CrazyAntics Focus Build Pt1 - Focus Fanatics
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Focus Fanatics > Ford Focus Discussions > Ford Focus Builds & General Showroom

Ford Focus Builds & General Showroom Post pictures and information of your Focus being built or your car images here. We want to see your Focus! More Images: Visit Our Online Ford Focus Gallery

Search This Forum | Image Search | Advanced Search    
Ford Focus Tire & Wheels FocusFanatics Merchandise

Reply
 
Thread Tools Display Modes
Old 01-02-2014, 03:05 PM   #1
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
CrazyAntics Focus Build Pt1

Its been a long wait staring at the parts accumulating in the corner due to financial shortcomings from the holidays but the time has finally come. We will be finally putting some more serious parts onto my 07 ZX3 with my d20. We will be putting on a cosi knockoff intake manifold and trying some of my own experiments as far as the power steering reservoir problem, as well as a focussport 4-1 race header. We will also be "deleting" the pcv valves and installing a catch can and installing Massive Speed's new EGR delete plate. And to top it off we will also be putting on an AEM wideband A/F ratio gauge to tune everything properly. Will also be replacing spark plugs and valve cover gasket and prettying it up a bit under the hood while i'm at it.

I just bought a camera so i'll be posting pics up soon of everything and doing a few write ups of the whole ordeal, can't wait to get to tearing it apart! T-minus 9 days! haha


Phestezio is offline  
    Reply With Quote
Sponsored Links
Advertisement
 
Old 01-13-2014, 11:16 AM   #2
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
So we started the work on the focus over the weekend and for the most part everything went together pretty smoothly. We got everything apart and cleaned and got the massive EGR delete plate and header installed and figured out where i'll be mounting the oil catch can for the PCV. I'll be posting up pictures and doing a few write up's in a few hours of what i've already completed and i'll post up the rest probably tomorrow after I finish up the car tonight.
Phestezio is offline  
    Reply With Quote
Old 01-13-2014, 04:25 PM   #3
Black05
Focus Enthusiast
 
Join Date: Nov 2013
Fan#: 123169
Location: Greenwood, IN
What I Drive: 2005 Black St

Posts: 82
FF Reputation: 1 Black05 Good Standing Member
Buy-Sell-Trade Rating: (0)
Interested to see pictures
Black05 is offline  
    Reply With Quote
Old 01-15-2014, 09:27 AM   #4
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
So I remembered my camera today, so i'm going to do some write up's on what i've been doing over the past few days starting with day 1, some of it might not be to detailed because I plan on doing a separate very detailed write up on almost everything i've done. Hopefully most of them will get posted to the how-to archive to help everyone.

Anyways Day 1
<a href="http://s1362.photobucket.com/user/ikiefer/media/Focus%20Project%20Pt1%20Day1/1050_zps811ef259.jpg.html" target="_blank"><img src="http://i1362.photobucket.com/albums/r684/ikiefer/Focus%20Project%20Pt1%20Day1/1050_zps811ef259.jpg" border="0" alt=" photo 1050_zps811ef259.jpg"/></a>
Phestezio is offline  
    Reply With Quote
Old 01-15-2014, 09:29 AM   #5
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
Sorry, trying to get the pictures right before I start typing
Phestezio is offline  
    Reply With Quote
Old 01-15-2014, 10:01 AM   #6
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
Ok, so anyways Day 1 haha

I had to start a day early so I could get the flexpipe welded while someone was open, so the first day I started by basically getting everything torn down. Starting with the old Mani-Cat.


I highly recommend buying one of these if you don't already have one, it makes getting the first 2 o2 sensors out a breeze.


This 3rd o2 sensor is almost impossible to get out while its in the car, the clearance between the manifold and the steering column cover is sooo tight I didn't get a pic of the stock manifold but its just as tight on the new header if not tighter.


And a few pics of the head with the manifold off, its nice and filthy, cleaning comes on day 2






Next I removed the stock Intake Manifold, I didn't get a pic before I took off the valve cover as well


And this is the whole reason i'm swapping the intake, the dreaded tumbler flaps. You can notice the quite large chunks of plastic missing from the ends of the rod.




And of course I took off the valve cover to paint it and replace the gasket, you can see how much oil it was leaking out the side all over the motor and you can see how much oil was leaking down on top of my 2 and 3 spark plugs


That was about it for day 1, mainly a tear down day to get everything prepped for cleaning and re-assembly, and I had to get that flexpipe out to get a bung welded in for the wideband before the weekend.
Phestezio is offline  
    Reply With Quote
Old 01-15-2014, 10:20 AM   #7
ElectricAL
Focus Addict
 
Join Date: Dec 2009
Fan#: 71376
Location: Minneapolis, MN
What I Drive: 2005 Silver ST

Posts: 673
FF Reputation: 2 ElectricAL Good Standing Member
Buy-Sell-Trade Rating: (0)
Wow dang! That intake and the flaps were gunked up! If wonder if most all of 'em get like that given enough time and mileage or if it's just under certain operating conditions??

