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Old 07-03-2010, 08:06 AM   #51
zlatky
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Hello everyone!

I kinda disappeared lately but my work-load plus my modding chores and obligations left me with virtually zero free time!...Right, then!...

...So, after a long-long time, I finally managed to get the 14 (A-4 type) pages long modding-list of Ivan translated by my friend Costas Zikeloglou (thanks a *lot* mate!). I trust you will have plenty of free time yourselves before even attempting reading it, huh! You have been warned! (lol!) ...

...So here it goes then! Njoy!

*/me takes a deep-deep breath*



IVAN PROJECT CAR

Last update: 01 / 07 / 10

Owner: Alex Zlatky

Car model / code name:


Ford Focus ST 170 / RS Mk I “SE*, 2000cc, 5d. / Ivan Project Car


Featured / Participated at:


1) "Power Techniques" (November ’05 Greek issue - I.C.E. presentation)
2) Athens Tuning Show No. 2“Top 100” pavilion (20 – 24/09/06)
3) Athens Tuning Show No. 3“Top 100” pavilion (26 – 30/09/07)
4) "Max Power" (March ’08 Greek issue – cover page + total presentation)
5) “XL” (July ’10 Greek issue – cover page + total presentation)


Achievements:


o "Power Techniques" Awards: 1st place (out of 300+ featured cars) @ the I.C.E. Category for the period 1998 – 2006 (November ’06 Greek issue)
o Qualification to the top-20 Greek tuned cars stage at Dunlop’s “Hottest Wheels” competition, within the context of Athens Tuning Show No. 3 (2007) [120+ competing cars]
o “Power Techniques” – “Top-5 Dyno Fighters” Monthly Competition / “1.800 – 2.000cc Turbo Tuned Cars Category” (July ’10 Greek issue): Position: 3rd



Stats (briefly) – Phase 3 (up to date):



@ 1,7 bars (1,85 bars overboost):
Power: (Flywheel / Wheels) : 570 – 590 Hp / 512 WHP @ 7.610 rpm
Torque (Flywheel / Wheels): 60,4 Kgr. / 53 Kgr. @ 5.680 rpm

Total weight (approximately): 1.600 Kgr. +
Existing modifications: 174




* Converted from Ford Focus mk 1 – 1.600cc 5d Trend S.I.P. Collection (’04)



- Page 1 -


- TBC (To Be Continued) -
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Old 07-03-2010, 08:08 AM   #52
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LEGEND:

STD: Standard equipment
P1: Phase-1 modifications (1.600cc N/A)
black dot: Turbo-phases. Namely,Phase-2 (1.600cc turbo) + Phase-3 (2.000cc turbo) modifications



Costs category:

Κ1: 1 – 500 €
Κ2: 501 – 1000 €
Κ3: 1001 – 1500 €
K4: 1501 – 2000 €
Κ5: 2001+ €


Orange coloration: Indicates already purchased modifications which will be applied / installed in the next 15 days.

Blue coloration: Indicates parts which have already been ordered and will arrive in the next 30 days.

Red coloration: Indicates parts which are already installed and will be removed / replaced in the next 15 days



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Old 07-03-2010, 08:09 AM   #53
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ECU adjustments & dynos of Ivan Project Car - Phases 1 & 2 (w/ Zetec SE 1.600 cc. engine installed):


Spring ’05

1st (non-turbo): HP: 122,4 Torque: 16,1 kgr.



04/11/05

2nd
(Turbo): @ 1,0 bar: HP: 270,0 Torque: 42,0 kgr.
[@ Mallioras Bros dyno]



Feb. ‘06

3rd
(Turbo): @ 1,18 bar (1,20 over-boost):
HP: 277,0 Torque: 43,0 kgr.
[@ Mallioras Bros dyno]



25/5/06

4th (Turbo): @ 1,14 bar (1,22 over-boost):
HP: 258,0 Torque: 38,0 kgr.
[@ Mallioras Bros dyno]



14/9/06

5th
(Turbo): @ 0,73 bar:
HP: 240,4 Torque: 31,5 kgr.



