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LoneWolf SEiW Turbo Rebuild Diary


LoneWolf
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Hello, I think time has come to start the rebuild thread of my SEiW.

Bought last October in the UK, it's a '94 chassis registered in '98. It has got a Ford CVH turbo 1.6 engine straight off an old Escort (from the paperwork I got it should be from '89), complete with the painful Bosch KE-Jetronic EMS. Other than that it's a pretty standard SEiW, Ford disc brakes all around, Ford 3.62 viscous LSD, kit bodywork. Straight after bringing it to Italy, I changed all fluids and filters, and installed a set of Ferodo DS2500 brake pads. On their way to Italy there are a set of new Spax dampers (thanks @DamperMan) and a new Sytec pre-pump filter and fuel hoses from Matt Lewis Racing.

The target of this rebuild is to have a very quick and powerful road car that can do a couple of track days each year just fine. Dry only usage. I'll do everything on my own to the limit of my skills, other than that my brothers and my uncle own a  couple of garages so plenty of help if needed :)

The rebuild will likely span a few years, I don't plan to ever sell it so I don't wanna rush, just enjoy the process (which will entertain me as much as driving it).

The first step is to have it ready for the next summer season. This will include:

- All fluids and filters (done)

- New brake pads (done)

- New dampers

- New tires

The second step is meant to sort out the engine part and related stuff. This will likely be done during the next winter season. Since the actual engine is pretty old, has got an awful management and it's actually not running well at all, I decided to swap in a VAG 1.8 20v turbo engine. I already got one (AGU engine code) which I'll probably rebuild in the next months (when I have time) to have it ready for the winter. It's gonna work together with a MS3X EMS and a GTX28 turbo for 350+bhp. At the same time, I'm gonna move the driving side to the left and add a widetrack kit. Other than that the objective here is to tune the engine and have the whole package to run very well.

The third (and last) step will start after the car out of the previous step runs very well and without problems. It will involve a complete rebuild from the bare chassis, a complete repaint, new wheels, etc. This step alone is probably gonna take a while, but at the end I'll have the car like I want it.

I've personally never done all this stuff, so this will also be a learning experience for me (which I can't wait to have!!! :) ). Any thought, advice or recommendation is welcome. I can only learn from this awesome community :)

I'll add some photos over the weekend. Sorry for the long post 😄

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Looking at the pictures your car was sourced from the same place as mine..    Thanks for the mention..   

 

Engine wise.    That’s a popular option across the channel.  Bell housings are available to do the job.    
 

in the U.K. it was popular to mix up Ford parts after all the zetec was the next evolution from CVH.      iIRC you can use the cvh head, turbo, etc on an early zetec bringing it up to  2.0 and a stronger bottom end.   All your engine mounts and gearbox still fit.     M

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On 14/03/2020 at 00:23, DamperMan said:

Looking at the pictures your car was sourced from the same place as mine..    Thanks for the mention..   

 

Engine wise.    That’s a popular option across the channel.  Bell housings are available to do the job.    
 

in the U.K. it was popular to mix up Ford parts after all the zetec was the next evolution from CVH.      iIRC you can use the cvh head, turbo, etc on an early zetec bringing it up to  2.0 and a stronger bottom end.   All your engine mounts and gearbox still fit.     M

Hey Tony,

Yeah I know, I've given a look at all options, however the Audi engine was just 100 pounds complete, and it's much more suited for a LHD car since it has the exhaust side (and the turbo) on the right and fitting the steering column on the left (intake side) is easier. Main downside is I'll have to sort some custom engine mounts, however I'm gonna use the T9 gearbox already installed (with RWD Motorsport bellhousing and Tracsport internals), so shouldn't be too difficult hopefully :)

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Fascinating build thread! I'll be following with interest.

 

Just a note of caution that as you are looking to increase the power significantly so you must increase the rigidity of the chassis/drive train to cope with this?

 

 

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5 minutes ago, Chris Broster - Bristol & Bath AO said:

Fascinating build thread! I'll be following with interest.

 

Just a note of caution that as you are looking to increase the power significantly so you must increase the rigidity of the chassis/drive train to cope with this?

 

 

Thanks Chris. Yes that is in the plan as well, but after the engine swap. The chassis is rust free and should be ok to start with, the engine won't be full power from the beginning, I'll be tuning it so it'll be a slow process :) The desired outcome of the engine swap is to have all parts working ok, the power will (slowly) come :) 

I've got some pics of the differential area of the newer chassis, however if anyone has good pics from various angles please post them here :) Thanks.

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If I recall, the 1.8t was an option offered by the German Westfield distributor, they may have parts available, (relatively) off the shelf?

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This is the Mega S2000 chassis, the core structural elements are common to Westfields high performance models, like the Sport 250 and S2000S (Supercharged S2000 variant), the Sport 250 has some different mounting bracket arrangements for the drive-by-wire throttle pedal etc, but the general structure is the same.

 

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Hope that helps.

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41 minutes ago, Dave Eastwood (Gadgetman) - Club Secretary said:

If I recall, the 1.8t was an option offered by the German Westfield distributor, they may have parts available, (relatively) off the shelf?

Wow didn't know about this, do you have any link or email address I can check/ask for please?

Oh, thank you very much for the detailed photos :)

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image.thumb.png.8974bd55c294e642f5ba2e616e78bc72.png

The 1.8t AGU I've got last week from the UK for 100 pounds, it's incredible how cheap are these nowadays... I would have spent 1k for same engine here in Italy.

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It’s not the engine but the management and custom fitting parts which adds up..

 

A type9 in standard form may not going to like the torque..   plenty of gearbox experts out there who can advise what will be needed.   Also shaft length/ clutch... I recently had some work done by a club sponsor 3J Drive line and was very pleased with the service.  

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The courier brought in some new shiny bits today...

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Nice set of dampers @DamperMan, if you have any advice for installation please let me know 😁

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Which gear box / bell housing are you planning on using?

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51 minutes ago, Paul Aspden The 2nd said:

Which gear box / bell housing are you planning on using?

I'm gonna use a T9 upgraded with Tracsport parts (gear set and case) and a RWD Motorsport bellhousing. From my research the Tracsport parts are the strongest available for the T9. Steve (the owner) told me they use them on caterhams with 300lb/ft of torque without problems.

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Thought that might be the bell housing you’re using. This is an interesting build and kind of where I want to be after I have put the rebuild on the road with the old zetec. I have a lot of history with Audi stuff and that block is capable of some serious power compared to its overall weight so this thread is of great interest. 
 

If you are going big with Audi / VW stuff then you might want to check out 034 Motorsport if you don’t know them already.

 

Good luck with the build

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11 hours ago, Paul Aspden The 2nd said:

Thought that might be the bell housing you’re using. This is an interesting build and kind of where I want to be after I have put the rebuild on the road with the old zetec. I have a lot of history with Audi stuff and that block is capable of some serious power compared to its overall weight so this thread is of great interest. 
 

If you are going big with Audi / VW stuff then you might want to check out 034 Motorsport if you don’t know them already.

 

Good luck with the build

Thanks Paul. I've decided for this route given the availability of that bellhousing, and the fact that the engine intake/exhaust placement is ideal for a LHD car (with my current CVH a conversion would be nearly impossible to do). Plus it's turbo, so a lot of fun 🤩

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