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project GO SLOW!!!!! rs2000 turbo track car


hardasrs

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this is my W reg rs2000 what has a boreham motorsport shell with no sunroof, it was my daily drive for a year then i brought my rs2k 4x4 as a work car and got a focus st170 estate as a family hack then decided to turn it into a track car and 400 bhp.

 

on the outside it is mint but as with most escorts it has hidden rot,

 

http://i626.photobucket.com/albums/tt342/HARDASRS/rs20001-1.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000-2.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000photes699.jpg

 

brought some black 17" team dynamics pro race 1.2 to go with the track look i wanted and there pretty lite

 

http://i626.photobucket.com/albums/tt342/HARDASRS/034.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/033.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/116.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000photes701.jpg

 

had to get a new battery tray welded in when the passenger foot-well carpet started getting wet. so had to strip the front of car car out and found rust on both sides near the door seals so brought a welder and had a go at patching it up.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsholpicsm01039.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000photes689.jpg

 

next on the list was a safety devices 6 point bolt in roll cage what i brought from Chris Birkbeck Rally Sport, took 2 moths to be made up in Poland, as i wanted just a 6 point bolt in and not a full multipoint bolt in cage so had to be custom made for me as they only sell a 6 point to fit a sunroof model and also i got them to add a cross section with seatbelt bars.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/050.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/049.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/046.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsholpicsm01021.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/045.jpg

 

brought 2 kevlar cobra imola s bucket seats re-trimmed in jaguar oatmeal and 2 schroth/safety devices 6 point harness, i had to make up my own seat mounts with runners as i didn't want them fixed so other people can drive the car.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/053.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsphone462.jpg

 

this is a maxi style swivel beam made by Andrew@A.L.D, have not got any pics of this as its still in bubble rap.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/31455532dc440dc797a10c95877da7e5c98.jpg

 

if ever the car does catch fire then I'm fooked big time , but have got a S.P.A electrical plumed in fire system to go in the car what would hopefully give me a few second to get the hell out of there if it ever catches fire.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/101_3342.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/101_3341.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/101_3345.jpg

 

the alloy tank i have is a radtec made one 40L it has a stump on the bottom with fuel collector inside and safety foam and fuel sender.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/101_3323-1.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/101_3319.jpg

 

here is AP racing brakes, I'm well happy with them as i only paid £400 for them. there 330mm 4 pots but only problem is they came of an st170. i did have mk3 Mondeo calipers and st170 discs fitted beforehand.

well my st170 ap racing brakes fitted with no mods needed, with the pro race 1.2 wheels there is still bags of room.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/fathead2426.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/fathead2425-1.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar99052.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar99054.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar99061.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar99059.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar99065.jpg

 

 

 

 

 

cant upload to many pic's at once so will be in sections

Edited by hardasrs
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didn't have much nice to say so made my comment smaller

 

 

wheels too big and too much power for FWD. Cage looks nice but you might as well have gone for the 16 point jobby for how far you've gone with this car

 

i wouldnt rly say the wheels were too big, loads of people run 17s on escorts...as for the power id be interested to know how you plan on achieving this figure. and as for having too much power, there are loads of focus RS (mk1 +2) or even frst's that produce more power than that so i wouldnt say its too much power for fwd. u are however gna need some serious running gear to keep it all under control though

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i have had to convert my fuel system because i have one of Andrew@A.L.D maxi style rear beams to go on the car, for the beam to fit the standard fuel tank needs to be binned. i know running the fuel lines in the car might be a safety issue but all fittings are Aeroquiped and running Teflon (PTFE) Stainless Steel Braided fuel lines, if i should smell fuel or see any leaks inside the car the car the only plus point is i will be able to pin-point it and sort it out sharpish. have fitted a 2L swirl pot, bosch 044 fuel pump, low pressure fuel pump, saff cosworth fuel filter, sytec bullet fuel filter and an one way check valve. i also had to modify Andrew@A.L.D rear strut brace because i needed to some how mount the Ralloy fuel filler bowl.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsphone478turbo.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsphone476.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsphone474.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsphone472.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000photes694.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/rs2000photes693.jpg

 

the best bit massive Spec turbo engine, made by Motorsport Developments in blackpool (rs-2000-turbo got this engine built up and it still not been run)

 

Its been converted to a 2.2l using a 2.3 crank, SO its known as a stroker and was built to run 500Bhp.