19/10/06

6th
(Turbo): @ 1,20 bar:
HP: 285,2 Torque: 33,6 kgr.
[@ “Powerland” dyno]



21/03/07

7th (Turbo): @ 1,50 bar:
HP: 280 / WHP: 251 @ 5.860 rpm
Torque (wheels): 32 kgr. @ 5.300 rpm
[dyno @ “Plex Tuning” – Yannis Andrianakis]



29/08/07

8th (Turbo): @ 1,50 bar:
HP: 312 / WHP: 280 @ 6.330 rpm
Torque (wheels): 34 kgr. @ 5.420 rpm
[dyno @ “Plex Tuning” – Yannis Andrianakis]



16/10/07

9th (Turbo): @ 1,50 bar:
HP: 321 @ 6.274 rpm
Torque: 38 kgr. @ 5.329 rpm
[dyno: “Dynomet Dk” – Option Press Publications]



01/02/08

10th (Turbo): @ 1,50 bar:
HP: 325 @ 6.270 rpm
Torque: 38 kgr. @ 5.320 rpm
[dyno: “Dynomet Dk” – Option Press Publications]



- Page 3 -


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Old 07-03-2010, 08:10 AM   #54
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ECU adjustments & dynos of Ivan Project Car - Phase 3 (w/ Zetec E 2.000 cc turbo-engine installed):



01/04/09
1st: @ 1,8 bar & with 5th gear:
Power (flywheel / wheels): 550 Hp / 485 WHP @ 7.340 rpm
Torque (wheels): 49 Kgr. @ 6.280 rpm
[Dyno: Plex Tuning – Yannis Andrianakis]



04/06/09
2nd: @ 1.9 bar & with 5th gear:
Power (flywheel / wheels): 560+ Hp / 489 WHP @ 7.420 rpm
Torque (wheels): 51 Kgr. @ 6.240 rpm
Ambient temperature: 37oC
[Dyno: Plex Tuning – Yannis Andrianakis]



19/05/10
3rd (current): @ 1.70 bar (1,85 bar overboost) & with 5th gear:
Power (flywheel / wheels): 570 – 590 Hp / 512 WHP @ 7.610 rpm
Torque: 53 Kgr. @ 5.680 rpm
Ambient temperature: 27oC
[Dyno: Plex Tuning – Yannis Andrianakis]



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Old 07-03-2010, 08:12 AM   #55
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Labors - (11 mods):



1) I.C.E. development & installation

2) Workshop machining (J. Mattis Enginetech):
a) Cylinder boring
b) Bearings finishing – tolerance adjust
c) Crankshaft balancing
d) Cylinder head porting
e) 3-metal crankshaft bearings
f) 3-metal big-end bearings
g) Assembling
h) Block skimming
i) Head skimming

3) Turbo conversion

4) Brakes (installation)

5) Suspension installation

6) Fuel line manufacture for FPR + FPR installation
+ under-bonnet items installation

7) Thinning mods for: a) body-kit arches (outer side, by aprox. 2cm)
+ b) all 4 arches (inner side)

8) Miscellaneous paintjobs due to (extra) body-kit mods

9) oil-pressure gauge installation

10) Sump oil return line

11) Wheel bearing lathe machining



- Page 5 -


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Old 07-03-2010, 08:14 AM   #56
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Mechanic parts / Cylinder head / under bonnet items - (72 modifications):


• Stand alone Vi-Pec V-44 ECU + especially made (for Ford Focus) Tacho control module + custom loom + electrical parts + installation / programming / dyno by Plex Tuning (Yannis Andrianakis) Κ5
• Engine: From Ford Focus ST 170 (2.000cc // code # 13 76 753) Κ5

MOUNTS:
• Mount base (code # 10 76 912) + Metal reinforcement (code # 14 40 059) Κ1
• Engine mount (code # 11 46 296) for Ford Focus RS mk1 (by Ford) Κ1
• Rear engine mounts (x2) – upper and lower (on x-member) Κ1
• Engine silent blocks by Powerflex Κ1


