SootySport Posted April 18, 2016 Share Posted April 18, 2016 You've been a busy boy. Nearly time to go and overtake some Clios Quote Link to comment Share on other sites More sharing options...
MWMSport Posted November 17, 2016 Author Share Posted November 17, 2016 Sorry for the lack of updates. A flat purchase and problems logging onto the forum (due to my computer, not the forum) have meant progress and updates are behind secdule. There was only one person I wanted to make the exhaust for my Westfield. He's a good friend of mine and an absolute pro at what he does and that's Mike, owner of Edwards Motorsport. I dropped the car too Mike with the dummy engine fitted to let him work his magic. As per usual from Mike, his work is breathe takeingly good. I'm pretty much going to let the pictures do the talking but I am so happy with the result. There are custom made EGT bosses in the bottom of each primary just as it comes out the head and he's also added a Lambda boss for my wideband. While the car was away with Mike, I started to think about the actual engine. The ST170 idea was only meant to be a stopgap until fitting an Ecoboost but I think I may have got a little carried away. Firstly I had the head ported by Neil Roper, I instructed Niel to come out to the gasket on the exhaust side to match the exhaust manifold. Time will tell if that was a good idea or not as I know the zetecs can suffer a bit from the exhaust ports cracking but I have a standard head tucked away in the garage just incase V2.0 is required with a little less porting. The head is fitted with Piper RALLY300 cams (but retaining the VVT) Piper, valve springs and Piper solid lifters. Originally I was only going to use the fast road cams as I wanted to retain a stock bottom end, but I started to get power hungry and as a result a little carried away. Now I had the RALLY300 cams with the VVT retained I knew I was going to need bigger valve cutouts in the Pistons and the engine was going to hugely benefit from being higher compression. The next thing on the list was some High Comp Pistons and forged rods. While looking through eBay looking for a Mk1 Focus RS flywheel for another project I have on the go for a good friend of mine, I stumbled across a lightweight flywheel that I could use on my build that the guy had brought and never used so I decided to buy that too. Next I stumbled across an issue. I took apart 4 old ST170 engines I had laying around and the cranks really weren't upto much. I had the option of buying more second hand engines and risk buying more junk or trying to source a brand new Blacktop 2.0 as the blocks and cranks are the same as the ST170. Newness got the better of me and after some research, it was acually more cost effective to buy a brand new Blacktop. I worked out after selling the head, inlet and all the other bits I wasn't going to use it will of cost me around £500 for a block, crank, full set of bearings, oil pump, waterpump, crank seals, fresh ally brackets etc with the added bonus of the lot being genuine Ford! After a quick phone call to the local dealer the Oil pump, water pump and front pulley would of cost more than that! 300miles in the trusty old Donkey (e39 530d) I had 2 brand new zetecs in my possession. (One for my mates project too) Next is to get them stripped down and ready for rebuild! Shame to break them down really!!! Quote Link to comment Share on other sites More sharing options...
Cleggy the Spyder Man Posted November 17, 2016 Share Posted November 17, 2016 New levels of madness Well done love it Quote Link to comment Share on other sites More sharing options...
Dave Eastwood (Gadgetman) - Club Chairman Posted November 17, 2016 Share Posted November 17, 2016 Love the looks of the manifold, classic bunch of bananas look! Mind you, I'd be lining that area of the bonnet with heat reflective matting, it must be reasonably close? Quote Link to comment Share on other sites More sharing options...
DE04* Posted November 17, 2016 Share Posted November 17, 2016 Enjoying reading this Quote Link to comment Share on other sites More sharing options...
MWMSport Posted November 17, 2016 Author Share Posted November 17, 2016 Love the looks of the manifold, classic bunch of bananas look! Mind you, I'd be lining that area of the bonnet with heat reflective matting, it must be reasonably close? Yes Dave, im going to cover the bonnet and surrounding areas in reflective gold. I was originally going to wrap the manifold but i think it's too nice to be hidden under wrap haha. Quote Link to comment Share on other sites More sharing options...
MWMSport Posted March 10, 2017 Author Share Posted March 10, 2017 Again, due to financial and time commitments towards my flat purchase progress updates on my pride and joy (more of a joy than the flat) have been slow. Not really too much to report but I have started to assemble my ST170 engine. I'm really hoping the car will see the road this summer and I really can't wait to drive it. The bottom end is back from the machine shop. The rotating assembly nicely balanced and block bored. Although the block was brand new so I could of used standard size Pistons, absolutely no one stocked them and there was a 6 month lead time for some high comps so I just went to the first overside. First job was to fit the crank in place. Due to using a silvertop sump on a back top engine, I had to buy a silvertop and Blacktop set of ARP main stud kits as I required cab 2&4 studs to be longer to refit the windage tray as I didn't want to not use one. I had to knock up some spacers for the longer studs to correctly space the windage tray away from the crank. Next job was to gap the rings. Using the figures from the Supertec information sheet the top ring was gapped to 16thou and the second ring 21thou. These are looser clearances than I was expecting but the maths checked out and at the end of the day, slightly loose is always better than slightly tight in my opinion as too tight can do serious damage. Once I was happy that the gaps were all spot on perfect, (I did have to buy one new box of rings due to accidentally opening the gap on one top ring to 18thou) all the pistons were installed into there new home and I started to add stuff like a WPR oil breather and the waterpump & housing. Next job was to fit the Marhle Motorsport big end bearings and check the clearances. Although not photo documented I previously checked the main bearings with Plastigauge and every one was 2thou clearance which I was very happy with. As you can see the main bearings Plastigauged at 2.5thou which is slightly looser than the mains but still perfect. Race/Motorsport bearings normally have very slight increased clearance anyway. Next I fitted the oil pump. I didn't have dry sump money in the budget so I decided to try a set of I.K. Engineering billet oil pump gears. I sent them down to my machine shop to be measured in a brand new Ford oil pump housing and against the brand new Ford gears and they were given the green light. The last thing I've managed to do is installed my thermocouples into my exhaust manifold. My ECU has permanent EGT monitoring and adaption for each cylinder. Thats it for now. Hopefully I'll have another update in the not so distant future now the flat is done. Quote Link to comment Share on other sites More sharing options...
