Ford Focus Mk2 [ST] Estate Sleeper - Build Thread

Ford Focus Mk2 [ST] Estate Sleeper - Build Thread

Author
Discussion

KingNothing

3,159 posts

152 months

Wednesday 7th October 2015
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CHR15 G said:
What does 'standard' mean...? I'll leave the actual engine internals for the moment, but I'm thinking induction kit, intercooler, exhaust and remap to start with. I'll aim for 300bhp for starters, then push for 350bhp when it's up and running.
Should be good, when you get an engine you should look at block modding it before you put it in, and standard internals and turbo should be good for 340bhp according to some of the latest packages being released by various tuners.

Patch888

701 posts

127 months

Wednesday 7th October 2015
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As above, the block mod can be done nice and cheaply when included with a cambelt and drive belts change. I've just had mine done for added peace of mind. The cylinder liners are known to be a weakness in the mk2 ST. All the best with the project.

CHR15 G

Original Poster:

267 posts

153 months

Wednesday 7th October 2015
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Thanks for the tips on the block mod. I've heard about it but don't know much about it. I'll probably do a precautionary belt change when I'm up and running anyway, so sounds like it will be good to do it then.

So I've already made a bit of progress on the project, but need to catch up with it on here. First up is the donor ST! I've found a written off car with fairly major body damage, but very little mechanical damage which is all concentrated on the LR suspension which I don't need anyway as it's different on the estate. Side airbags have deployed, which again I don't need, but none of the dash ones that I do need!

It's got a Puma Speed induction kit with a K&N cone filter, ProAlloy intercooler, full Milltek exhaust and an RS clutch. The previous owner (who crashed it) has assured me (with no proof) that its 350bhp, so I'll take that as high 200s which I'm still happy with. Anyway, pictures...









This last photo shows my barn space that I've got to work in. It's a really nice space, perfect for working on two cars side by side, but it is a little dark.


Max M4X WW

4,788 posts

181 months

Wednesday 7th October 2015
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Has this been done before? I didn't think the extra cylinder would fit in the older Focus but hoping to be proved wrong!

Amirhussain

11,486 posts

162 months

Wednesday 7th October 2015
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Looking forwards to this!

CHR15 G

Original Poster:

267 posts

153 months

Thursday 8th October 2015
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Max M4X WW said:
Has this been done before? I didn't think the extra cylinder would fit in the older Focus but hoping to be proved wrong!
I think that a guy in Holland has done the engine swap, but he also did all the bodykit and wheels.

The red Focus in the foreground isn't the project car, that just my run around which will die due to rust soon.

Max M4X WW

4,788 posts

181 months

Thursday 8th October 2015
quotequote all
CHR15 G said:
Max M4X WW said:
Has this been done before? I didn't think the extra cylinder would fit in the older Focus but hoping to be proved wrong!
I think that a guy in Holland has done the engine swap, but he also did all the bodykit and wheels.

The red Focus in the foreground isn't the project car, that just my run around which will die due to rust soon.
Ah apologies, skim read!

Barchettaman

6,281 posts

131 months

Thursday 8th October 2015
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Awesome project!
Have you found a suitable donor estate yet? Ebay.co.uk threw up a few possibilities!

CHR15 G

Original Poster:

267 posts

153 months

Thursday 8th October 2015
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Barchettaman said:
Awesome project!
Have you found a suitable donor estate yet? Ebay.co.uk threw up a few possibilities!
Yep, got the estate already! I'm a bit behind writing up here and have made a bit of progress, but i'll try and catch up.

It turned up not very far from me for a bargain price and a smokey 1.6 diesel, the guy even delivered it to me. It's got 149998 miles on it, was tempted to take it around the block just to get it up to 150k. It's an LX with er...aircon and that's it, really is quite basic in there. I think the previous owner keep chickens in it because it is full of feathers, or maybe he just owned a pillow factory, but I'll swap the interior anyway.









The last picture below shows some of the barn and how much lovely space I've got to work in, never had this much dry, indoor, dehumidified (!!) space before so I'm really looking forward to it.