• Alternator of 105 Ah (max. 120 Ah @ 6.800 rpm) by Motorcraft + belt by Ford (code # 10 49 613) Κ1
• Tension - pulley kit (code # 11 14 544) - by Ford Κ1
• External tension – pulley assembly with alloy-housing + ball bearing (code # 12 02 943) by Ford Κ1
• Gear shift lever (code # 45 56 688) + cable assembly - selector lever control (code # 44 86 724) - all by Ford Κ2
• External, adjusting, fuel pressure regulator A1000-6 by Aeromotive (part # 13109) + OEM pressure gauge K1
• Ignition coil for Ford Focus ST 170 / RS mk1 by Ford Κ1
• Battery: OPTIMA - "yellow top – YTS 4.2” (12v, Rate: 55Ah, deep cycle, maintenance free) K1
• Platinum plated battery poles (x2) by Phonocar (positive: “4/481”, negative: “4/482”) K1


Fuse boxes + fuses:
a) Under bonnet: Model “4/490” with volt gauge by Phonocar + ANL 150 Ah fuse
+
b) In trunk: i) Model “4/490” with Volt gauge by Phonocar + ANL 2 x 150 Ah fuse + custom leather wrapped wooden base
ii) Model Nr. “30.3801-01” (AGU gold) by C-quence
[K1]


Wires: a) Ground: Model “4/291” by Phonocar (2m)
b) Power: Μodel "4/313" from the “Platinum Line” series by Phonocar (1 AWG // 50mm2 // 7m)
c) Power: Model “Powerline” by Alphatech (4 AWG // 2m)
[K1]


Garrett GT 3582 [BB] (code #: CN: 714568 – 5003S // LB: 8649Z)
Max. HP: 500 - 650
Compressor Wheel: Trims: 56mm // Inducer: 61,4mm // Major: 82mm
Compressor Housing: Inlet: 70mm // Outlet: 50mm // A/R: 0,70
Turbine Wheel: Trim: 84mm // Wh. Dia.: 68mm // A/R: 0,63
Exhaust Housing: Inlet flange: T3-turbine
Outlet flange: 4 bolt turbine
A/R: 0,63
[K3]

• Alloy inox exhaust manifold (with high resistance to extreme temperatures) by N.S. Racing K3
• Alloy inox downpipe (Φ. 80) by N.S. Racing Κ2
• Exhaust pipe (Φ.80) + 2 silencers (all made with alloy inox) by N.S. Racing Κ2
• Custom alloy inlet manifold with larger plenum: Developed – manufactured – installed by Hercules parts K1
• Custom alloy injection rail by Hercules parts K1
• Wastegate (external) model “V 44” by TIAL in silver color (Counter Bore: 1,875” Inlet / 1,750” Discharge, chamfered edges), plus 2x TIAL springs, with 1 bar total setting (“Large Green” = 0,8 bars + “Small Yellow” = 0,2 bars) Κ2
• Turbo pipes: a) Φ.60: From turbo to I/C & b) Φ.70: From I/C to throttle body – both by N.S. Racing K1
• Cone air-filter (100mm) by BMC K1
• Silicone hoses (boost, etc.) by Samco and Forge K1
• Hose clips by Würth K1
• Engine gaskets for Ford Focus ST 170 (all by Ford) K1
• Head gasket (0.5mm with O-ring) for Ford Focus ST170 (by Ford) K1
• Water pump (by Ford) K1
• Low temp thermostat by Ford K1
• Lower radiator hose from Ford Focus RS mk1 K1
• Metal heater pipes (custom) + heater hoses Φ. 18 / Φ. 16 K1
• Injectors (x 4), 1.000cc, by SARD (code # 63518) Κ2
• Metallic boost, vacum & fuel supply hoses K1
“Nissen” type I/C by Ordońez (front mounted, air-to-air, & high-flow) for 650+ Hp with 68x38x6,2 cm dimensions, having a 50x36x62 cm cell, and with Φ.12 pipes (imported from U.S.A.), plus a modified upper section by Hercules parts Κ2
• Throttle body (manufactured in the U.K.) made of alloy inox (Φ. 80) and with ball bearings, adaptor, and a Φ.90 hose K1
• Oil cooler by Setrab K1
• Forged pistons (x 4) for Ford Focus RS mk1 (84,8 mm) by Accralite Κ3
Arrow billet rods (set, balanced) K4
ARP head bolts K1

