DJ Wilmas 111S S2 T series 400bhp Elise
Discussion
Test Fitting on the engine today
Was a little bit of a pain to go in, but removed a couple of sensors and with some giggery pokery she is in.
Cambelt engine mount is different from the Duratec (3 holes on ecoboost 2 on Duratec), but we should be able to use it. Main issue is height, but will put a shim under the chassis engine mount and should be able to get the engine nice and level.
Next is the Turbo, close on the inlet but the outlet hits the main chassis. Dont see this as being too much of a problem will be able to rotate it 45 degrees (New bracket for actuator) and should fit
Couldnt get under the car but the other issue was the Aircon Bracket hitting the drivers side water hose, should be able to get round this
Plenty of clearance on the pulleys even with the double crank pulley (supercharger)
Also the Oil Filter Housing was removed, looks like i will need to fit a remote filter which i already have
All in All, not a bad day out. Hopefully have a few more updates before Xmas
Gearbox is being rebuilt to a k series bellhousing and Flywheel has been ordered 4.25kg
Was a little bit of a pain to go in, but removed a couple of sensors and with some giggery pokery she is in.
Cambelt engine mount is different from the Duratec (3 holes on ecoboost 2 on Duratec), but we should be able to use it. Main issue is height, but will put a shim under the chassis engine mount and should be able to get the engine nice and level.
Next is the Turbo, close on the inlet but the outlet hits the main chassis. Dont see this as being too much of a problem will be able to rotate it 45 degrees (New bracket for actuator) and should fit
Couldnt get under the car but the other issue was the Aircon Bracket hitting the drivers side water hose, should be able to get round this
Plenty of clearance on the pulleys even with the double crank pulley (supercharger)
Also the Oil Filter Housing was removed, looks like i will need to fit a remote filter which i already have
All in All, not a bad day out. Hopefully have a few more updates before Xmas
Gearbox is being rebuilt to a k series bellhousing and Flywheel has been ordered 4.25kg
Christmas came kinda early today, luckily the wife was out too 
Grant from GB Enterprises sent me a nice new 4.2kg lightened flywheel, this has been made for the PG1 box but drilled to suit the T series Helix clutch i have. Dual Mass flywheel is about 10kgs (no scales) so a decent saving. I even fitted the Focus clucth (its the same size as the T series), shame the PG1 uses a funny spline
The Gearbox is with a great friend who is changing the bell housing from T series to K series and we are looking at reducing the final drive to 4.2 as this is similar to the ford Gear ratio's 1 to 4. Fifth being 23mph per 1000rpm which isnt too bad
Also hated the foam filter i had so bought a massive K&N Air Filter again from Grant
Please note the carpet wasnt my choice, its a new house and the previous owner was Scottish and Colour Blind (its for sale if anyone wants the carpet)
Grant from GB Enterprises sent me a nice new 4.2kg lightened flywheel, this has been made for the PG1 box but drilled to suit the T series Helix clutch i have. Dual Mass flywheel is about 10kgs (no scales) so a decent saving. I even fitted the Focus clucth (its the same size as the T series), shame the PG1 uses a funny spline
The Gearbox is with a great friend who is changing the bell housing from T series to K series and we are looking at reducing the final drive to 4.2 as this is similar to the ford Gear ratio's 1 to 4. Fifth being 23mph per 1000rpm which isnt too bad
Also hated the foam filter i had so bought a massive K&N Air Filter again from Grant
Please note the carpet wasnt my choice, its a new house and the previous owner was Scottish and Colour Blind (its for sale if anyone wants the carpet)
i bought the wife a little Xmas present, she loved it, then mentioned we could of changed the tartan carpet for what it cost and she had better be getting something nice for Xmas
Think i got away with it but saw this on eBay and thought i best have it
Its a Pro Alloy Charge Coooler, these have been run up to 550bhp
Think i got away with it but saw this on eBay and thought i best have it
Its a Pro Alloy Charge Coooler, these have been run up to 550bhp
So things have been slow for a reason, we worked out that the Std Turbo wont fit with the subframe where it is. I can chop this about but not a fan of this, it would be easy to do but......when i have a GTX2867R sat in my office doing nothing i needed an excuse to fit it
This brings with it some problems, the std pistons tend to go after 300bhp, the Guys in the USA throw Meth and Water at the problem which helps get them to a higher rated BHP but its a bodge for me. So this means i need new pistons, then i might as well get some rods, uprated bearings a new PCV plate. Then there is the question of how much fuelling the Ecoboost can do, see below, and i may need another way of inputting more fuel.
