Dj Wilmas T Series 111S S2 400Bhp Ish

[DJWilma]

Have purchased a few things

 

The ecoboost has a balancer shaft which weighs about 10kgs, also takes a bit of power to spin and allows the engine to spin easier. Mountune sell a baffled sump insert and balancer delete kits so purchased this

 

 

 

Essex Autosport have sent over the mounting kit and adaptors for the duratec, may need a little change on the top mount

 

 

 

Also purchased the adaptor plate and silicone hose kit. Adaptor will fit so at least we can trial fit the engine and box in a few weeks time.

 

 

Have also taken some measurements for a lightened flywheel but using the larger 228mm t series clutch that held 400lbft on the last engine, rather than the std K series

 

Have also been contacted by specialist components about engine management and a loom, more on this when I get the ecu but as they supply zenos it's a great starting place.

 

Idea now is to run the std engine at about 280bhp get it working then go for the 420bhp I'd like next year possibly with a forged engine......or the 2.3 if it's available

[Dr H]

Awesome stuff. Looking forward to seeing how this goes.

 

Are you having the flywheel made? I might need one making so would be interested to here how you go if that's the case.

[DJWilma]

I am, I use www.gb-ent.com as I have always bought my bits from Grant.

 

He is a middle man and puts his mark up on but does all the measurements and talks to his suppliers etc so takes out the hassle

 

Cost will be around the 400 mark for a sub 4kg flywheel

[DJWilma]

Things are going slower than expected, surprise, but works tough and end of year yada yada, anyway

 

I have still to test fit the engine, hopefully in next few weeks, but i am confident it will go in. The gearbox adaptor looks to fit so i thought i would spend some more cash the wife doesnt know about

 

So, Simon from Specialist Components (MX5man) has just sent me the Delta GDI4 ECU with a modified Ford Engine Loom. This came with a 280bhp Ecoboost map, from their Engine Dyno and testing. As said before they supply Zenos (its not the same map) and the cost was half that of the competitor GDI ECU's and looms without mapping so its saved me £1500. Plus this will be a great base map to move forward with and should give Factory driveability (y) 

 

http://twinkam.co.uk/epages/191f6b26-60bf-483c-b021-755a0c9099c1.sf/en_GB/?ObjectPath=/Shops/191f6b26-60bf-483c-b021-755a0c9099c1/Products/SC356

 

I have 14 wires to connect and the 6 wires to the DBW Pedal, plus Simon has assured me he will give all the technical help i need :v6 

 

[Dazzx10r]

That's fantastic, looking forward to see how this progresses, are you keeping a tally of the cost? It would be interesting to know a ball park figure od the full conversion. I really think this could be the future engine of choice.

[Alex B]

I'm with Daz, it's definitely a strong contender for the next engine conversion fad.

[DJWilma]

Yes to costs, and it will be comparable with an AUDI install but and its a hoping but, i would say its 40 - 50kgs lighter. 

 

Had a play with the adaptor kit for the Duratec 

 

The Rear Mount, is i think, is incorrect too but then again i may be wrong

 

 

But the adaptor plate fits the engine

 

 

But i tried to get it to fit the PG1, and I cant get it to line up. Spoke to the ever helpful Wayne at Essex Autosport and he assures me it is the correct one. I checked their website and it looks the same so will have another go at fitting

 

Loom is fitted to the engine, have a couple of questions for Specialist Components, and realised that the engine supplier chopped off the injector loom (why i have no idea as it took some skill to cut the injector loom)

 

Also removed the starter and the aircon unit, now need to find a single crank pulley

[Dazzx10r]

What's the reason for using the PG1 box over the Focus 6speed box other than the driveshaft issues? I would have thought the Focus box would have been quite an upgrade over the PG1. Keep it coming, it's a great project.

[DJWilma]

What's the reason for using the PG1 box over the Focus 6speed box other than the driveshaft issues? I would have thought the Focus box would have been quite an upgrade over the PG1. Keep it coming, it's a great project.

 

Dont know is the honest answer, the theory was to use the PG1 as i know it can handle the torque, plus i had a ATB fitted and a diff for the ford is expensive (compared to already having it) and using the Duratec engine mounts and adaptor plate seemed easier than getting the gearbox to fit and then make drive shafts, diff etc. I never checked the gear ratios.

 

I think this is the thing i should of thought about the most, but didnt 

 

Today is a good day

 

Managed to pick up a C4 K series Pg1 from my mate Tony, who has a magic shed with rover bits in it, cheap as chips and bolted it to the engine

 

 

I also spotted a decent sized chargecooler and Tony kindly let me have it for a good price. Will use this with the std engine and it's twice the size of my home made affair

 

[DJWilma]

Test Fitting on the engine today

 

 

 

Was a little bit of a pain to go in, but removed a couple of sensors and with some giggery pokery she is in.

 

Cambelt engine mount is different from the Duratec (3 holes on ecoboost 2 on Duratec), but we should be able to use it. Main issue is height, but will put a shim under the chassis engine mount and should be able to get the engine nice and level.