• Custom camshaft-set by Cat Cams (code # 2291017):
Cam base diameter: 38,2mm
Clearance: 0,25mm / 0,25mm (intake / exhaust)
Duration: a) [0,1mm + cl.]: 277o / 262o (int. / exh.)
b) [1,0mm + cl.]: 243 o / 224o (int. / exh.)
Valve lift [cl. = 0]: 12,00mm / 10,80mm (int. / exh.)
Peak angle: 110o / 120o (int. / exh.)
Timing [1,0mm + cl.]: 11/52o (int.) / 52/-8o
Lift @ TDC {cl. = 0]: 2,65mm / 0,55mm (int. / exh.)
Intake camshaft: For use without vanos-system
+
Camshaft Pulley (cancels Vanos)
Retainers (custom setup “A”) by Cat Cams
Valve springs (custom setup “A”) by Cat Cams
[Κ3]


• Camshaft tension-belt for Ford Focus ST 170 (by Ford) K1
• Followers K1
• Boost gauge / EGT gauge: model # 403-Α053 (meter control unit) + # 403- A961 (EGT white) + # 403-A955 (Boost KPA white) from the EL-II Limited Edition Series (System Meters “EL Digital Network”) by Apex-i K2
• Oil pressure gauge: From the EL-II Limited Edition Series (code # 403-A963) by Apex-i K1
• Fuel pump No.1: By Walbro (265 lt. / h) + adaptors + filters K1
• Fuel pump No.2: (operating simultaneously): Code # 0580 254 044 by Bosch (300 lt. / h // max.: 6,5 bar) K1
• Fuel line for pump + injection rail K1
• Custom alloy tank + fuel pump pre-filter by FIAT K1
• Iridium Spark plugs (x4) – model ITV 27 by Denso K1
• Spark plug wires (8,5 mm) KV-85 for Ford Focus RS mk1, by Magnecor K1
• Open-type single-piston dump valve (50mm) with pink spring (=12 psi / 0,82 bar), by TIAL K1
• Racing cat, “Motorsport”-type, (made in Germany) with 100 cpi (up to 600 Hp) – by AGS K2
• Breather tank, model GRV-12003506 (1lt., Φ.9) by GReddy K1
• Water, oil, and misc hoses K1
• Construction of a custom 3-point front alloy strut bar with custom round alloy mounts – all by Hercules parts K1
• Stainless steel fuse box cover by Torquesteer K1
• Brakes-fluid tank + cap (both made by stainless steel) by Torquesteer K1
• Power steering fluid-tank + cap (both made by stainless steel) by Torquesteer K1
• Header tank with see-through glass + cap (both made by stainless steel) by Torquesteer K1
Stainless steel washer bottle tank + cap by Torquesteer
• Intake air temperature-sensor (part no. # 5972332) taken from Fiat Punto GT (installed at the intake pipe) K1
• Idle valve by Bosch K1
• Engine oil pump for Ford Focus ST 170 (by Ford) K1
• Starter for Ford Focus ST 170 (by Ford) K1
• Custom A/C pipes K1
• Radiator hoses (upper + lower) K1
• Speedo sensor K1
• 2nd water temperature sensor (for accurate reading) K1
• 3-bar MAP-sensor by Marelli K1
• Ignition coil (CDI, 4-way) XPS-4 by MW Κ2
• Radiator fan (2nd) with diam.: 25-28 cm. + radiator fan (3rd) with diam.: 20 cm. (both by SPAL) + relays (x2) + new wiring layout by Kateyiannis Panayiotis Κ2



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Old 07-03-2010, 08:19 AM   #57
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Transmission - (15 mods):


