500+bhp Mk3 Fiesta Project

[mwstewart]

Old Gregg said:

Yep, me too. Amazing work and dedication, OP, I'm looking forwar to following this.

What does CDS stand for though?

Thank you. CDS = Cold Drawn Steel. It's stronger than regular hot formed/rolled steel and is usually the material of choice for Roll Cages.

[mwstewart]

http://bbs.rsownersclub.co.uk/showthread.php?t=256...

Ian is the guy building my engine.

[Conian]

I'm confused by this, on one hand you're clearly a genius, a visionary and a hell of an engineer, on the other hand, youre a mentalist spending a lot of time and money on a Fiesta!

But despite my above mixed feelings, I am 100% glad that nutter/geniussesses like you exist, thanks for sharing all this

[anonymous-user]

mwstewart said:

Hopefully I've asked for a 7k RPM cap for exactly those reasons. I don't expect the gearbox to last forver but I do expect the engine to last for 20k,Ian has assured me that my targets will be met. Turbo choice is crucial in my case and a custom spec unit will be ordered.

I think you unfortunately suffered at the hands of a manufacturing defect there, as there are too many high power cars with the MTX that haven't had issues. This guy: http://www.rsownersclub.co.uk/rsocbb/showthread.ph... has run 500bhp through his for more than a few thosuand miles now, and there are no issues to report.

Target date for completion is July, I'm looking forward to it

all the 8 odd RS's i drove all pretty much ate their gearboxes at some point....... And as i say, they were all std, 215bhp on engine dyno. Now, of course, a lot depends on how you drive it, but i bet with a genuine 500bhp, on a std MTX75, i could break it in very short order ;-)


if you assume you make the 500bhp at 7000rpm, thats a BMEP of 32.7bar, which is some going (not impossible, but quite brave on a zetec (or any proddy engine for that matter really)

[mwstewart]

Conian said:

I'm confused by this, on one hand you're clearly a genius, a visionary and a hell of an engineer, on the other hand, youre a mentalist spending a lot of time and money on a Fiesta!

But despite my above mixed feelings, I am 100% glad that nutter/geniussesses like you exist, thanks for sharing all this

Thank you, too kind. I agree, it's not right, is it? It's not only Fiesta's that I've worked on: http://www.mwstewart.co.uk/cars

[anonymous-user]

You'll be familiar with this place then:





;-)

[mwstewart]

Max_Torque said:

You'll be familiar with this place then:





;-)

I used to work there

[mwstewart]

FYI Current 'Hall of fame' for the Mk3:

Paul R - 12.78 @ 114, 0-60 of 4.89 and 0-100 of 9.52 (260bhp)

Paul J - 11.86 @ 124mph, 179.8 top speed 440bhp)

Sunny - 178.8mph top speed (380bhp)

[stabbed rat]

mwstewart said:

FYI Current 'Hall of fame' for the Mk3:

Paul R - 12.78 @ 114, 0-60 of 4.89 and 0-100 of 9.52 (260bhp)

Paul J - 11.86 @ 124mph, 179.8 top speed 440bhp)

Sunny - 178.8mph top speed (380bhp)

Those are some pretty big bhp differences, I take it traction was the biggest factor here?

[mwstewart]

stabbed rat said:

Those are some pretty big bhp differences, I take it traction was the biggest factor here?

Traction and driver I think 250-280bhp is around optimal for standing start times, for this car anyway.

[Greg_D]

Hi there OP/max torque,

sorry for the thread hijack.

but you both clearly know a thing or 20 about zetec's. i have a silvertop zetec 2.1 (calibra turbo pistons) that has had a light rebuild, i am running FRST inlet and ERST T3 turbo and 600cc injectors, running emerald ecu head is mildly modded ~(standard valves i think), i am about to go and get it tuned/dyno'd, what sort of power do you think that sort of setup should reasonably be able to produce/sustain?

[Sir_Dave]

Great read ....

I remember your work from when i frequented www.fiestaturbo.com as a young 'un

[mwstewart]

Greg_D said:

Hi there OP/max torque,

sorry for the thread hijack.

but you both clearly know a thing or 20 about zetec's. i have a silvertop zetec 2.1 (calibra turbo pistons) that has had a light rebuild, i am running FRST inlet and ERST T3 turbo and 600cc injectors, running emerald ecu head is mildly modded ~(standard valves i think), i am about to go and get it tuned/dyno'd, what sort of power do you think that sort of setup should reasonably be able to produce/sustain?

Hi there,
If it's a regular T3 (.36 housing) then 11psi is the safe limit, and I would expect 250bhp at this boost pressure from your provided spec. There are however some considerations:

1) Using boost pressure as a (very rough!) guide, the standard valve springs can support a maximum of 10psi due to the elevated cylinder pressures resulting from forced induction.
2) As you don't mention rods, I'll assume you're using the standard items with the wrist pin bore enlarged to suit the LET pistons. The important factor here is ensuring that the power output is limited to ensure the standard rods won't break; 260bhp (using BHP as a rough guide) is a safe limit for the standard cast rods, regardless of whether they are shot peened & have ARP bolts.

Thanks,
Mark

EDIT: I forgot to add that those injectors are on the large side for your spec. I don't know how good Emerald is in terms of resolution, but to be on the safe side for a better idle you can trade down to something around 440cc.

Edited by mwstewart on Monday 14th March 14:07

[mwstewart]

Sir_Dave said:

Great read ....

I remember your work from when i frequented www.fiestaturbo.com as a young 'un

I should really stop playing with these old things...

[Gallen]

Amazing build and documentation,

How the hell do you know how to do all of this! Fabulous.

[Greg_D]

MWStewart,

thanks for the sage advise, extremely useful

it looks like 10psi and 250hp is going to be the result then, that would suit me just fine.

passionford is useless for this sort of advise, they were talking about 20-25psi (which seemed high to me for my target hp ceiling of 280hp)

bunch of boy racers

[mwstewart]

Gallen - Thank you The thread should hopefully start to become a lot more interesting over the months leading up to summer.

Greg – No problem! I am registered there but I don’t tend to use the forum. Is the engine going in your race car? If it’s not too much trouble then I would recommend a set of updated valve springs to prevent high-rpm misfires, as you’re no doubt going to be up to around 7k in no time at all I think Piper do them, if not my engine builder can supply them either via me or direct (message me if you’re interested). I believe they are £130. Additionally have you got some ARP bolts fitted? If not, make sure the rev ceiling is set to at most 7k, ideally 6.9k: the standard bolts stretch – I have in the past spun bearings, which was lucky, as most failures involve the rod leaving via the block!

Thanks,
Mark

[Greg_D]

i can't PM you mark, there are a couple of tedious q's i would like to run past you without completely hijacking your thread.

is there any chance you could PM me so i can reply

Cheers

Greg

[mwstewart]

Greg_D said:

i can't PM you mark, there are a couple of tedious q's i would like to run past you without completely hijacking your thread.

is there any chance you could PM me so i can reply

Cheers

Greg

Greg, Sure, message sent.

[Biker's Nemesis]

I can't see all of the pictures at work, I hope i can view them when I get home.

Outstanding work fella.