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  1. Tim (TimDave25) - Joint Thames Valley AO

    1.6 Ecoboost Conversion

    It's about time I got started with a rebuild diary it's been a slow start so you have not missed much. I have owned my 1996 factory build 2.0 Zetec for about nine years. It started as a tourer, roof, heater, etc. As time went by I wanted to do more and more to the car to explore it's potential. I started with weight loss, loosing the heater, carpets, etc, etc. The car went down from 640kg to 584kg. I then invested in wishbones, suspension, and setup. When possible, I have had tuition on track and have seen myself and car develope and improve. I initially thought about improving the driveability of the engine and changing from carbs to ITBs but wanted to explore more power. Toting up the price of parts easily gets to over 3k. My concern is that if something goes wrong the "bit in the middle" becomes expensive to replace. I once damaged an engine on a trackday (oil starvation) and it was quick and not too expensive to replace the "bit in the middle". So wanting more power, driveability, and an engine which would be easy to source and replace were my criteria. I stared looking at the 2.0 ecoboost but it didn't take long to be persuaded by the 1.6 because it's lighter so more akin to a seven, it's got just as much power, it's still in production by ford, it's used by formula ford and others so tuning options are available. The stock engine in a fiesta ST is 180bhp but using the type of ECU you need in a Westfield sees between 220 and 230. By changing the turbo only it's possible to get 300bhp! Next up was the gearbox, while my MT75 means I have a nice wide tunnel it's not going to work with the engine. The 2.0 ecoboost shares the bolt pattern with a duratec and the 1.6 ecoboost shares it's with the sigma. I didn't want to use a type 9 as one of the foundations of this project is about using modern engineering. Initially I bought a Mazda RX-8 6 speed gearbox and conversion plate but found the even my wide tunnel would need to be made wider by cutting into the passenger footwell. I later found that Vittesse Ltd make a Mazda MX-5 MK3 (known as N7 from an NC) to sigma adaptor kit which includes a billet flywheel. This is my solution! The gearboxes are readily available second hand or brand new.
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