So my fit the std engine and have fun has gone for a burton and its back to i need 450bhp
A friend popped down to have a look at the car on the weekend and it gave me a chance to chat to Tech1 about what we need to do, mainly after speaking to Simon at Specialist Components as he confirmed that above 300bhp the pistons are the weak point.
I also spoke to Total MPS in Newcastle who have made a 420whp (2.0, GT3071) and 895whp (2.3 and wow) ecoboost engine.
Their 2.0 had forged rods / pistons and bigger injectors but using the std fuel system made 420 at the wheels which is more than i want (didnt say need) but it was on the limits, so advised additional fuelling
So the list of things to do just got bigger, and a whole lot more expensive.........carpets for the new house will have to wait
1. Custom Engine Mounts the Duratec ones definitely dont fit
2. Custom Loom, remove the elise engine loom and place the ECU and new relay / fuse box in cabin (saves weight, honest)
3. Mounting of the GTX above the subframe, small adaptor needed and Randy thanks for the advice i never took but it will be V-band
4. Tial 0.86 a/r Exhaust housing
5. New Forged Pistons and Rods
6. Upgraded Head Bolts
7. PCV Plate, the Ecoboost has a habit of holding boost pressure in the crank case so needs venting via a catch can
8. Bosch Motorsport Pump and 4l swirl pot
9. Inlet adaptor plate to hold 4 x injectors (std ported) or 2 x injectors after the throttle body (SC have made one before)
10. Build engine and send it and the ECU back to SC who will run it up on the Engine Dyno
11. Re-fit Engine
12. Fit charger cooler
13. Fit Custom exhaust
14. Try not to change mind
15. Drive it, hopefully further than the last car
Seems pretty easy written down
Also are the any Moderators watching this, if so can you change the title to ECOBOOST
This brings with it some problems, the std pistons tend to go after 300bhp, the Guys in the USA throw Meth and Water at the problem which helps get them to a higher rated BHP but its a bodge for me. So this means i need new pistons, then i might as well get some rods, uprated bearings a new PCV plate. Then there is the question of how much fuelling the Ecoboost can do, see below, and i may need another way of inputting more fuel.
So my fit the std engine and have fun has gone for a burton and its back to i need 450bhp
A friend popped down to have a look at the car on the weekend and it gave me a chance to chat to Tech1 about what we need to do, mainly after speaking to Simon at Specialist Components as he confirmed that above 300bhp the pistons are the weak point.
I also spoke to Total MPS in Newcastle who have made a 420whp (2.0, GT3071) and 895whp (2.3 and wow) ecoboost engine.
Their 2.0 had forged rods / pistons and bigger injectors but using the std fuel system made 420 at the wheels which is more than i want (didnt say need) but it was on the limits, so advised additional fuelling
So the list of things to do just got bigger, and a whole lot more expensive.........carpets for the new house will have to wait
1. Custom Engine Mounts the Duratec ones definitely dont fit
2. Custom Loom, remove the elise engine loom and place the ECU and new relay / fuse box in cabin (saves weight, honest)
3. Mounting of the GTX above the subframe, small adaptor needed and Randy thanks for the advice i never took but it will be V-band
4. Tial 0.86 a/r Exhaust housing
5. New Forged Pistons and Rods
6. Upgraded Head Bolts
7. PCV Plate, the Ecoboost has a habit of holding boost pressure in the crank case so needs venting via a catch can
8. Bosch Motorsport Pump and 4l swirl pot
9. Inlet adaptor plate to hold 4 x injectors (std ported) or 2 x injectors after the throttle body (SC have made one before)
10. Build engine and send it and the ECU back to SC who will run it up on the Engine Dyno
11. Re-fit Engine
12. Fit charger cooler
13. Fit Custom exhaust
14. Try not to change mind
15. Drive it, hopefully further than the last car
Seems pretty easy written down
Also are the any Moderators watching this, if so can you change the title to ECOBOOST
Looks like the engine will be taken apart shortly as going to forge it, possibly adding some cams and maybe a new intake with ported injection
Luckily Tech1 have agreed for me to post items to them so the wife doesn't kill me. The horse also helped out as he needed a tooth pulling which I had to pay for, insurance will send cheque, so wife thinks I am lovely and that the carpets will have to wait.....again
Tial 0.82 a/r exhaust housing and V Band adaptors turned up
As did a 4 litre swirl pot, and I know it's a cheap ebay item but it pressure tested ok and was the biggest I could find
Luckily Tech1 have agreed for me to post items to them so the wife doesn't kill me. The horse also helped out as he needed a tooth pulling which I had to pay for, insurance will send cheque, so wife thinks I am lovely and that the carpets will have to wait.....again
Tial 0.82 a/r exhaust housing and V Band adaptors turned up
As did a 4 litre swirl pot, and I know it's a cheap ebay item but it pressure tested ok and was the biggest I could find
Its been a while since my last update as i've been doing some head scratching about what to do
So, parts are limited in the UK and i had not heard great things about total MPS and they didnt have all the bits i needed so decided to look to the USA. This means cheaper prices but more import tax and a lot longer delivery
Spoke to a few tuning companies and settled on www.speedperf6rmanc3.com
Gave them a call told them what i wanted to do and they giggled, mainly as most tuning as in 99.9% uses the Ford ECU with a tuner tool, like cobb. They use a lot, and i mean most tuned ecoboost engines, of Meth injection where as speed just use pump gasoline, i explain its called petrol. They have 450whp engines running the same turbo as i do, even better its at the wheels with rev limits of 6750rpm.
