[stupica1]

*UPDATE!*

Gave up on the escort wiring harness, So I put the focus wiring and PCM back into the focus.

went to start the car and the fuel pump was dead, checked all the wiring noticed there was a ground that came loose just before the fuel pump under the rear seat, so after snugging that down the fuel pump worked again. problem 1 solved.

scanned the car for codes:
-rear 02 sensor (was just unplugged).
-p1233
-p1000
-p0320

I got the car started with the cam position in and it will only stay running at WOT...but at WOT the revs bounce around from 2000 - 5000rpms, just a constant back or forth.
So I did as mentioned in above posts and unplugged my camshaft sensor, started it again, no bouncing revs, but she wouldn't idle (also mentioned above), I did manage to rip the focus around the block and scare the crap out of my neighbors (seeing as my car has no front bumper cover,fenders or hood and is crazy LOUD). The drive around the block went okay, First gear is solid! runs great (minus not being able to idle), second gear starts okay at low revs seems really weak. Couldnt get it up to 3rd

But the good news is she actually does run (WOOHOO!) and drives really nice. Just have to work out some kinks.

After my little cruise around the block, I parked it in the driveway and she wont start again. Fuel pump kicks on but just doesnt seem to want to start again.

So thats where I am at with this project! what do you guys think?

[stupica1]

another update! got car to run and idle. woohoo! I win.

[euro_zx5]

Not get'er running properly and start driving it! lol

[moon111]

(04-13-2012, 12:18 PM)stupica1 Wrote: another update! got car to run and idle. woohoo! I win.

What was it?

[stupica1]

Just unclipped the cam position sensor ahaha. Thats and a brutal fuel leak that i gotta fix asap.

[stupica1]

Long time ive updated. But heres whats new. Had a nasty vacuum leak somewhere, and thanks to ken ztwsquared i got a new intake and throttle (along with new sensors and some other goodies), i got that cleared up. So car is running and idling okay. Not as smooth as i wanted so im thinking the timing is slightly off. So thats my next plan of attack to get it drivable.

[stupica1]

So doing the timing on the motor...noticed that my bottom tentioner was sitting funny.



After looking at it I decided it must just be loose and went to tighten it...well that didnt work out to well. Turns out the threads are mangled and it popped off. So now I'm left with this hole in my block and wondering how in the world am I going to fix this.

[ZTWsquared]

(05-29-2012, 07:40 AM)stupica1 Wrote: So doing the timing on the motor...noticed that my bottom tentioner was sitting funny.

After looking at it I decided it must just be loose and went to tighten it...well that didnt work out to well. Turns out the threads are mangled and it popped off. So now I'm left with this hole in my block and wondering how in the world am I going to fix this.

Did you try re-tapping the threads? If that doesn't work you can always use the Helicoil or E-Z Lok inserts.

[stupica1]

I have to borrow my buddies tapping kit and then get a new bolt for the pulley too. Its not very deep. only about 1/4". If retapping doesnt work then im going to try a heli coil. This is literally the last thing I need to do to make the car driveable...it was supposed to be an easy timing belt swap. haha

[ZTWsquared]

(05-30-2012, 08:42 AM)stupica1 Wrote: I have to borrow my buddies tapping kit and then get a new bolt for the pulley too. Its not very deep. only about 1/4". If retapping doesnt work then im going to try a heli coil. This is literally the last thing I need to do to make the car driveable...it was supposed to be an easy timing belt swap. haha

Since you don't have the option of using a bigger bolt, you may have to tap it - then put an insert in it to get it back down to the original bolt size - doesn't look like there's a lot of meat left to tap for the original size.

[stupica1]

Yeah just tried re-threading it...didn't work to well. So I'm thinking making the hole a bit larger and putting an insert in. There is also two bolts on either side of the hole, so I'm also thinking making a small plate with a hole drilled in it for extra support on that bolt. seeing as it has all that tention from the timing belt, I want to make it as strong as possible.

[stupica1]

So got bored today, not much to do when its rainy out. Except make some new decals for the car. haha Seeing as my car has so many different parts from various cars in it (escort motor, contour kit, focus, and even some mazda stuff in it), I decided to make a fitting banner for the windshield.



Also decided to do a battery relocate to the trunk. I rigged it up quickly just to make sure everything worked properly (which it does). So I have to clean it up a lot and get a battery box still.

[stupica1]

So fixed my hole problem I was having with that timing tentioner...Used some JB weld steel stik (works awesome!) to fill the hole, re-drill and re-thread the hole. Used a heli coil after that just for safe measures and to top it all off I made a fancy gold plate just to make it wasnt going anywhere!



Also got a nice shipment in of tubing for my turbo All I need now is an intercooler. More pics to come!!!

