I’ve decided to change the car around again. The motivation this time is to get the car running with a bit more power for the Albury Auto fest.

For those that didn’t see my last turbo thread, I rebuild the engine abit over a year ago. It was nothing special, balanced bottom end, ported head, ED pistons, stainless valves, modified inlet manifold. It was all a big learning experience for me as I’ve never really done any mechanical work before, and working in the IT industry I don’t get exposed to anything like this. Nether the lest I did 90% of the work myself, and after getting a quick tune to run the engine in, it made a good 260RWKW on 10psi.
I was fairly happy with the result, but I always was going to go back and get it tuned properly to around 15psi after the engine had been run in.
I’ve been driving the car for work over the last year and have done over 20,000 ks with no dramas at all. Its been a great daily driver, which is easy to drive in traffic, doesn’t over heat, still has things like aircon and cruise control, and I’ll get 9.5 litres to 100k’s on the highway..

So the new list of things to do is:

Injectors: Siemens Deka 600cc to replace the current 360cc ones
Billet fuel rail.
AEROMOTIVE 1:1 fuel regulator
Larger fuel line
Intake plenum: Simular to the ones Ebs_4l make
80mm Throttle body
Billet crow cam
New Lash adjusters
MSD coils
MSD DIS4 ignition
Some more mild head porting
Powerbond harmonic balancer
2500RPM high stall converter
Replacement auto.
Lokka lock rite diff
Front shocks
B&M line locker
Fairlane Dash Modified with Line locker warning light
New power/earth lines from the battery in the boot
Setup a Apexi RVC-R boost controller

If I get time, and want to loss the sleeper look
EL/BA XR hybrid front and rear bumbers
EL XR bonnet vents.

So as you can see I’ve got a few things to do and the Albury Auto fest is on the 23-25 so it only gives me a few weeks to get it all done and tuned..

I started yesterday morning and pulled the inlet/exhaust manifolds out, and pulled the head off. To my surprise the head gasket is absolutely stuffed. The water jackets, especially the rear ones on the gaskets have been badly corroded.
The only explanation I’ve got at the moment is it’s from electrolysis, mind you, there is no extra corrosion on the head/block. I’m running an allow radiator, which might need to be grounded better..
It was a good quality permiseal head gasket also. I might look into using a different brand when I put the thing back together.

I did a bit of work to the head today, and also open up the bottom half of the inlet manifold a bit more.
I’ll drop the head off to get a very light surface on Monday, and drop the bottom half of the inlet manifold of to get polished.

I’m going to get the rocker cover polished also, but I’m not sure if I should get the EF one done or an AU one. I think the AU ones might look a bit better polished with a box plenum, any thoughts?

There isn’t a lot more I can do today: maybe Pull the old fuel line out: Run new wires for the MSD DIS 4. Clean the block surface.

As always I’ll take heaps of progress pictures to keep you guys up-to-date.

A couple of pics of what the car looks like at the moment



Old Engine Setup



Current Bottom Inlet Manifold


Corroded Head gasket

I just got off the phone to Geoff from Snort Performance about a new wastegate spring. When I put the engine together, I ran the lightest spring possible to make sure I wasn’t going to have any over boosting problems whilst I was running in the engine.

As always Geoff is been more then helpfully and is organising a stronger wastgate spring for me.

To give a shameless plug to a buisness, Snort Performance have been and incredible help with everything I've done to the car, from suppling hardware to sharing their vast turbo'ing knowledge, and I'm sure I wouldn't had such a good result without all their help..

anyway, back to cleaning up my inlet ports......

Looking very sleeperish there
Nice looking underbonnet setup though

looking good.

whats that blue line coming of the catchcan then going over the plenum?

do u have any problem with oil being sucked up by the vacum line going to the turbo?

Very nice!

The blue line runs back to the manifold with a one way valve on it. The line that runs over to the turbo intake wasn't providing enought vacumn at idle. So, when its off boost the manifold provides vacumn, and when its on boost the turbo inlet provides the vacumn, and the one way valve stops the manifold boost pushing back into the catch can.

ok i see thats a good idea, thankx

I'm selling off the parts I'm not going to be using again.
A list can be found here
http://www.fordmods.com/forums/viewtopi ... 054#584054

I've cleaned up around the valves on the inlet ports. This took alot more time then I originally thought. Mostly because I've been hand sanding it to get a nice smooth finish, it was just too tight to get into with the die grinder...


Anyway, I think that’s all I'll end up doing with the head, I spend a few hours rounding off the ports on the inlet manifold, and removing the external casting marks, Its hard to see in the photos, but they are now nice smooth rounded edges . Nows its off to the polishers to see what they can do..

mate, looking really good and nice to see you did most the work yourself!

You have a PM !!
also what computer are you running with that setup ???

I'm running a Wolf 3d V4 ECU.

holy s**t if i pulled up next to you i reacon id think to easy...
i would get show up so bad id cry...
your car will be nuts inside and out ones your done...
are you gona put mags on??? if so what are you looking at???
nice work mate...

Well, Just a quick Update.
Things are moving a little slower then I need them too.
I've dropped an AU rocker cover and the bottom of my manifold off to get polished. The polishers have told me I'll be luckily to get them back before late next week, which will make things a little hard.
I've got my freshly reco'ed gearbox back, with all the go fast/strong bits installed, now’s its just a matter of fitting it back in with the dominator 2500RPM high stall.


My head is ready to be picked up, I'll grab it tomorrow. It just got a very light machine to make sure its dead flat, and the valves reseated. Along with the head gasket setup and a new set of lash adjusters it has cost me a bit more then I expected.

The new fuel rail is at the post office waiting to be picked up.

New injectors showed up a few days ago.

I'm picking up the new 10mm fuel line tomorrow and also 13 meters of 0 gauge cable to run new power/earth

I've started to setup the new 80mm throttle body to suit where I want to run the throttle cable, and also modify it to run the standard ford throttle position sensor.



So this weekend, I need to get the following finished.

1.Head back on.
2.Plenum made.
3.Fuel rail brackets made.
4.Gearbox re-installed.
5.Run new fuel line,
6.Run Power/earth lines
7.Install new Harmonic balancer

So its going to be a busy weekend for me.

I’m still waiting on the MSD coils, MSD DIS4 and fuel regulator to show up. These are getting me a little worried as they aren’t going to be straight forward to fit.