 

Technical Notes

 

Mains bearings size 0.25 undersize

 

Big end bearings 0.25 undersize

 

Installed top ring gap 0.40mm

 

Installed middle ring gap 0.45

 

Installed oil scraper ring gap 0.40mm

 

Crankshaft end-float 0.14mm

 

Big end axial play 0.11mm

 

Big end bolt length after stretch 51.04mm

 

Camshafts dialed into Inlet 114 DEG Exhaust 108 DEG

 

Engine measurements after machine work

 

Bore 86.50mm

Stroke 91.00mm

Swept Volume 534.72

Clearance volume on all 4 cylinders is 83.0cc

 

Compression Ratio 7.45:1

 

Machine Work

 

Rebore existing block

Bore Honing (cross hatch)

Fitting under piston oil jets

Crank grind and polish

Dynamic Balancing

Port and polish head ports

Skim head flat

4 valve guides and seats

Modify sump for crank

 

Replaced all the following parts with high quality new parts

 

JE custom pistons and rings

Farndon custom H - Section steel rods

Crank main & big end bearings

Thrust washers (U&L)

Oil pump

4 under piston oil jets

 

Ancillary Components

 

Genuine gaskets and seals

Genuine head bolts

Camchain

Camchain tensioner

Camchain guide

Camchain head guide

Oil pump chain

Oil pump chain tensioner

block to turbo oil pipe

Block oil bungs

Block breather fittings

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSC00090.jpg

 

this it a Tigart over the gearbox manifold, it is being modified, first, it is being brought 3" forward nearer the slam panel so i wont have any access problems with the thermostat now, second, my new turbo a gt2871r has a t3 flange and the tigart had a t25 so that coming off for the t3 flange and a pipe added or the 45mm turbosmart external wasegate.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF1286.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/PICT0015.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSC00085.jpg

 

bit the bullet and brought this for £740 of a chap on the sxoc site and has been built for up to 465 bhp. he got it is brand new and it is was a special order direct from Garrett as most gt2871r have an internal wastegate but this don't as it has an t3 housing so I'm going to have to go external plus it will be better at controlling boots now. it has 0.63 exhaust housing so should spool up pretty quick too. for the wastgate i brought a Turbosmart Hyper-Gate 45

 

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsnepics1260.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsnepics1257.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsnepics1254.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/mumsnepics1246-1.jpg

 

trail fitted mg zs front splitter i got a genuine one for £40 off ebay. once fitted i think it looks good and a little different from the normal splitters, but will look much better when its sprayed white. got to make up some end bits as there to small and looks odd.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/robphone027.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/robphone043.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/robphone041.jpg

 

have got lots of other parts but not fitted them yet, will add more pics, cheers for looking:)

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would it nt have bee easier to go zetec turbo no?

 

dont by any means think im advising you to do that as this is an awesome project, i just know the rs2k unit doesnt respond half as well as the zetec does to tuning

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would it nt have bee easier to go zetec turbo no?

 

dont by any means think im advising you to do that as this is an awesome project, i just know the rs2k unit doesn't respond half as well as the zetec does to tuning

 

when i first started this track project about 4 years ago, it was only going to be running the standard rs2k lump, but the turbo lump turned up at a good price so all my plans change, every one goes down the zetec turbo path, dont see to many rs2k with a blower fitted. cars not finished yet. just a hobby really.

 

Quaife MTX-75 ATB diff

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts141.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts317.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts316.jpg

 

 

 

motorsport RS2000 quick rack 2.25 turns lock to lock

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts311.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts313.jpg

 

 

venhill braided brake lines front and back with fittings.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts322.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts327.jpg

 

 

wilwood bias valve for the rear.

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts157.jpg

 

 

single pass custom intercooler (was made for rs-200-turbo) fits just in-front of the radiator with no mods needed at all,

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts337.jpg

 

 

S.P.A design duel gauges

 

fuel pressure/ water temp

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar496.jpg

 

oil temp/oil pressure

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts161.jpg

 

volts/ fuel level

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscar476.jpg

 

i wanted to have the gauges visible so removed the heater control unit and placed the gauges there.

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts062.jpg

 

as the car will still be road legal i wanted to keep the heater matrix and heater control so i had some spare carbon fiber and relocated it were the stereo once lived (not finished yet)

 

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts078.jpg

 

eBay bargain. got the flocked dash for £60

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts089.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts243.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts229.jpg

 

 

carbon fiber door cards front and rear with pull straps from performance-trim.com

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts103.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts106.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts114.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts121.jpg

 

 

KW Coilover Kit - Variant 2

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts125.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts132.jpg

 

 

RS 4 spoke steering wheel what has been re-leathered by a chap who works for Bentley

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts067.jpg

 

 

brought this cover of a chap on here, like the look of it but needs a tidy up

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts163.jpg

 

gordon spooner f2 bias pedal box

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulscarparts302.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts135.jpg

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Great project. Look forward to seeing it go.

 

The only problem with fuel lines in the car is that it absolutely stinks, may not be a problem for you, fuel gives me headaches so might just be me.

 

I have to say i'm worried about the undersized crank, especially with the horses you're after, you're gonna be hauling some boost on that thing.