At this power the engine starts to get expensive, the timing crank pulley is held on with friction washers and if it slips then the timing goes and bye bye engine so the crank needs to be keyed, the pulley(s) then needs to be changed as well. Pistons are first to go, but even the forged Mahle pistons are rated to 25psi, so first on the list was a set of custom forged Mahle pistons. I will have a little slap on start up so be it they are rated to 250bhp per cylinder and as much boostness
OEM bearings are good, but the MPS boys (same bottom end) use Clevite bearings if they use high revs, so i bought these
Next up, above 25psi the head starts to lift. So i was one of the first people to have the CA625+ head bolts, these are power station grade steel (which is what i do for a living) and are good for 35psi. Main benefit is i dont have to machine the block as they are std 11mm
Next up is the PCV, positive crankcase ventilation, basically uses manifold vacuum to pull the oil fumes out and a non return valve to stop pressure going in and another valve that allows air in (to replace the air being sucked out). Its mainly for emissions and they clog up and cause problems so its being removed and a catch can fitted
I also bought an oil take off, this means i can use a remote oil filter and oil cooler and the oil filter housing had to be removed to fit the engine so thought it easier to do it this way as i already have the cooler and filter housing. took a while to find one with inlet exit on the bottom. This is a std duratec part so i hope it fits
i bought more parts but as it was cheaper to ship seperately they sent two packages, ones in customs still so hope to have that next week.
Also been speaking to Piper as the std cams are low lift and short duration, 224 degrees for the exhaust with 7.5mm lift
Good news is they are looking at some custom cams for me, which will allow me to rev more than std with a linear power curve. I will of course loose some bottom end, but it wont be worse than the t series which was more than tractable. Plus i have lowered the gearing
So next is the inlet manifold and cams........
So, parts are limited in the UK and i had not heard great things about total MPS and they didnt have all the bits i needed so decided to look to the USA. This means cheaper prices but more import tax and a lot longer delivery
Spoke to a few tuning companies and settled on www.speedperf6rmanc3.com
Gave them a call told them what i wanted to do and they giggled, mainly as most tuning as in 99.9% uses the Ford ECU with a tuner tool, like cobb. They use a lot, and i mean most tuned ecoboost engines, of Meth injection where as speed just use pump gasoline, i explain its called petrol. They have 450whp engines running the same turbo as i do, even better its at the wheels with rev limits of 6750rpm.
At this power the engine starts to get expensive, the timing crank pulley is held on with friction washers and if it slips then the timing goes and bye bye engine so the crank needs to be keyed, the pulley(s) then needs to be changed as well. Pistons are first to go, but even the forged Mahle pistons are rated to 25psi, so first on the list was a set of custom forged Mahle pistons. I will have a little slap on start up so be it they are rated to 250bhp per cylinder and as much boostness
OEM bearings are good, but the MPS boys (same bottom end) use Clevite bearings if they use high revs, so i bought these
Next up, above 25psi the head starts to lift. So i was one of the first people to have the CA625+ head bolts, these are power station grade steel (which is what i do for a living) and are good for 35psi. Main benefit is i dont have to machine the block as they are std 11mm
Next up is the PCV, positive crankcase ventilation, basically uses manifold vacuum to pull the oil fumes out and a non return valve to stop pressure going in and another valve that allows air in (to replace the air being sucked out). Its mainly for emissions and they clog up and cause problems so its being removed and a catch can fitted
I also bought an oil take off, this means i can use a remote oil filter and oil cooler and the oil filter housing had to be removed to fit the engine so thought it easier to do it this way as i already have the cooler and filter housing. took a while to find one with inlet exit on the bottom. This is a std duratec part so i hope it fits
i bought more parts but as it was cheaper to ship seperately they sent two packages, ones in customs still so hope to have that next week.
