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Old 04-11-2010, 10:38 PM   #1
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Wagamos' turbo rebuild inc. engine

Some of you know me on here. I had a ton of problems about a year or so ago installing a used turbo kit. Got it up and running and then last fall I tried to push the engine a bit further and the engine decided that it didnt want to. I started to notice smoking on warm starts. Checked compression and it was like 50 psi lower in piston 4. I lowered boost and made it through winter and still is running now.

How she sits


I figured Id like to fix up the car this year with taxes soo.... My plans are

-build an engine so I can push ~280-300whp eventually
-new manifold to replace mine b/c it keeps cracking everytime I get it fixed.
-new wastegate because my valve is bent on it.
-probably redo some of the IC piping n such.

A few weeks ago I purchased a svt engine sans the head for $200. Figured SVT internals + std zetec head = golden. Was advised to just put in new rings and bearings. Found out it had more wrong with it than I thought. Pistons had hit the head. When I pulled them out today I found that 3 of the 4 are toast. 1 had part of the piston by the rings fall out when i pulled it. Two others are cracked in the same area. Also found metal shavings in the oil pan and turned out the rod bearings on piston 1 and 4 were shot as well (hence the shavings). Now comes the even stranger news. They are not oem pistons that I pulled.

Engine partly tore down.


Different Piston tops


Different Piston


Piston Carnage


Oil pan Carnage


Tom said that Ford pulled a bunch of svt engines and rebuilt them. I think that is what i have but they have 050 stamped on the pistons so i assume they are .050 over bored. Is this a safe bore to still boost on? Also curious if anyone knows where I can get pistons this size. If worse comes to worse I might dump the block and start over with lower mileage engine with hopefully no bore issues, but then id be talking all new internals and down $200. Im trying to keep this as affordable as possible and since im not shooting for crazy whp i was hoping to keep cost down with svt internals.


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Old 04-11-2010, 10:57 PM   #2
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little off topis but how did you get your battery where it is??? how did you mount it i like that spot
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Old 04-11-2010, 11:16 PM   #3
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you can use a duratec battery box.

that sucks about the engine. i know how you feel. my new v8 is in pretty bad shape as well... your almost better off just taking out the regular zetec and building it with some probe and eagles
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Old 04-11-2010, 11:40 PM   #4
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^ agree with eagles and probes. But that does suck. I hope I don't end up seeing that. lol. Good luck though.

I can't wait for the progress.
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Old 04-12-2010, 12:17 AM   #5
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Glad to see your getting her fixed Jeff. I'll keep my eyes posted on this thread.
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Old 04-12-2010, 12:34 AM   #6
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bummer...
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Old 04-12-2010, 01:06 AM   #7
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I made a piece to go over the mount with a little support and then rubber straps. I want to make it better but havent gotten around to it. I might look at the duratec battery. I know probe and eagle would be easier, but also $800 about more for a bunch of power range that Ill never use. Thats why I wanted svt internals. Im wondering if I can find out where ford had these svt replacement pistons made and maybe pop a new set in or something. Just waiting on tom or someone to chime in. I wonder if I have to scrap this engine or what.

The only plus here is that im not really pushed for time. My car still runs even if it does have lower compression. I wanna do stuff right. Also want to build it as much myself for experience and to save money.

Im really nervous about buying another block. I usually have this kinda luck with stuff. Id hate to grab another engine and then find out that I need to bore it. Would like to save that cost and just hone it.

Thanks everyone.
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Old 04-12-2010, 06:55 AM   #8
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i got my block bored honed and cleaned for $162 very cheap
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Old 04-12-2010, 09:43 AM   #9
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if you wanna do it right then it is going to cost money. if your rod bearings spun there is a good chance that the crank is ruined or at least need to be turned and larger bearings put in. which would probably cost more than a focus crank is worth. i can understand you wanting to do it cheap but i really think getting your hands on some new ford over bore pistons and all the machine work will cost just as much as going forged.
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Old 04-12-2010, 10:46 AM   #10
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I got some news for you buddy, those are stock zetec pistons, aside from the .050 stamp

plus the intake valve relief looks a little hogged out on both sides and between the reliefs on the exh side is a little different.

based on this my guess is the .050 stamp means the crown height on them is .050 higher and they just modified the crown design to accomodate the differences in the SVT head

Here is stock zetec vs stock svt



and yours again to compare without scrolling forever

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