My RS Turbo - Plenum project (+ MORE!)

BenTaylor · Post by **BenTaylor** » Tue Oct 28, 2008 10:32 am

Awesome work, love seeing all the mental stuff you do with this engine

Christian and Beccy · Post by **Christian and Beccy** » Mon Jan 19, 2009 2:57 pm

Time for a bit of an update. I was going to leave it until I had more done, but I didn't want to end up swamped with progress material!!

So, next step was to begin with the MTX Gearbox conversion. After buying a Series 1 front suspension set-up, which initially looked like it was in nice condition, but transpired to be not quite so, I decided that I wanted to stay with my Turbo Technics front suspension set-up. I've run it for years, its MINTIER than MINT and I like it. So, I set about designing my own MTX brackets to allow me to stay with the TT bits. This conversion would essentially allow fitment with standard suspension (of course that doesn't apply to me), but just a point to note.

First came the wooden mock-up.......

I designed this to work with the Series 1 style mounts, which I had already bought from Rapid-Ford (thanks Dan/Natalie).

This was closely followed by the metal version of the wooden bracket, I am very pleased with how this turned out......

....which was then welded onto the car.

Well, obviously, by this point I was commited to some repainting. :lol:

In for a penny, in for a pound. :lol:

Pics to follow.......

Christian and Beccy · Post by **Christian and Beccy** » Mon Jan 19, 2009 2:58 pm

I got busy with the Welder!! Obviously an engine bay naturally has alot of holes, some needed, some not. F**k it, lets just weld everything up!! PMSL.

Then the alterations I had to make from when I converted to run the alternator on the back of the engine were finally made-good. Previously it was a bit 'temporary'. :lol:

Followed by a bit more welding/grinding.......

....and a bit more.......

.....and more still!! :lol:

I re-did the battery tray side, because I wasn't ever really very happy with it, so thats totally flat now. At this stage, I was feeling VERY VERY daunted and VERY VERY deep in the shit.

To be continued........

Christian and Beccy · Post by **Christian and Beccy** » Mon Jan 19, 2009 2:59 pm

I also had made a rather handsome Alloy Strut Brace. I think it will be strong enough. :lol:

The configuration now allows me to run a straight brace. Did I mention that the engine is 30mm lower than standard?? :lol:

On that subject, here is the other mount that I modified to lower the engine and I gave it some more strength while I was about it. I did get Gary/Chris' help with the welding up of holes in the engine bay, but I did do a fair bit of it myself and certainly the heavy-metalwork I can weld, having just played around and practised.

Then I managed to track down somebody to paint the engine bay. Hmmmm, now there's another story!! :x :x

Christian and Beccy · Post by **Christian and Beccy** » Mon Jan 19, 2009 3:00 pm

Oh go on then, a bit more.

I bought a brand-new genuine Scuttle panel and although mine didn't really need doing that bad, there was some mild corrosion at the bottom of the screen and some other paint damage (all caused from when the car got paint-strippered a few years ago). Paint stripper had got under the windscreen seal and done it damage. Shame really, it is in amazing condition apart from that. Anyway, I had that fitted and also a new front panel. Again, Paint stripper had got into one or two places and caused some agro. Thats all fixed now, alog with further no-longer-needed holes. More pics of that later.

For now, savour some more of my woodwork.......

In the worlds of my old mate Rolf, "Can you tell what it is yet??". :lol:

Christian and Beccy · Post by **Christian and Beccy** » Mon Jan 19, 2009 3:01 pm

So, here's a look at the new Intercooler. Also a peak at the painted 'bay. Can't show you that yet as it will give one of my other 'tricks' away. :lol:

Anyway, I've always had GREAT results with the GRS and its only for the sake of messing wth stuff that I have decided to have a go at something else. I am very sceptical, why fix what ain't broke and all that. This cooler is 60mm thick and a fancy dense core. Don't really remember the in's and out's (that conversation was had a while ago), but its quite spangly. Of course its single-pass too. I do favour twin-pass, but you don't get anywhere if you don't try!!

I have got myself into a position with this car that I really didn't want to get it. One part of me is sick of it and wants to bail out, but another has a curiosity to have a bit more fun in it. I just don't feel like I'm quite done with it.

The plan is for it to be a bit more of an all-rounder though and in all honesty, I just want to drive it.

The reality is, I'm absolutely fucked and seriously stressed out over it, as I said earlier, I am in WAY over my head, can't afford to pay someone to do the work, but can't leave it unfinished either. So, I'm grafting to get it done and just tackling it. Then I really want to leave it alone and enjoy it, perhaps even do the odd trackday!

RX7 · Post by **RX7** » Mon Jan 19, 2009 3:54 pm

It'll be worth it when done mate and very unique !!

I like the way you are thorough and scratchbulid mockups first :thumb:

pablo · Post by **pablo** » Mon Jan 19, 2009 5:19 pm

Excellant work

The feeling you'll get when it's finished will make all the agro worth it. Once ours is up and running we plan to come over with it and chat over a few igeas that we have for it. We'll book it in first as we know how valueable your time is.

Coyote · Post by **Coyote** » Mon Jan 19, 2009 9:49 pm

Good on ya mate! Old Fords rule!!!!!! :twisted:
Wait for it! gonna get hate mail on here for that statement I bet :roll: :lol:

Christian and Beccy · Post by **Christian and Beccy** » Tue Mar 03, 2009 2:44 pm

Update time!!

Further to the Wooden Intercooler, I thought it was only right to use items sourced from B&Q to make the Intercooler pipes. :lol:

Firstly, the Intercooler to Throttle Body pipe. This is 60mm, made from Marley PVC Pipe and bonded with Hot Glue. I hope it will be OK for 30psi of boost.

I'm pleased that I have been able to have such a simple pipe for this part of the system. The Air Temp sensor is mounted underneath hidden from view.

Next, the Turbo to Intercooler. The turbo exits at 52mm and whilst I would have liked to make the pipe 60mm due to the necessity for the tight bend at the end, it really couldn't happen. However, I really think that, taking into account the power I want to achieve, 52mm is plenty. Also, both pipes are relatively short and simple, so the fact that there is one serious bend doesn't really worry me too much.

Off to the fabricators they go to be made from Alloy. Hope they won't be too expensive, I'm FAST running out of money!