SXRORY Posted March 11, 2017 Share Posted March 11, 2017 Makes my grill spray and oil change look a bit plop. some real dedication to the cause here. Quote Link to comment Share on other sites More sharing options...
MWMSport Posted March 11, 2017 Author Share Posted March 11, 2017 10 hours ago, SXRORY said: Makes my grill spray and oil change look a bit plop. some real dedication to the cause here. Not at all mate. I was actually thinking of painting my grill. Do you have any pictures of it? Quote Link to comment Share on other sites More sharing options...
SXRORY Posted March 12, 2017 Share Posted March 12, 2017 16 hours ago, MWMSport said: Not at all mate. I was actually thinking of painting my grill. Do you have any pictures of it? Not the same thing. I had a rusty westfield metal grill thats not part of the body Quote Link to comment Share on other sites More sharing options...
MWMSport Posted April 2, 2017 Author Share Posted April 2, 2017 Got a little bit more done to the Westfield. The loom is now 99% complete and my friend Will Pedley has been back over to start calibrating the sensors and getting the CanBus working between the dash and ECU. I must say I'm beyond impressed with the capabilities of the electronics package. It's going to be awesome This morning I picked my head up from the machine shop. It's been ported and has had piper 300 cams, Piper valve springs and Piper soild lifters fitted. I wasted no time getting to work and bolting the head to the block. I've used ARP headstuds and a Focus RS headgasket which is 1.4mm thick to begin with giving 12.8:1. Once it's on the dyno and I can see what ignition figures it's taking I might swap to the 0.6mm gasket and map it again to see if there is anymore power to be found. Next i bolted my cams in. I was hoping to start getting my head round the base setting of the inlet cam today but I forgot to order the cam seals! I want to find the point of contact under advance and then retard the cam to a position of safety so under maximum dephaser advance the valves can't hit the pistons. Although I have big pockets in my pistons, from some rough calculations I still don't think I will be able to safely use the full swing of the dephaser. Hopefully ill be able to pick up the seal I need tomorrow and it won't be too long to wait until there is another batch of progress to report. I'm starting to REALLY miss my Westfield. 1 Quote Link to comment Share on other sites More sharing options...
MWMSport Posted April 25, 2017 Author Share Posted April 25, 2017 Bit of an update, the cars been a bit 2 steps forward 1 back recently. My Flywheel is drilled for use of either a pinto or zetec clutch kit. The best value for money and strongest clutch was the pinto one. I went for an AP CP2000-5 as I didn't want the pedal feel to be too aggressive so stayed organic over a paddle. It took 3 different company's to finally supply one. The company that came through was called Motorsport Tools, I'll defiantly be going straight to them first next time! Anyway after the clutch arrived it was time to get the engine in the hole. I bled the clutch first of all just to make sure it was working correctly since the swap to the pinto clutch. You need to remove the spacer from the release bearing when going from the zetec clutch too the pinto item. All was good! Next step was to get the ITBs on. Firstly I drilled and tapped the base manifold to take some air fittings to allow me to run idle control. This a pretty simple job and all went to plan. Now things started to go a bit backwards. There had been a miss communication between the machine shop and they hadn't matched the inlet to the head. When using Blacktop bodies on an ST head the bottom of the port needs opening out as ST ports sit higher in the head. This meant when fitting my bodies, there was a nasty lip where the port and manifold didn't match. I really wasn't happy about that so I decided to remove the head, strip it back down and get it sent back to the shop for matching. Luckly the machine shop were super super fast in getting my head sorted and it was ready for collection in less than 48h. It was a fairly quick job to get it all back together although I've lent out my DTI so can't redo the cam timing just yet. I also swapped over to a mechanical billet cambelt tensioner to try and help with "belt flap" at high RPM which is where the spring loaded tensioner starts to bounce and allows the timing to move. Next it was time to finalise the dash wiring and get it fitted for good. It was a bit of a PITA as the old contour dash had bolts for it all over the place and cut outs for the gauges meaning when using my carbon dash, I was very limited where I could use bolts as they were going to be on display and needed to be equal to look neat. I also used a bit of edging strip round the outside just to tidy it up. No long now and hopefully it will be time to try and start it for the first time. 1 Quote Link to comment Share on other sites More sharing options...
Stephen W Posted April 25, 2017 Share Posted April 25, 2017 What will the car be used for? Seems a hell of a spend for no end goal? Quote Link to comment Share on other sites More sharing options...
Dave Eastwood (Gadgetman) - Club Chairman Posted April 25, 2017 Share Posted April 25, 2017 23 minutes ago, Caterfield said: What will the car be used for? Seems a hell of a spend for no end goal? Not sure in the OP's case.. That's a dangerous question to ask with these cars! While there often is a particular goal, whether it's sprinting, trackdaying, or touring, they're also a hobby, as such doing it because you want to have a try is also an equally valid reason! 1 Quote Link to comment Share on other sites More sharing options...
MWMSport Posted April 25, 2017 Author Share Posted April 25, 2017 Mainly touring and trackdays. But I enjoy the technical problem solving of the build a lot. I'm also trying to develop my tuning skills and calibration skills too the next level. (I'm a train driver by trade) Onces its been used for a bit, I'll decide how I want to progress it again. More than likely it will be suspension next. Quote Link to comment Share on other sites More sharing options...
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