 

I do like that exhaust manifold though.

 

Good luck with it mate.

 

How big a gap is there between intercooler and rad? Wants to be about an inch or you'll cook the engine.

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Great project. Look forward to seeing it go.

 

The only problem with fuel lines in the car is that it absolutely stinks, may not be a problem for you, fuel gives me headaches so might just be me.

 

I have to say i'm worried about the undersized crank, especially with the horses you're after, you're gonna be hauling some boost on that thing.

 

I do like that exhaust manifold though.

 

Good luck with it mate.

 

How big a gap is there between intercooler and rad? Wants to be about an inch or you'll cook the engine.

 

 

thanks

 

the fuel lines are PTFE Core (Teflon) so should stop the smell coming through

 

intercooler has plenty of room from the rad

 

to tell you the truth, im not all that clued up engine wise, what's the problem with the crank, was built buy a good engine builder at a cost of 6k

 

maxi style swivel beam made by Andrew@A.L.D, tried to show some of the movement

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts049.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts040.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts041.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts043.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts058.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulrs2000parts051.jpg

 

turbosmart eBoost2 40psi boost controller, just got to figure out where I'm going to mount it now,

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/112_3991.jpg

 

got my nissan sr20det injectors today after waiting over a month for them due to the Canadian postal strike,

they are rated at 780cc at 43.5psi/3BAR fuel pressure so good for 415bhp at 80% duty cycle and at 4 bar 860cc and be good for 460bhp. also came with caps to hold the injectors in place. got the injector loom of sxoc.

 

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsinjectors008.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsinjectors025.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/paulsinjectors040.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/injectorscan.jpg

 

Turbosmart Dual port blow off valve(4 in 1) so ive got a few choice's of sound or non at-all

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3264.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3266.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3270.jpg

Supersonic

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3268.jpg

dual port

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3276.jpg

plumb back

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3274.jpg

Megasonic

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3272.jpg

Andrew@A.L.D done my flywheel

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3281.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3280.jpg

Turbosmart external wastegate Hyper-Gate 45mm 2011 modle

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3256.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3252.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3254.jpg

will be doing a hydraulic clutch conversion brought a Wilwood slave cylinder

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3278.jpg

Turbosmart 800 fuel pressure regulator and fuel pressure regulator gauge

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3248.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3249.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3262.jpg

2x manifold flanges to make up a spacer to bring out my Tigart manifold about 3" to clear thermostat housing, the manifold will be in 3 parts so hopefully it wont crack as its over the gearbox,

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3283.jpg

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The smell will still come through.

 

You may well get away with the crank, Ford cranks are pretty strong. Anyway, grinding journals of cranks makes them smaller and weaker, then putting boost on top of it puts a lot more loading on them. As i say, it might be fine. I don't have any experience with the 2.3 stuff but going by Zetec and RS2000, it wouldn't take it.

 

But that's enough of a downer on this good thread. Carry on Sir.

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had to order the external fire and kill switch recess direct from lotus, there off the Exige Cup, not cheap at £200, wanted something different and proberly will make up a black surround like the one in the last pic

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3246.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3242.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF3212.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/j.jpg

 

cutting two big holes in the wing, i must be mad lol

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41362.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41302.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41282.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41272.jpg

 

just used electrical tape for the surround to see how it would look, will get something properly made up for it,

 

got a carbon fiber mondeo super touring car rear spoiler like this one

 

 

http://i626.photobucket.com/albums/tt342/HARDASRS/250.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/KGrHqNi8E7DBhF4hGBPZdQ4KeD60_12.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/KGrHqRHJEQE88dEze0oBPZdQ9LYDQ60_12.jpg

 

needs to have a little bit shaven off the alloy brackets to sit flush on the boot,

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41572-Copy-Copy.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41492-Copy-Copy.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41482-Copy-Copy.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF41602.jpg

 

my new inlet has arrive from Andrew@A.L.D and had to get some pics up, im very happy with it, its a prober meaty bit off kit so will handle boost pressure no problem, got trumpets fitted inside too. will still be using standard throttle body, its for the turbo engine so air is forced through anyway plus want to keep the precision on the throttle pedal, don't want to be at full air flow with fitting a bigger tb and only having the throttle pedal half way if you get what i mean, but if it dose not work out there is plenty of meat on the new inlet to fit bigger. flow is 50% more than the standard plenum,

 

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF51612.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF51602.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF51592.jpg

http://i626.photobucket.com/albums/tt342/HARDASRS/DSCF51582.jpg

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Nice build. Crank will be fine. Injectors aren't a direct fit into a Ford manifold though, if you value using o-rings properly. I'd get your fabricator to modify the manifold to take end-fed injectors.

 

RS2000 is a much better engine than the zetec.

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