300hp 1.6 Fiesta tdci

[Ryan_Tango]

I have to hear this monster run! Keep up the hard work!

[FourD]

Well done. Waiting for videos! [emoji51]


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[m1tch]

Whats the insurance like on that thing?

[tdci38]

I will find  out soon enough currently limited to 250hp

[Garethgray]

Any up date on build 

[Eatonm112]

A really cool build loved the pics. Its great to see people doing their own R&D then sharing it. 

The way emissions and tax is going we will see a lot more smaller displacement engine builds.

[zain611]

On 8/11/2019 at 12:43 PM, Eatonm112 said:

A really cool build loved the pics. Its great to see people doing their own R&D then sharing it. 

The way emissions and tax is going we will see a lot more smaller displacement engine builds.

Yeah sadly. The ULEZ charge for example if they agree to extend it to the whole of London in 2021 a lot of people with diesels made before 2015 will be charged £12.50 to drive it. I'd sadly have to sell my fiesta zetec s 1.6 diesel as I don't have money to spend that everyday. 

[tdci38]

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Been a while since my last update engine is in bits! whilst in my fabricator workshop a puddle of water appeared leaking from the head, removed the head you could see that the cylinder liners had dropped ever so slightly and in doing so damaged the shim I used in conjunction with a custom head gasket to lower compression. After having a few words with the engine shop who obviously blamed everything and everyone but himself and started going on about materials and movement etc. but when my fabricator explained that he had put the engine in a press and the liners moved again he looked embarrassed and said he does it by feel but it might not have been enough (no S..T) the fabricator then explained that he applied 10MT of force the engine shop looked in shock, he then had to explain about stretch bolts elastic deformation at 78000N which is around 8.2T and thats with stretch bolts and a compressible head gasket but we are not using either and will put more load onto the sealing rings. The machine shop had no clue what he was on about! We got the engine shop to deck the block and skimmed the head ready for assembly, next we done away with the shim and just increase the thickness of the head gasket the head gasket is made of High Chromium Steel with steel O-rings manufactured by Redline Head gaskets in south Africa. Redline refuse to post the first gasket to the UK and ended up taking like six weeks to arrive. Delivery cost more than the gasket itself. Station motorsport setup an account with DHL who had a depot in South Africa so we thought happy days but no redline wanted no part to the point they wouldnt even delivery to DHL depot in south Africa! DHL arranged pickup from redline and delivery to the uk, tracking didnt start until it hit the UK three weeks go past then four weeks no word from from the courier so contacted DHL to ask have they at lease collected the gasket DHL replied gasket has been lost somewhere in transit! two week later gasket found now and on route to the UK gasket arrives but a few days before one of the pistons had fallen from a bench piston didnt look damaged but did not want to take the risk so ordered another machined the valves cut-outs and sent it off for Ceramic coating taking another four weeks, now Engine finally ready for reassembly next week.
Talking about going aftermarket ecu there is not many choices of Performance common rail ecu that can run Canbus at a reasonable Price Adaptronic is one and Bosch Motorsport both ridiculously expensive another one is scs delta which is more affordable but lacks some of the features of the other two but will run and due to the faster processer should run the engine better then the oem edc16 ecu. Specialist Control Systems did start to evolve the ecu but havent completed the firmware I may just purchase the ecu and hope that in the future updates are made available

[tdci38]

SCS aftermarket ecu for common rail diesels could be calibrated on the oem ecu but I wanted to keep to the custom theme where oem wont cut it![/QUOTE]
 

[tdci38]

engine rebuilt again this time with custom valve springs sorry this is taking an age just problem after problem.

