green one

i have copied this from another forum but though people would to see it on here there will be abit of a dump of posts .a little bit about the car this is as it sat as of a couple of days ago it had a 1600 bored 40 thou, ported head, mild cam, twin side draft dellortos,celica 5 speed, escort diff, gt front brakes, lowered, 15 inch superlites, painted porsche ascot green done in my drive way, some nissan seats a few custom fibre glass bits in side , pair of 15 inch fusion subs amp couple of down lights in the boot. ive done every thing on the car except exhaust and wheel alignment. i managed to get a photo shoot with street machine ford magazine a few years ago




now the next stage i purchesed a mondeo and stripped the motor and few other bits out of and the rest went to scrap metal

then the motor come out of the cortina


and in with the zetec


its in the engine bay but thats about it i was hoping the inlet was going to fit but no luck an no go on the exhaust manifold or the sump so me being a tight ass these will be made or some thing else modified to fit so progress will be slow from here.

having trouble copying from the other site so ill just write a bit about the photos.
these are photos of the inlet manifold cut off

part of a old stainless muffler that will become the inlet manifold

manifold partly done

ive got the inlet manifold finished spent a fair bit of time getting the idle control mounted to it out the way.
engine mounts are done using standard mounts
pcv modified to fit behind the engine mount
and sump and pick done i used a 1600 kent sump cut the flange of the top and welded a new one on
i didn't take to many photos doing this but ive got some finished ones
also got my clutch made just using standard flywheel ,clutch plate to suit the celica box and modified pressure plate
i got an exhaust manifold flange cut as a favour for doing some work for someone
so here are some photos





 

started on the extractors yesterday spent a couple of hours mostly looking and working out how to do it
then finished tacking them in place today. also started the coolant pipes got them tacked together as well just have to weld properly and ad some brackets to hold them

its all go went for a little test drive around the block earlier and it had a bit of a dead spot when accelerating wheather i was driving or not but it still had old fuel in it . so i bolted the bonnet back on grill and finnished a few thing and went to get petro. i take off on the first up hill and it bogs down bad pull over then go again by this time i no ive got no petrol but its mostly down hill from then on i went back streets but the first sine of a hill and it stops i can get it to run but only just i try ring my wife to bring a jerry can but my phones cut off so it decide to start pushing i get over the crest roll down to the intersection try again to take off but no go. luckerly there are a couple walking that give me a push of roll down the hill from there made it through the next intersection got it to run enough to get into the servo. put some fuel in took of from the servo not overly hard but it starts stepping out sideways nothing like to old 1600 that i had to rev the gusts out of it to get it to go. had a bit more fun on the way home sounds strong pulls hard makes all the stuffing around making every think worth it.


im not real happy with the bottom rad hose once i find the right bends that reduce it will look better
i think in total i would be under $1000 its a bit more than i though at first but no bad

Nice work!

Awesome home fabrication!!
 
I've not seen the sump created that way.. Some more pics would be great (if possible)
 
What did you do for the water take off at the back of the head.
 
Exhaust looks spot on.
 
Shaun

Nice work and nice car fair play, what did you do with your 1.6 motor you took out.
 

hey mate, looks awsome. some very nice mods
 
you dont happen to work at hills auto elec?  i rekon ive seen it a few times.
 

escortinadriver

Awesome home fabrication!!

I've not seen the sump created that way.. Some more pics would be great (if possible)

What did you do for the water take off at the back of the head.

Exhaust looks spot on.
 
 
 
i didn't take any more photos when i was doing the sump but i just cut the mounting flange of and bent some 3mm x 25mm plate to the shape of the motor then welded it to the sump i had it bolted to a board to try and stop it going out of shape it seems to have worked so far for the 10 dollars it cost it was wrth a go
 
the water outlet is the original mondeo one it clears the fire wall with the motor in the original spot then just a hose bend to a stainless pipe
 
 


Shaun

eamonlad
 
to old motor is sitting in my drive way it not it to good a shape it was low on compression and pumpinng oil out the dip stick

krt10
 
thanks
i do work at the auto elec i think it was your blue escort i worked not long ago seems to be a few people around the hills

whooligan
thanks
they are nice motor puts the 1600 to shame it makes the car nice to drive .
i did a fair bit of research before doing it  i think i have seen just about every thing to do with a zetec on the net and felt like i was the one going around round abouts

Good Stuff JP can't wait to get mine up and running
 
I wish i had the time to fab everything i think im going to cheat and buy the kit from the UK.
 
Patrick

What did you use for the intake manifold flange
It looks like you cut the plastic runners after(before) the injector bosses and the just attached the rubber hoses. is this right???

It turned out really well

Patrick

Yeah the old man took it there a while ago. That was before I decided to swap engines.

Another Adelaide is so small story. I did work experience there back in 2005 for school.

You going to be at the small ford show? Gonna try get both mine out

cuttback
i wish i could have bought a kit but money doesn't come easy with one income and two young kids so i had to wait for them to go to bed before i could do anything so most of it was done in my lunch break.
as for the manifold i did cut the plastic after the injectors then heated the plastic and pushed a metal tube inside to make them round then let it cool then pulled the tube out and then put silicone 45 degree bends to the planum chamber

krt10
theres a good chance we met ive worked there  since 2000
im going to try and get to the show just hope there are more cars there this year i spent some time at the pub last year killing some time 

yeah we ended up leaving early last time, hopefully there are some more cars this year

JP how's the project haven't heard from you in a while
Cheers
Patrick

Jp I like your style mate. good to do it yourself on the cheap. Can you elaborate with what you did for engine control and fueling. I get the feeling you run the stock ECU, what did you do for road speed indication?
 

I haven't been on here for a bit not much happening with the car at the moment I drive it for three months every day till the rego ran out a few little teathing problems with coolant leeks and stuff. The tyres were getting bald so put the stock wheels back on with the 155's that was some fun for a couple of weeks I forgot to take any photos of it with them on I do have a video but not sure how to put in on here. Had a busy run of birthdays for a couple of months so now that's over it's time to drag it out of the shed for some body work some rust is starting bubble in sections and maybe a hole respray if a can be bothered.

And the ecu is just standard with out any egr ,exhaust pressure sensor or carbon canister solinoid hooked up the standard mondeo fuel pump mounted in the cortina tank nothing special seems to ok I can still get pretty low on fuel and have no problems one of the best parts I was using about 50 dollars of premium unleaded for about 400kms which is around 9litres for 100kms

I'll post up more pics soon

WOW what a clean car..  like that, because the car body is shining like new make car and your work is also good. I guess you are pretty expert in all this work, anyhow I like your car, thanks for sharing.