 

 

Next is the Turbo, close on the inlet but the outlet hits the main chassis. Dont see this as being too much of a problem will be able to rotate it 45 degrees (New bracket for actuator) and should fit

 

 

Couldnt get under the car but the other issue was the Aircon Bracket hitting the drivers side water hose, should be able to get round this

 

Plenty of clearance on the pulleys even with the double crank pulley (supercharger)

 

 

Also the Oil Filter Housing was removed, looks like i will need to fit a remote filter which i already have

 

 

All in All, not a bad day out. Hopefully have a few more updates before Xmas

 

Gearbox is being rebuilt to a k series bellhousing and Flywheel has been ordered 4.25kg

[DJWilma]

Christmas came kinda early today, luckily the wife was out too

 

 

Grant from GB Enterprises sent me a nice new 4.2kg lightened flywheel, this has been made for the PG1 box but drilled to suit the T series Helix clutch i have. Dual Mass flywheel is about 10kgs (no scales) so a decent saving. I even fitted the Focus clucth (its the same size as the T series), shame the PG1 uses a funny spline

 

 

 

The Gearbox is with a great friend who is changing the bell housing from T series to K series and we are looking at reducing the final drive to 4.2 as this is similar to the ford Gear ratio's 1 to 4. Fifth being 23mph per 1000rpm which isnt too bad

 

 

Also hated the foam filter i had so bought a massive K&N Air Filter again from Grant

 

 

 

Please note the carpet wasnt my choice, its a new house and the previous owner was Scottish and Colour Blind (its for sale if anyone wants the carpet)

[DJWilma]

i bought the wife a little Xmas present, she loved it, then mentioned we could of changed the tartan carpet for what it cost and she had better be getting something nice for Xmas

 

Think i got away with it but saw this on eBay and thought i best have it

 

[DJWilma]

So things have been slow for a reason, we worked out that the Std Turbo wont fit with the subframe where it is. I can chop this about but not a fan of this, it would be easy to do but......when i have a GTX2867R sat in my office doing nothing i needed an excuse to fit it

 

This brings with it some problems, the std pistons tend to go after 300bhp, the Guys in the USA throw Meth and Water at the problem which helps get them to a higher rated BHP but its a bodge for me. So this means i need new pistons, then i might as well get some rods, uprated bearings a new PCV plate. Then there is the question of how much fuelling the Ecoboost can do, see below, and i may need another way of inputting more fuel.

 

So my fit the std engine and have fun has gone for a burton and its back to i need 450bhp

 

A friend popped down to have a look at the car on the weekend and it gave me a chance to chat to Tech1 about what we need to do, mainly after speaking to Simon at Specialist Components as he confirmed that above 300bhp the pistons are the weak point.

 

I also spoke to Total MPS in Newcastle who have made a 420whp (2.0, GT3071) and 895whp (2.3 and wow) ecoboost engine.

 

Their 2.0 had forged rods / pistons and bigger injectors but using the std fuel system made 420 at the wheels which is more than i want (didnt say need) but it was on the limits, so advised additional fuelling

 

So the list of things to do just got bigger, and a whole lot more expensive.........carpets for the new house will have to wait

 

1. Custom Engine Mounts the Duratec ones definitely dont fit

2. Custom Loom, remove the elise engine loom and place the ECU and new relay / fuse box in cabin (saves weight, honest)

3. Mounting of the GTX above the subframe, small adaptor needed and Randy thanks for the advice i never took but it will be V-band

4. Tial 0.86 a/r Exhaust housing

5. New Forged Pistons and Rods

6. Upgraded Head Bolts

7. PCV Plate, the Ecoboost has a habit of holding boost pressure in the crank case so needs venting via a catch can

8. Bosch Motorsport Pump and 4l swirl pot

9. Inlet adaptor plate to hold 4 x injectors (std ported) or 2 x injectors after the throttle body (SC have made one before)

10. Build engine and send it and the ECU back to SC who will run it up on the Engine Dyno

11. Re-fit Engine

12. Fit charger cooler

13. Fit Custom exhaust

14. Try not to change mind

15. Drive it, hopefully further than the last car

 

Seems pretty easy written down  

 

Also are there any MODS checking this thread, if so can i change the title to ECOBOOST not T Series ?

[DJWilma]

 

This is a very rare 4.2 final drive for my U spec PG1, so this will make a C4BSTU box (additional bearing) all steel caged and new seals.

 

 

 

Once this is back we make the engine mounts

[DJWilma]

Looks like the engine will be taken apart shortly as going to forge it, possibly adding some cams and maybe a new intake with ported injection

 

Luckily Tech1 have agreed for me to post items to them so the wife doesn't kill me. The horse also helped out as he needed a tooth pulling which I had to pay for, insurance will send cheque, so wife thinks I am lovely and that the carpets will have to wait.....again

 

Tial 0.82 a/r exhaust housing and V Band adaptors turned up

 

 

As did a 4 litre swirl pot, and I know it's a cheap ebay item but it pressure tested ok and was the biggest I could find