think lol

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Number plate relocated to increase airflow

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Melted oil drain with its heatshielded replacement

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Last edited by d170sam on Sun Mar 11, 2018 5:20 pm, edited 1 time in total.
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d170sam
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FRP 591, FRP replica, plus turbo conversion project

Post by d170sam » Sun Mar 11, 2018 5:18 pm

A few more pics :)

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Fuel system, pump and filter now under the car, new -8 bottom hose to replace the restricting -6 one that was originally used, i might redo some of the other hoses to neaten them up a little

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Being recovered when the fuel pump crapped out and left me stranded in the snow last week :(

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Cheeky snow shots

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Think this might be the point i became a petrol head! lol

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Simonavis
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FRP 591, FRP replica, plus turbo conversion project

Post by Simonavis » Tue Mar 13, 2018 9:37 am

Can I have a drive in it now please :lol: :lol:
It looks absolutely stunning!!!
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Brian'
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FRP 591, FRP replica, plus turbo conversion project

Post by Brian' » Tue Mar 13, 2018 9:27 pm

Really cool! The engine bay looks so discrete not like there is a turbo anywhere haha. Awesome job! :)
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PumaJay
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Post by PumaJay » Wed Mar 14, 2018 8:51 am

That looks mega!

Have you screwed your number plate to the bumper? Go for one of these removable ones.... https://www.staticplates.com/
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Lord B
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Post by Lord B » Wed Mar 14, 2018 9:49 am

Is there plans to get it in track to show its real potential. Would love a boosted puma, but that's some serious investment.
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