• Single clutch disk (240 mm, 6-paddle, 470 lb) + pressure plate + bearing (all by AP Racing) K3
• Gearbox for Ford Focus RS mk1 (code # 13 04 012 – by Ford) with ATB Limited Slip Differential by Quaife + gearbox bearings from Ford Focus RS mkI (code # 12 14 775) – all by Ford Κ5
• Upper gearbox mount (code # 11 33 020) by Ford Κ1
• Clutch release hub + bearing (code # 43 58 475) for Ford Focus ST 170 (by Ford) Κ1
• Lower gearbox mount (torque restrictor) - code # 11 02 416 (by Ford) Κ1
• Clutch pressure plate (extra) by AP Racing K1
• Single mass flywheel + mount (all from Ford Focus RS mk1) K1
• Clutch pump for Ford Focus RS mk1 + lower clutch spring (code # 1076905) – all by Ford K1
• Power steering pump (code # 45 29 171) + its’ relevant pulley (code # 10 53 151) + pump bracket (code # 11 39 196) – all by Ford Κ2

From Ford Focus ST 170 & RS mk1:

• Half axle drive shaft (right) - code # 11 39 963 K2
• Half axle drive shaft No2 (right) from Ford Focus RS mk1 + shaft mount Κ2
• Half axle drive shaft (left) - code # 11 39 964 Κ1
• Knuckle (right) - code # 43 56 608 Κ1
• Knuckle (left) - code # 43 56 607 Κ1
• Wheel hub (x2) - code # 13 33 147 Κ1



Suspension - (2 mods):

• Anti-roll bars (front – rear) by H&R K1
• Coil-over (monotube, nitrogen filled, with adjustable top mounts) DT2 by Hot Bits (for Ford Focus mk1) + longer springs (230-30, 60/86) by Hot Bits + drilling of top mount reinforcement plates + under top mounts reinforcement plates + custom rear spring spacers from acetal (Φ. 61, 2cm height) by Hercules parts Κ5



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Old 07-03-2010, 08:21 AM   #58
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Exterior Modifications - (18 mods):


[STD] Xenon HID (OEM Ford)
• Χenon bulbs (6k Kelvin) D2S by Arcmen K1
[STD] Fog lights (OEM Ford)
[STD] “Quickclear” heated windshield with heated washers (OEM Ford)
• Rear lights – model 913 by Hella [K1] + with double layer painting in black color (DMS-design), and diluted coating with white / “gold” pearls by Design Perfection
• Hood “Mach 5” by Graham Goode (for Ford Focus RS mk1) + steel mesh for ducts by Louis Auto Tuning K3
• Hood paint by Design Perfection: a) Outer side: black base color (double layer), DMS-design, with diluted coating and with white / “gold pearls” b) Inner side: mat black color K1
• Body-kit custom paintjob (except hood) in custom color (consisting of 2 different blues and 1 coral green shade) plus various body-kit details – all by Design Perfection Κ5
• Window tint films by Madico: 5 x ON 20-XSR + 1 x ΟN 55-XSR (for windshield) pieces. Installation by Costas Yiannikelis K1
• “Smoked” side repeaters K1
• Custom “Ivan” hood & boot badges, by Torquesteer K1
• Carbon fibre roof spoiler by H&R K2
• Wide (5dr) full body kit “Mk1 Zion” (# 105450-1) from the U.K., + body-kit modifications by Leonidas Lavdas + metallic mesh + internal custom fog-lights brackets by Design Perfection Κ5
• Aerial “Samurai” by Autostyle K1
• Front-shield wipers-set (code # 1354282) by Ford K1
• Fuel cap-cover TR / Z by Simoni Racing K1
• Customized stickers (yellow) of «Ivan Project Car» main modifying Houses and technicians, by Bolonakis Group K1
• Fog lights with Gear’s Xenon-kit (H3 lamps, 6k Kelvin) K1
• Badges: Chrome “SE” initials on the trunk + “RS” badges (x2) – all by Torquesteer K1
“RS” anti-theft valve caps by Torquesteer K1
• Rear right door airbrush paintjob by Extreme-motopainting K1



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Old 07-03-2010, 08:23 AM   #59
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Interior modifications – (19 mods):