[stupica1]

Got my front mount intercooler in today finally!



Seeing as I have my aluminum tubing as well I decided to do some test fitting.






So far everythings fitting spot on, which is a bonus. Gotta pick up some T-bolt clamps still and one reducer that I missed when ordering. Then It's off for tuning!!![/align]

[02ztsian]

Synapse BOV FTW!
I have one on my Merkur as well!
You probably already know this but use T-bolt clamps-I used two worm-gear clamps (the rest were T-bolt) and blew a coupler off at 20 psi.
Looks like good progress.

[stupica1]

I've heard the synapse bov is one of the best. And for the price I got it for I definitely couldn't pass it up lol

[stupica1]

It's Been a long time since i've updated here, But here's whats new!

Opted to ditch the VCT head due to timing issue and lack of VCT deletes out there to purchase (and didnt wanna bother trying to make one). So I did a quick head swap.




I must say a head swap on the zetec is extremely easy to do. Nice upgrade ARP head studs, along with camgear bolts (best investment for my focus to date, makes timing so much easier to do).
Mounted my front bumper for test fitting with the intercooler and fits like a glove. perfect fit! Now to do some extensive front body work to that bumper. It's in rough shape as you can see.



More pictures to come!

[stupica1]

Well it's been a while since ive updated this thread, and there's lots of goodies added!

Quick update - after several timing belt issues...and i mean several...I finally managed to get it timed properly with no issues! no walking off the gears no pulleys breaking, notta, so it runs! woohoo! Also upgraded my camgear bolts to ARP, best money i've ever spent haha $75 for 2 bolts...but theyre soo much better than stock by far!

After getting it running nicely, turns out my alternators shot after putting a whopping 3kms on it! haha literally drove it up and down the street a couple times and it died on me! wtf...so I snagged another one from hardk0re...and with my luck and his parts...it caught fire haha. just the terminal extension though. phew! haha luckily I keep a fire extinguisher in my car now..



Now onto the body...

while priming the doors I noticed they were pretty brutal and rusted out. So luckily GFXJamie had a very lovely SVT part out so I snagged the doors and fenders off it. Looks killer!



As for my bumpers...the custom mades ones took one hell of a beating while the car was originally on the road for the whole...2 months haha So I took the time and re-inforced them on the inside and put all new rivits in, now just waiting till its in the garage again for fiberglassing. puddy and paint. That goes for both front and back. They look ugly now...But just give it time! Also picked up a new trunk lid, a nice clean look with no spoiler on it. also silver of coarse.

I also managed to snag Scorchers wheel spacers to try a new look. Doesn't look bad at all in my opinion. Still not sure how they ride though, Found out that 1 wheel stud in the back is stripped...so I gotta drill it out and replace it. time to upgrade to ARP.



wheelspacers...



Finally, onto the interior!

major overhaul here with some racing seats and corbeau LOW brackets for the focus. Its just like driving on the floor. With me being so tall its nice to have all the spare head room for once! haha. Also added to the car is guages...lots and lots of guages...7 in total now.




Since I wasnt expecting sooo many snagges (the plan was to get it on the road this spring), the car is going back underground for another major overhaul to finalize it to get it DONE for the first meet next spring!
This winter will include the turbo installation, new motor mounts...(350,000+ kms on these mounts), new subframes (front and back), 3" exhaust (coming soon! old one for sale). Lots of body work & Paint, and a good cleanup of wiring and hoses under the hood. clean that sh*t up! haha

[stupica1]

Time for another update on the never ending project! woohoo!

I finally got everything together to get the tiny turbo physically installed on the car! I made up my own custom extension pipe to make the turbo fit properly. I took two catalytic converters that were no good, removed there flanges and welded them together worked awesome!

---

So since the turbo's been installed and seeing as its parked for the winter, I can't tune my car until spring. sooo...After talking to DrunkinMonkey about wire tucks and seeing some of those crazy honda's done so clean...I decided to give it a go instead of my quick wire tuck I did before...when doing it properly, beware to make a mess!

Removed the dash, middle section, and passenger seat. Took out all the wiring and and fuse box from engine...now the fun begins!




I had to remove the ECU to get the fuse box to fit in nicely right beside the blower motor. fits beautifully actually. I want to tip it upwards still though so the fuses will be easier to access once everything is all put back together. But so far so good!



Took all the wiring and strung it through the passenger side fender. Surprisingly most wires will still fit where they have to go without much modifying. you just need to remove all the loom and electrical tape...this takes time...lots of it haha.



I am going back down to the garage tonight to continue working on it. I will update everything with more pictures later on!

[incognito27]

Nice build. Wish i had a garage and another car to use as DD so i could tear apart my front end to clean and fix up the engine area.