EGR system in action-- Recirculating stuff to cause those deposits?? Yech!
ElectricAL is offline  
    Reply With Quote
Old 01-15-2014, 10:52 AM   #8
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
Day 2

Started off day 2 by doing some intense cleaning on the motor, there was so much grime and filth caked on it took a couple hours and about 8 cans of brake cleaner, and a little elbow grease to get it clean

BEFORE


AFTER


After everything was all nice and clean, well a hell of alot better than it was, it was time to start putting some stuff back on. I started with the header, I installed the flexpipe to the header first and dropped it all down in at once, you don't have to but thats what I did. I also used the OBX graphite gasket since it doesn't have the hole for the EGR port like the stock one. I also replaced all the exhaust manifold nuts since they were all very rusty.




You can also notice in the bottom right corner of this picture that there is a black metal bracket touching the header, I end up bending this on day 3.


After the header was all snug and in place I started modifying the PCV on the crankcase, if you look above at the AFTER cleaning picture it is located almost in the middle of the picture, right below the 2 and 3 intake ports with the little purple fitting. This is what is looks like removed from the car, however I already removed the valve from the cover in this picture, the orange side of the valve goes into the cover and the little black ring goes over it and snaps into place.


I opted for drilling the valve instead of cutting off the bottom, I found a 3/8" drill bit is ALMOST perfect, you just have to use a knife afterwards to scrape off a little bit of the lip it leaves on the inside until the spring and plunger fall out.


And this is the valve with everything removed. The little black lines you may notice on the orange side of the valve near the end is where you would want to cut if you opt for cutting off the end instead.


After I had that done and back on the car I started on the Massive EGR delete plate. I already removed the coolant return hose in this picture.


The EGR on the intake side, with the EGR tube removed.


And the EGR valve off the car.








And with the Massive EGR plate installed. It uses the stock gasket and the plate comes with everything you need.




This is the coolant line you have to modify, the kit comes with a straight barb or a cap to just cap off the tee, personally I would run the straight barb as I did instead of just capping off the tee it looks better.


That was about it for day 2, I messed with where i'm going to mount my catch can a little bit and started painting the valve cover and fuel rail but that was about the majority of day 2, day 3 was mostly painting so I won't count that as my day 3 haha.
Phestezio is offline  
    Reply With Quote
Old 01-15-2014, 11:14 AM   #9
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
Day 3

Day 3 was mostly little things since I forgot to order the input cable for my SCT Livewire and i'm still waiting on it and I can't really do much without it I decided to take it nice and slow and work on some little things. I started off by bending that bracket touching the header in one of the day 2 pictures. You can see how its touching here


After I bent it away from the header.


Its hard to tell but the bright white on the top and bottom of the pic are the exhaust runners, the top bright white is the same as the runner you see in between them. I'm trying to show the distance in between the bracket and the header.


That took about 10 minutes and then I started putting my o2 sensors back in the exhaust. You need to use the first pre-cat o2 sensor, and it helps to put a little anti-seize on there as well, just don't over tighten it! Mine looks pretty burnt out i'll probably replace it in a few weeks.






I didn't have a 7/8" wrench to fit the top of the o2 socket but if you do you can always put the socket on and use a wrench to turn it, clearance here is next to nothing.


I ended up using a 22mm open end wrench to tighten down both o2 sensors.


This is about the time my camera died haha, After this I installed the wideband sensor into the flexpipe and made a bracket for my catch can out of plexiglass as a quick prototype for the steel one I will make today. Then I cleaned up the valve cover surface and re-installed the valve cover with a new gasket and called it a night.

I also started installing some of the hardware into my new knockoff manifold and noticed a few little problems, nothing that can't be modified to work but it will hold me up another day or so. Basically all I have left to do is install the manifold and put it all back together to be tuned. I'll be doing an extensive write up on these cosi knockoff manifolds, they aren't just plug and play like a real cosi but for the small amount you need to do to it its worth the 600 dollar savings in my opinion.

Overall this has been pretty smooth sailing, no major hiccups... knock on wood
Phestezio is offline  
    Reply With Quote
Old 01-17-2014, 08:39 AM   #10
Phestezio
Focus Enthusiast
 
Phestezio's Avatar
 
Join Date: Apr 2012
Fan#: 97562
Location: Summerville, SC
What I Drive: 2007 Oxford White ZX3

Posts: 430
FF Reputation: 4 Phestezio Good Standing Member
Buy-Sell-Trade Rating: (0)
So its been a little rough sailing the past couple days but I think i've figured out all the issues and a solution. Just as everyone said the manifold touches the reservoir, it touches it all the way at the bottom where it goes into the pump, which I was not expecting it to touch there haha. but no worries because I will just grab an 05 style power steering pump today for like 40 bucks and swap it on and run a little extra power steering line to the reservoir and return, and this gives me a good reason to replace my tensioner as well.
Phestezio is offline  
    Reply With Quote
Reply

Bookmarks & Social Networks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 06:50 PM.


Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Terms of Use : Privacy Policy : Advertise Information : Site Map

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Acura TLX or Fiesta ST. You can find all Ford Focus and Focus ST related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area.