[STD] Full leather interior
[STD] Clima (Ford OEM)
• White dial kit by Speedhut (custom-made / patent pending), with: 10k rpm tachometer & 280Km/h speedometer, double color lighting (blue / turquoise), & light adjusting switch K1
• Leather gear gaiter – model: “G7 111/A-black leather/blue addition” by Simoni Racing K1
• Pedals + footrest : Model “Stealth Airmetal Top” by momo K1
• Silver-colored handbrake knob by momο K1
• Nickel gear lever-surround K1
• Mats (x4): Model “TSRFFO-4” by Simoni Racing K1
• Lighted custom case at right boot dome, made by Dragiotis Andreas (www.dragiotis.gr) K1
• Central column polyester construction for housing boost, exhaust temp, and oil pressure gauges, made by Dragiotis Andreas (www.dragiotis.gr) K1
• Polyester frame construction (leftwards from the central panel) for installing the turbo controller made by Dragiotis Andreas (www.dragiotis.gr) K1
• Polyester facade construction (around the speedometer / tachometer area) + faux leather coating, made by Dragiotis Andreas (www.dragiotis.gr) K1
• Bucket seats (x2) Sparco “Milano” (model ’06): Black leathered, with lumbar adjustment, alloy runners (for back & forth movement), back and legs adjustments (for both driver and co-driver) + mounts + 4-point racing belts model “SR 901283 E” by Sabelt + runners for the belts Κ5
• Custom door sill plates (x4) by Torquesteer K1
• Carbon look tax disc-holder, by Torquesteer K1
• Digital Navigation System: S 1000 by TiBO + amplifying antenna Κ2
• Interior lighting by CTD (Car Tuning Development) consisting of 2 single lines of blue-led rods by Lampa + illuminating (blue) “on-off” switch by Pro-type K1
• Black & mauve Connolly-type leather-coating at the steering wheel and door cartons, by Autostop K1
• Bluetooth hands-free car-kit Parrot MKi 9100 K1
• Custom MDF boot-floor with vinyl leather and fiberglass coating [designed and constructed by Dragiotis Andreas (www.dragiotis.gr)] + lighting with 2x 30cm blue-neon tubes by Foliatec K2
• Custom polyester case (at the right cup holder) by Dragiotis Andreas (www.dragiotis.gr) K1



Rims / Tyres – (2 mods):


• Rims: O.Z. Racing – Canova BD (8x19”, 5x108, ET 38), silver color K4
• Tyres: Goodyear Eagle F1 Asymmetric – 225/35/19 K3



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Old 07-03-2010, 08:25 AM   #60
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Brakes / Safety systems – (18 mods):


[STD] ΤCS (Ford OEM)
[STD] ESP (Ford OEM)
• Brakes: [All the following modifications that are custom, have been made by Hercules parts]


I) Front:

a) 6 – piston calipers by Galfer K3
b) Custom Φ.369mm x 28mm alloy drilled disks with alloy hats K1
c) CNC lathe-machined alloy hats + bolts K1
d) Custom alloy caliper adaptors (x 2) + bolts K1
e) Βrake pads “Tuning Line” (model "1055" / "199 21 00" for 6 piston-calipers) by Galfer K1
f) Custom spacers set (45mm), made by “7075” alloy-type (CNC lathe machined) K1
g) Custom wheel bolts K1
● h) Stainless steel brake-lines by Goodridge K1
● i) Wheel bolts (x 8) 14mm from Ford Transit K1
● j) ATE Super Blue Racing brake fluids K1


II) Rear: OEM single-piston calipers were sustained, along with the following modifications:

a) Custom Φ.300mm x 10mm alloy solid disks with alloy hats K1
b) CNC lathe-machined alloy hats + bolts K1
c) Custom alloy caliper adaptors (x 2) + bolts K1
● d) Brake pads by ATE
e) Stainless steel brake-lines by Goodridge
f) Custom spacers set (50mm) made by “7075” alloy-type (CNC lathe machined) +
g) Custom wheel bolts K1

• Park Assist: DESO “Parking Assistance System A-2651” K1
• Car-alarm: Clifford 590.2 + spare key with immobilizer K2
• Car tracking system (GPS & GSM Pager) Ampire Loc 100 K1
• Tire Pressure Monitoring System (TPMS) “E-109S” by Orange Electronic K1



- Page 10 -


- TBC -
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Ivan Project Car:5 1 2 WHP @ 7.610 rpm / 5 3 Kgr. of (wheel) torque @ 5.680 rpm (19/05/10)
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