[tdci38]

engine up and running again mapping hopefully no more problems
changed from a quaife diff to a gripper plated diff and added a CAE shifter which is meant for an mtx75 from a mk1 focus rs, only found out afterwards that the mtx75 box from the focus rs work totally different from all other mtx75 so needed to be modified to work.
cae shifter


Plated gripper diff


completed engine bay

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[tdci38]

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another update idle part throttle mapping completed, coolant system started to pressurise first time blowing my radiator changed for a new rad then again the ecu shut the engine down. stripped the engine again! turns out the liners have spun letting in combustion into the coolant causing high pressure, instead of trying to fix what the machine had cocked up in the first place, so I have bitten the bullet and now going for a full closed deck conversion from Westwood liners and going to their machine shop of choice Stanwood engineering in Doncaster who are the only ones to have a brand new RMC CNC machine and can profile and fit the new liners to suit, turns out quite a few of the big players in the tuning world will only use these guys shame I didn't know beforehand could of saved me months of headache and money! six weeks lead time making the liners then the machine work, most probably looking at another three months in total.

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[tdci38]

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in the interim I more power so have to  increase the size of the turbo but the M45 supercharger will become a restriction so I acquired an M90 from a xj6 jaguar

[tdci38]

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I always wanted an AP racing brake kit I phoned Reyland about their four pot Caliper brake kit 330mm kit for the mk6 fiesta but before Purchasing I asked if I wanted the best road/track brake kit what would you offer me? they suggested a six pot calipers with RSL29 pads i wanted red calipers seeing as everything on the car is black need to break the colour up a bit and fully floating on the rear AP are out of stock and I am looking at lease 12 weeks lead time!

[tdci38]

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Hi
Not much of an update ***** waiting game for more custom bits Stanwood Engineering who are doing all the machine work have said my pistons and head-gasket are no longer of any use, I need a set of custom pistons and a compressible head-gasket this is due to the closed deck liners will protrude the block, my current head-gasket is of a thickness to lower the compression ratio and is a reusable solid plate, now the block will get built the proper way with pistons that can stand mega heat Stanwood never do anything by half measures. With a bombproof block be rude not to up the ante a little! so I bought myself a Darkside developments GTD2872VRK 5th generation ceramic roller bearing turbo with a billet 71mm comp wheel capable of over 400hp just hope its not too extreme.

[tdci38]

 

The rebuild is going good new set of pistons have been machined to move the oil squirters over to the hot side of the piston and valve cut-outs, currently getting a triple ceramic coating. I wanted to change the cams the oem pair are hollow with press fit lobes and gear, too much of a risk to use in this engine I've seen cams where the lobes have moved bending the valves and literally destroying the engine, Newman are making a custom billet set for me keeping duration the same but increasing lift these are on a six week lead time which goes for most of the custom bits on this car............ lets not talk about cost I had a budget but that's been blown into space, several times I thought of stopping this project which is very unique, there is a compound charged diesel fiesta using twin turbos but the engine is standard, we have come across many issues in terms of restrictions that you have to overcome to achieve big power, 300hp should be an easy task the new  turbo can flow over 400hp then the air is getting compressed again by the supercharger should see 60psi at the manifold hopefully we do a good job of heat management so it doesn't become too big of a problem,

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[tdci38]

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sorry these are all updates taken off another site I am on regular so the dates of the posts and timings wont match

 

[tdci38]

supercharger gone to Powerhouse for a rebuild and porting, the porting will obviously let in more air making the supercharger whine a lot louder

[Eatonm112]

On 10/9/2019 at 4:30 PM, tdci38 said:

SCS aftermarket ecu for common rail diesels could be calibrated on the oem ecu but I wanted to keep to the custom theme where oem wont cut it![/QUOTE]
 

I have a Delta GDI 4 which will be used to run my 1.0 ecoboost. Had to go that way as I needed port fuel injection for extra fuel. Going back to Delta they are a great company to deal with and extreamly helpfull I had them get a tune into mine remotly so I could run it up a while back.

[zain611]

Coming together really well. It'll be hard for me to throw money on engine mods on my DV6. 

Can't wait to see the finished product. Didn't know darkside development had a turbo for our engine 

[Eatonm112]

On 10/9/2019 at 4:40 PM, tdci38 said:

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in the interim I more power so have to  increase the size of the turbo but the M45 supercharger will become a restriction so I acquired an M90 from a xj6 jaguar
 

I am interested in why you think the M45 will be a restriction. How is the turbo and SC set up and what is the drive ratio in relation to thhe crank?