Also been speaking to Piper as the std cams are low lift and short duration, 224 degrees for the exhaust with 7.5mm lift
Good news is they are looking at some custom cams for me, which will allow me to rev more than std with a linear power curve. I will of course loose some bottom end, but it wont be worse than the t series which was more than tractable. Plus i have lowered the gearing
So next is the inlet manifold and cams........
Thanks as its all about looking good
Finally the remaining bits turned up today
I have some Manley Forged rods, these are the I version and perfect for what i need
Next is the keyed lower pulley, my god its heavy, but the std engine has a friction washer and they tend to stop working above 400bhp its best to key it. Will need to key the crank too
Also checked the Oil adaptor against the gasket and the Duratec one fits so happy with that
Cams have been specc'd and ordered from the ever helpful Piper
Just need these to be delivered and a full engine gasket set and we can build the engine
Mk1 engine mount is being made as we speak as well
Its almost like i have a project moving at last
Finally the remaining bits turned up today
I have some Manley Forged rods, these are the I version and perfect for what i need
Next is the keyed lower pulley, my god its heavy, but the std engine has a friction washer and they tend to stop working above 400bhp its best to key it. Will need to key the crank too
Also checked the Oil adaptor against the gasket and the Duratec one fits so happy with that
Cams have been specc'd and ordered from the ever helpful Piper
Just need these to be delivered and a full engine gasket set and we can build the engine
Mk1 engine mount is being made as we speak as well
Its almost like i have a project moving at last
Cams have been spec'd and ordered from Piper, just need a full gasket set and we are good to build the engine "FINALLY"
But, i after asking many many peoples and many many companies to make a custom dash i finally got one fitted to the car today
Its still a prototype but i said i'd have it there and then. Fantastic piece of kit and its plug and play. No fancy screens for people to see and adds to the std look inside. Easy to use and was fitted within an hour
Showed it to a neighbour who has a VX220 and a MK2 escort and he wants one too
Just simply awesome
https://youtu.be/db5A7uYEtPY
But, i after asking many many peoples and many many companies to make a custom dash i finally got one fitted to the car today
Its still a prototype but i said i'd have it there and then. Fantastic piece of kit and its plug and play. No fancy screens for people to see and adds to the std look inside. Easy to use and was fitted within an hour
Showed it to a neighbour who has a VX220 and a MK2 escort and he wants one too
Just simply awesome
https://youtu.be/db5A7uYEtPY
So the Ironman is out of the way and the new house is starting to look like the wife wants it (still have the tartan carpet)
So i have had some time to speak to Piper, who are genuinely wonderful. I asked for some cams for the specs and what i wanted and got talking. Ended up talking about three specs and they have added them to the website and sent me all three specs hoping i will try them all. i did say i may not have the time or money to do so but they sent me three cam specs to play with, and i just have to send back the ones i dont want
The rally specs are the ones i wanted, but need to check the lift and the rev range they have also increased the lobe for the fuel pump from 4.7mm to 5.5mm. We have no idea if this will work but thought we would give it a go
The other issue is no one has revved an Ecoboost past 7000rpm, i am told Mountune have but they dont give out details, and we have no idea if the fuel pump (it has a spring return so may float) or the VVC (both cams) will cope with the revs
Only one way to find out
http://www.pipercams.co.uk/pipercams/www/product_n...
Full gasket set is on order from Ford and engine build is pencilled in for next week
JUst need to to get all the parts put together, engine mount fitted and..........
So i have had some time to speak to Piper, who are genuinely wonderful. I asked for some cams for the specs and what i wanted and got talking. Ended up talking about three specs and they have added them to the website and sent me all three specs hoping i will try them all. i did say i may not have the time or money to do so but they sent me three cam specs to play with, and i just have to send back the ones i dont want
The rally specs are the ones i wanted, but need to check the lift and the rev range they have also increased the lobe for the fuel pump from 4.7mm to 5.5mm. We have no idea if this will work but thought we would give it a go
The other issue is no one has revved an Ecoboost past 7000rpm, i am told Mountune have but they dont give out details, and we have no idea if the fuel pump (it has a spring return so may float) or the VVC (both cams) will cope with the revs
Only one way to find out
http://www.pipercams.co.uk/pipercams/www/product_n...