Fastdruid

8,623 posts

151 months

Thursday 8th October 2015
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Excellent project, watching with interest.

Rather jealous of your workspace though, in building a kit car in a single garage and I'd kill to have that kind of space!

Barchettaman

6,281 posts

131 months

Thursday 8th October 2015
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Any chance of the ST bonnet going on the estate? It might add a certain 'je ne sais quoi'

CHR15 G

Original Poster:

267 posts

153 months

Friday 9th October 2015
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Fastdruid said:
Excellent project, watching with interest.

Rather jealous of your workspace though, in building a kit car in a single garage and I'd kill to have that kind of space!
Thank you, and yes you can't beat a good space. I've worked on cars in single garages before and I've just not enjoyed it as much.

CHR15 G

Original Poster:

267 posts

153 months

Friday 9th October 2015
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Barchettaman said:
Any chance of the ST bonnet going on the estate? It might add a certain 'je ne sais quoi'
I know what you mean and I had thought the same. Unfortunately my graphic designer/petrolhead friend said it would be too much, so I'm currently thinking just wing mirrors, much like Dale's Seat from a few days ago.




shalmaneser

5,930 posts

194 months

Friday 9th October 2015
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This looks like a great project, following with interest!

CHR15 G

Original Poster:

267 posts

153 months

Friday 9th October 2015
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When I started this project I promised myself a new set of ratchets as the set I had was all mis-matched and bits missing. After a lot of looking around and speaking to people I settled on Teng. It turns out that a set of ratchets and sockets turns out to be not much less than one of their tool kits, and I needed a new toolbox anyway so a bit of man maths later and I ended up with this little lot.









Unfortunately I can't blame my tools now.

R6VED

1,365 posts

139 months

Friday 9th October 2015
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Nice little collection there. Considering that this is PH I am surprised no one has noticed that the numberplate on the old Landy looks a bit like Finger Blast :-)

ChrisR99

452 posts

110 months

Friday 9th October 2015
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Sounds like an interesting project!

Sad to hear that the red MK1 will die soon, no hope of saving it? I really love those.

CHR15 G

Original Poster:

267 posts

153 months

Friday 9th October 2015
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R6VED said:
Nice little collection there. Considering that this is PH I am surprised no one has noticed that the numberplate on the old Landy looks a bit like Finger Blast :-)
Amazing! Never ever have I thought about it like that in the last 10 years!

CHR15 G

Original Poster:

267 posts

153 months

Friday 9th October 2015
quotequote all
ChrisR99 said:
Sounds like an interesting project!

Sad to hear that the red MK1 will die soon, no hope of saving it? I really love those.
Unfortunately I can't weld and it needs a lot doing, so would be very expensive. The mk2 is almost exactly the same underneath if that's any consolation?

KarlMac

4,457 posts

140 months

Friday 9th October 2015
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A few pointers for you when tuning so you don't make the same mistakes I did when tuning mine.

Things that will break so you might as well replace / uprate while its out:

- Boost solenoid
- Recirc valve
- Turbo actuator

For tuning, consider the following:

Intercooler - easy, go for the Auto Specialist one (if it fits your application). The standard one can barely cope at standard boost.

Induction - I've tried them all, by far the best was an RS airbox mated to a Dreamscience or Elevate crossover pipe with a k&n cone. Requires RS ecu holder and some wires moving but nothing an hour on the drive can't sort. Guides online.

Injectors - try and pick up a second hand set from an RS, normally readily available secondhand.

Downpipe/Cat - Mongoose. Dead straight forward.

Clutch. As per intercooler the standard clutch dies at anything above standard boost. A new RS one from Ford is fine. Was cheaper from a Volvo dealership for some reason. Fitting this keeps decent road manners and will cope with decent torque.

The Block Mod. The cylinder liners are incredibly thin and fragile. High boost/high heat ovals the bores which leads to cracking. This is A Bad Thing. The Block Mod involves adding some small ally shims into cooling channels to supply support. Seems to work.

Mapping - lots of off the shelf maps available (my favourite is Collins Performance). Live mapping has proven to be best on these though.

Its a great engine, it does have a number of issues that need addressing though.

Good luck!