Dj Wilmas T Series 111S S2 400Bhp Ish

[Dr H]

Bottom one for me. Less is more and all that.

[DJWilma]

So there is good news and not so good news and good news again

 

Good news is the engine build is on its way, i got very excited and finally thought we'd get things moving and done and i could drive the car. However, we fitted the rods and pistons to the engine and.........see below

 

 

Something didnt look right, the pistons were not sitting right in the block. As first we thought possibly that being a GDI engine the pistons sat lower but i called Speedperf6rmanc3 in the USA and turns out that i accidentally ordered the 2.3 Ecoboost rods and not the 2.0 ones.......

 

 

Bugger. However the ever helpful Marshall suggested a quicker fix than returning the rods, a 2.3 crank........a stroke of genius (pun intended) and they had just received a set of std 2.3 cranks which are forged and...i stopped him there and ordered one.....as a favour they even keyed and then balanced the crank for me........tops guys

 

Next issue will be customs clearance and Tech1 finding a slot to build the engine

 

Problem i have now is the GTX2867 will be on its last legs at 8000rpm, so a GTX3076R would be better, then i can have 550bhp and can tell everyone in the pub. If the wife finds my bills i am dead, although she has a new kitchen we still have the Tartan carpet a year after moving......

[DJWilma]

These just arrived too so I am happy with that

 

Also the 2.3l crank has arrived, the joyous moment. The last piece (hopefully and may of said that before) of the puzzle

 

I was so happy when I dropped it off at Tech1, but Paul wasn't as chuffed. He is normally smiling when I drop something off and his body language was terrible. Long of the short is he and his business partner have decided to part ways and he will be closing the work shop

Bollocks

Good news is he will build the engine for me, this I didn't want to take elsewhere and he has a workshop at home and will finish this. When, was the next question and Paul smiled.

So I now have to find someone stupid, sorry enthusiastic, enough to take on a project half done. I may of found someone but if anyone local knows of anyone (I don't) I would appreciate it.

I'd like to do it myself but don't have the time, or the mechanical know how to make the engine mounts and so on.

I think someone is trying to tell me something, and I think its don't give up

[LIVY]

What an epic read. I really hope this works out for you and you are right someone is trying to tell you something. Push through to the end because there aren't enough people like you willing to try something a little bit different. Good on ya

[DJWilma]

Thanks Livy, i hope so too. I hate seeing the car on my drive with the cover on especially in this weather

Some more goodies have arrived courtesy of Speedp3rform6nce, cant praise these guys enough for their support and knowledge

 

This time its the auxiliary fueling systems, i did want the JM manifold but its taking too long and as i am only going for 450bhp SP advised this kit would be simpler, easier and perfect for what i need. Apparently the std inlet flows pretty well and its also light.

 

The reasons for this kit are two fold, the GDI engine needs a High Pressure fuel pump(above 200bar) and these run out (depending on who you talk to) at around 350bhp, the injectors run out not far after(depending on who you talk to). Uprated injectors are available but and they need more flow. The 2.3 has 4 lobes, the 2.0 3 lobes, on its cams and a different High Pressure Pump but it was a nightmare to change to this. There are some upgraded pumps, but these cost a fortune and are untested at the RPM i want to go to (saying that the std one is too). This kit has an inlet adpator plate with 4 injector holes, and 4 bottom plugs if i want to run meth/water (which i dont). Injectors are 640cc which are big but they are std FoMoCo for ease. Also combined, ported and direct, i should be able to run about 750bhp (which i wont, yet, maybe, possibly, shouldnt do).

 

Sounds complicated but Specialist Components already have the software to run both port and direct injection already (so i wont need the additional controller), and most High Power GDI engines, like the Mercs, run both port and direct.

 

Issue will be with the mapping but i will send the engine back to Specialist Components as they have probably the most experience on these engines in the UK, so need to get an exhaust manifold making and hoping Maniflo in Salisbury can help.

 

I have also found someone stupid enough to take on the engine mounts, and they are local ish, so having a ready mapped engine will make their and my life easier. 

 

The Complete Kit

 

The Inlet adaptor

 

FoMoCo Injector, which is a bosch item

 

Additional Controller that i dont need

[DJWilma]

Engine is being built, all parts fit......so far

 

[PeteB]

What does the chain drive on that motor? Oil pump?

[DJWilma]

Yes thats the oil pump

[DJWilma]

So progress at last, Engine builder got a new job (after needing a break) and engine was in one place and tools in another

 

Anyway a month later the three of them got re-united and the engine is being built (again)

 

Issue i had was the Main Bearing studs, the OEM items are stretch bolts and once used you need to measure the stretch and then change the torque accordingly, so i rang Speedperf6manc3 and  asked what this should be. The ever helpful, if busy, Pablo explained that i needed to fit ARP bolts. 

 

Next problem was searching for the correct bolts, ARP catalogue number came up at £270 and no one in the UK had any, and they were 6 weeks delivery. Rang Pablo again, and asked him to ship some. Turns out the ARP bolts for the 2.3MPS DISI engine are the same as the ECOBOOST, and £175 ! Luckily i found a supplier in the UK, who also sent sweets with the delivery.....

 

 

 

Pauls managed to fit them this week and cams are next

 

 

Cams are on lifters as per the Duratec but they are not shimmable, instead the buckets come pre-sized. Great idea but Paul needs to fit the cams check the gaps and then order some buckets.......more delays ffs 

 

Good news on the cams, i decided to fit the full blown 12mm lift cams capable of 650bhp and 8000rpm........just need a bigger turbo, chargecooler, radiator, bigger tyres, more cooling and the head porting.........hmmmmm

[DJWilma]

Well its Christmas soon.......

 

Engine progress is slow, the last (please for the love of god) challenge is the cam followers. Ford in their wisdom made the ecoboost (like the duratec) with mechanical followers. They then made cam followers "un-shimmable" so you have to buy the correct followers shimmed accordingly.

 

Luckily i only need three, and these have been ordered direct with Ford

 

Then the engine needs building and dressing, flywheel, clutch and gearbox then ship it off to get a manifold made then off to get dyno'd 

 

 

arp studs fitted to the big ends too, old vs new

 

 

 

#nevergiveup

[DJWilma]

Well New Year, New Engine !

 

Its finally been built, well almost the flywheel, clutch and box need to go on and the gearbox.

 

Engine with the external oil filter bracket and PCV delete and breather

 

 

Without the inlet fitted

 

 

With the new auxillary fuel manifold, basically a spacer with ports for 630cc injectors and ports for meth injection

 

 

Engine Fully built

 

 

I then need to make an exhaust manifold adapter (engine has on internal exhaust manifold) which needs to have an external wastegate something like this 

 

 

 

If anyone can make one for me let me know as the USA is the only place to get them and they only sell them as kits with upgraded turbos ffs

 

Worst still Garrett have released a GEN II GTX2867R which would be perfect for this engine, the current GTX2867 will run out of puff above 7500rpm.........and the internals are not interchangeable

 

However good and bad news, the tartan carpet has gone and we now have Brimstone  

 

[jonnyfox]

Lol well done on both counts :-()

[chris_h]

Looking really good. These projects need a serious amount of stamina! Have you got a realistic target completion date?

[DJWilma]

The summer

 

Just not decided on a year yet

[jonnyfox]

Ha ha me too.