Full gasket set is on order from Ford and engine build is pencilled in for next week
JUst need to to get all the parts put together, engine mount fitted and..........
So finally a year later than expected the engine is in bits!
Block looks in almost new condition, should be as it covered 2000 miles
Nicely built engine, definitely Japanese was the wording by Tech1 but built to last.
Pistons and rods look meaty too
New vs old pistons
Crank again looks solid, apparently the are good for lots of power and 8500rpm. Main think to notice is the gear for the balancer shafts
This photo does not do the weight of this unit justice, it's close to 10kgs (man pick up test). It's not needed so that's good news
Mountune baffled sump and balancer shaft delete kit fitted
Oil blocked for balancer shafts
Crank is off to have the keyway installed and now decision is what cams to fit
Std head flows well, some 550bhp engines in the USA (running meth injection) but with std ports. Spoke with Marshal at speedperformance and he advised the head are twin track as they create "a tornado" effect in the chamber to aid combustion. I can port the head at a cost of £900 ($960 but then shipping and import costs) but was advised it's not needed below 600bhp
Hopefully have it built by next week.....
Block looks in almost new condition, should be as it covered 2000 miles
Nicely built engine, definitely Japanese was the wording by Tech1 but built to last.
Pistons and rods look meaty too
New vs old pistons
Crank again looks solid, apparently the are good for lots of power and 8500rpm. Main think to notice is the gear for the balancer shafts
This photo does not do the weight of this unit justice, it's close to 10kgs (man pick up test). It's not needed so that's good news
Mountune baffled sump and balancer shaft delete kit fitted
Oil blocked for balancer shafts
Crank is off to have the keyway installed and now decision is what cams to fit
Std head flows well, some 550bhp engines in the USA (running meth injection) but with std ports. Spoke with Marshal at speedperformance and he advised the head are twin track as they create "a tornado" effect in the chamber to aid combustion. I can port the head at a cost of £900 ($960 but then shipping and import costs) but was advised it's not needed below 600bhp
Hopefully have it built by next week.....
I love how switching to the Ford engine was a way of getting rid of all the issues you had with the T series and just having a useable car, and now you're going for it with this engine instead 
I may of got slightly confused with the, simple engine swap for useable power malarky and just gone full steam, it got worse this month too
So there is good news and not so good news and good news again
Good news is the engine build is on its way, i got very excited and finally thought we'd get things moving and done and i could drive the car. However, we fitted the rods and pistons to the engine and.........see below
Something didnt look right, the pistons were not sitting right in the block. As first we thought possibly that being a GDI engine the pistons sat lower but i called Speedperf6rmanc3 in the USA and turns out that i accidentally ordered the 2.3 Ecoboost rods and not the 2.0 ones.......
Bugger. However the ever helpful Marshall suggested a quicker fix than returning the rods, a 2.3 crank........a stroke of genius (pun intended) and they had just received a set of std 2.3 cranks which are forged and...i stopped him there and ordered one.....as a favour they even keyed and then balanced the crank for me........tops guys
Next issue will be customs clearance and Tech1 finding a slot to build the engine
Problem i have now is the GTX2867 will be on its last legs at 8000rpm, so a GTX3076R would be better, then i can have 550bhp and can tell everyone in the pub. If the wife finds my bills i am dead, although she has a new kitchen we still have the Tartan carpet a year after moving......
So there is good news and not so good news and good news again
Good news is the engine build is on its way, i got very excited and finally thought we'd get things moving and done and i could drive the car. However, we fitted the rods and pistons to the engine and.........see below
Something didnt look right, the pistons were not sitting right in the block. As first we thought possibly that being a GDI engine the pistons sat lower but i called Speedperf6rmanc3 in the USA and turns out that i accidentally ordered the 2.3 Ecoboost rods and not the 2.0 ones.......
Bugger. However the ever helpful Marshall suggested a quicker fix than returning the rods, a 2.3 crank........a stroke of genius (pun intended) and they had just received a set of std 2.3 cranks which are forged and...i stopped him there and ordered one.....as a favour they even keyed and then balanced the crank for me........tops guys
Next issue will be customs clearance and Tech1 finding a slot to build the engine
Problem i have now is the GTX2867 will be on its last legs at 8000rpm, so a GTX3076R would be better, then i can have 550bhp and can tell everyone in the pub. If the wife finds my bills i am dead, although she has a new kitchen we still have the Tartan carpet a year after moving......
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