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Old 04-24-2013, 11:42 AM   #11
MainiaxMotorsports
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What I Drive: 2002 Rally-Spec SVT w/ 2.5L swap

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Quick Notes:

1. Battery has been moved to the back of the car
2. you will see a voltage regulator under the hood on the right - that was to trouble shoot an electric gremlin we finally tracked down - just left it in- lazy ;)
3. stock plenum, but REALLY would like to get the Cosworth style for flow - know the 2.5L inlets are larger - we shall see if that mates up
4. Tune will be critical (but i know a guy ;)
5. you will also see an aluminum braille battery box unit we had built - under the motor mount bolt - cosmetic at this point
6. Run HotBits suspension with 250 lbs springs for gravel, and 450lbs springs all around for tarmac - sways on tarmac, rear sway disco'd for gravel
7. Someone asked - i ran Advan A048 tires in a 225/50/16 config for the Tarmac Rally - however, should have run proper tarmac tires for another edge - lesson learned
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Old 04-24-2013, 12:30 PM   #12
Fernando_221
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Quote:
Originally Posted by 1turbofocus View Post
Actually the VCT doesnt work off 12 volts and never hits 12 volts it like most VCT works off of variable voltage off load vs RPM

If this isnt hooked up properly or a VCT Elim then he is loosing some TQ and HP

Tom
Humm I was suspecting about that, the VCT solenoid works with a voltage curv.
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Old 04-24-2013, 12:32 PM   #13
Fernando_221
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Quote:
Originally Posted by MainiaxMotorsports View Post
Ok, thanks to the ninjas on this forum - i am going for it. Here is what we are doing.

1. I have a 2002 Focus SVT Rally car - that started life as a production class vehicle in Rally America, USRC, and NASA

2. We then did a Zetec (out) for a 2.3L Duratec (IN) swap - the car is now Open 2wd Heavy and Group 2 depending on the sanctioning body. Runs the MTX75 Tranny. She runs great, is "competitive", but is not fast and requires a LOT of rev management to stay in the power band, and torque is really not there to dig out of corners on either tarmac, track, or gravel (insert also ice/now) stages.

3. I just bought a 2.5L Duratec i4 out of a 2010 Ford Fusion !!!!!

Let the Build begin......will be documenting each step on this thread for others to follow - including all HIGH FIVES, and OH SHIT moments....enjoy.

The Car with 2.3L Duratec


The Engine Bay with current 2.3L Duratec Setup



The Bell Housing w MTX75
[pic pending]

The Dash Cluster w Custom Wire Harness Circuit Breakers


The Car on Stage moving right along ;)


NEXT POST:
The new (pulled) 2.5L I4 Duratec from a 2010 Fusion Arrives
[pic]
If you use the 2.5l from 2010 Fusion, you'll have to cut the front cover (timing cover) near the PS pump OR use the 2.3 front cover.
When you put the stock Focus PS pump, the belt will not fit, it hits the 2.5 timing cover. You have to modify the cover or use the 2.3 cover.
If you cut the 2.5 cover, you have to weld some plate inside.

We have to do this on the 2.5 Focus swap. Better thing is to use the Focus 2.3 cover.
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Old 04-24-2013, 01:33 PM   #14
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Quote:
Originally Posted by Fernando_221 View Post
Humm I was suspecting about that, the VCT solenoid works with a voltage curv.
Basically yes , It gets its info for the curve mostly from Load and RPM but many other things come into play as well , need to get VCT Elim for the 2.5 , something I will have out soon

Tom
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Old 04-24-2013, 02:10 PM   #15
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figures I sell my car the year before people get serious about 2.5 swaps

this is great. looking forward to more pics as this progresses!
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Old 04-24-2013, 03:28 PM   #16
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Subscribed! Good luck with the swap
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Old 04-24-2013, 08:01 PM   #17
MainiaxMotorsports
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PLENUM for 2.5L Build

So, one of the ideas i wanted to make sure i addressed was the ability to goto a Cosworth Style plenum vs. stock intake. So, i reached out to a manufacturer, and searched the web.

1. Here is a pic of the 2.3L Head inlets i found on another forum
2. here is a pic of the 2.5L Head inlets below it (credit goes to the other forum poster)



3. The manufacturer says the bolts will line up, however, to get full advantage of the airflow capabilities of the plenum - a bit of machining can be used to open up the inlets on the plenum side

Here is a pic of the inlet side of the plenum style i will go with - my thought is to machine out some of that metal to insure it is matching the head side inlets in diameter.This way my TUNER has more air to work with.


Engine is supposed to be delivered friday !!!
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Old 04-24-2013, 09:23 PM   #18
reillydog
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Yea baby! Good luck Ty

Can't wait to see how this turns out.
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Old 04-25-2013, 02:02 PM   #19
MainiaxMotorsports
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while i wait for new motor - why not FLOCK THE DASH

So, i am a wicked cheap but i have always wanted to Flock my Dash in the Rally Car (aka Lil Red) to cut down on the glare of the stock focus finish (see pics)

So, i looked online at all the Flocking kits, services, etc. Too much.

I went to the local JoAnn Fabric store, and bought .666 yards (72" x 24") of black FELT FABRIC
$7
I bought some loctite professional grade spray adhesive
$13
I then bought an Xacto knife
$4

TOTAL PARTS $ 24



I popped out the air vents
I sprayed on the glue
i layed the felt out over the dash
wearing rubber gloves i smoothed it all out when tacky
i then trimmed all the edges

I dont know about you...but it looks BEAUTIFUL !!!!

BEFORE


AFTER


Took 30 minutes and $24
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Old 04-25-2013, 07:50 PM   #20
MainiaxMotorsports
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And out she comes ......

Had a little spare time this afternoon between conference calls - so started the 2.3L dis-assembly. And before i get flamed - YES, i know some of this could have stayed on the block as the new motor will have it - however, i may try to re-use some components (NOT THAT CHEAP PLASTIC INTAKE PLENUM - omg - what a pig - totally convinced the Cosworth Style Plenum is the only way to go......)

[IMG][/IMG]
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