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Zetec Turbo Build: 230-250whp, then 330+whp

175K views 657 replies 57 participants last post by  starfuryt550 
#1 · (Edited)
I thought I would finally post my plans as this is getting much closer to being all put together after a long time collecting parts:

* My goals are 300-330whp once I put in the new engine I am building.
* Current goals on the stock engine are 230-250whp.

I suppose I will start with a parts list, let me know if I am missing anything:

Vehicle:
- 2002 ZX3, manual tranny, 88k on clock.


INITIAL (on stock block):
- Turbonetics T3 super 60 .43 AR turbo, ceramic exhaust coating, polished.
- Turbonetics EVO wastegate (multiple psi springs)
- Custom manifold by TurboFab
- Custom DP and WG dump by Top Speed
- SVT 2.5" trubendz exhaust conversion
- Zetec 2.5" trubendz flex pipe
- 50lb injectors
- 2000 Intake manifold, ported
- Focus Central 70mm throttle body
- 180* thermostat w/new housing
- Lakewood traction bars --> might switch to TopSpeed's new design once out
- FS lower stress bar --> Will have to come off as the dp will not clear with it on
- CFM billet aluminum tensioner
- Massive 3 piece UDP
- Gates racing timing belt and acc belts
- Focus Power piping and intercooler
- Greddy type-S BOV
- Innovate wideband AF gauge
- AEM TruBoost turbo controller gauge
- Autometer digital oil pressure gauge
- STR high flow fuel rail
- EGR blockoff plate
- CFM breather plate
- SCT flash tuner
- TopSpeed battery tray/catchcan, slim battery, new terminals
- New much better conduction 1666 strand power cables, new grounds.
- stage3 coolant tank
- stage3 power steering tank
- JayRacing aluminum coolant junction
- New silicone vacuum hoses
- New billet aluminum vacuum junction
- ARP head studs
- New silicone coolant hoses

12/25/2010
* I am switching all of the cooling system including hoses to -an hoses from 16 for the largest, 12 for mid size, and -6/-8 for smaller lines. Dominic is going to make a me a new -16an billet flange and fitting to attach to the stock thermostat housing as well as fab up an aluminum radiator w/-an fittings and side tanks.

* I am converting the entire power steering system from the retarded rubber and hard lines passing over the header to complete -6an lines with a fluidyne cooler to replace the makeshift crappy stock cooler. (Check posts on pgs 2-3+ for info on this and progress. It will soon be made as soon as the snow stops and I can go outside and take some measurements).


POST BUILT ENGINE:
- 2000 zetec block
- 9.0:1 Probe pistons
- Eagle Rods
- Stock bearings
- New svt oil pump
- new svt water pump
- Centerforce billet 9lb flywheel
- Torsen T2 LSD
- APR flywheel bolts
- ARP main bolts

* I may be missing things I have but I will try and remember...

* All of the above I have already bought and have installed some parts.



My questions are:
1) I need a clutch at some point, im sure it won't last long. I need some recommendations. I dont have a ton of money for this so an Exedy hyper-single for $1,100 isnt good lol.

2) I was going to have Terry Haynes from HMS install my LSD...he recommends getting the tower keyed, recommendations?

2.1) I was also thinking new shift forks in the tranny if i do a complete overhaul?

2.2) I wanted to lower my final drive gear to one from a duratec or zetec to a 3.41 (if i remember the num correctly) with pzev. Reason being to ease the power off the line for better traction.

3) I know my T3 super 60 is good for 325-330 if i remember correctly. What would be a good replacement after I want more power?



I'm gonna have more questions, but I will appreciate thoughts, comments, suggestions, criticisms!
 
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#3 ·
sexy.

that's a REALLY nice build you got going on.
 
#8 ·
i disagree, but i am sure the difference is minimal. i ran the MSD coil on both my nitrous zetec car and my SVT motor and it was perfectly fine. its a good coil, but so is the stocker.
 
#9 ·
Had to buy new rear discs and pads.

Dismantled all calipers and took them in for powder coating.

That was about it yesterday. Didn't get too much time for [:)][:)][:)][:)][:)][:)]*.

also painted the front discs black so they won't rust.

I got for the rears:
- Hawk HPS pads
- Centric blank discs, black.
 
#14 ·
I have the tool for that, I just can't get the interior mechanism out to remove the rear seal.

It's alright though, I dropped if off at quick lane and they said not to worry they'd take care of it and have it done early in the morning!





 
#16 ·
I have some issues to report, not with this, but my daily driver:

My clutch is shattered into pieces on the mazda3.

The differential locked up, literally exploded, destroying the shift forks and the gearing inside the tranny.

Mazda quoted me $4,200+tax to install a new tranny and a clutch. FML

I got some good things going, though, thanks to some friends and Elliot on here for helping me out.

Looking to get a 2009 2.3L manual tranny with 11k on the clock for $300 from the dealer/shop we got my moms car from last year.

OEM or replacement clutch for $200-300

Installation for $300.

If this all works out I will be ecstatic. If not, FML again lol.
 
#22 ·
dude, you're luck is terrible this week it seems man.

good luck with everything. hope insurance is taking care of it.
 
#27 ·
Nice stuff....looks like a parts store/speed shop..
 
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