sporadic's Turbo Duratec build #3 - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum > Ford Focus Tech Discussions > General Forced Induction

General Forced Induction The place to chat about turbochargers, superchargers nitrous systems and custom engine fabrications.

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

Reply
 
Thread Tools Display Modes
Old 06-21-2014, 10:27 PM   #1
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
Talking sporadic's Turbo Duratec build #3

History:
Build #1 (2007): Stock motor with custom Thunderbird IHI turbo
Build #1b: Upgraded IHI turbo to a hybrid
Build #2 (2012): Upgraded turbo to GT2871r. Switched to external wastegate.

Current build:
Same GT2871r
SuperTech 10.4:1 pistons
SuperTech rings
CXRacing forged H-beam rods
ARP head and main studs
Clevite main and rod bearings
Crower valve springs and retainers
Exedy Hyper Single clutch
Torsen LSD

Goal: 375whp+ and/or 115mph in the 1/4

The motor I'm building is the original out of my car. It suffered an overboost with the IHI turbo and damaged/broke a ring landing and began smoking like crazy. This happened a few years ago, but I'm just now getting around to rebuilding the motor. This is my first ground-up rebuild. With the exception of some very minor scratches (can't even feel it with a fingernail) the motor was fine and fully rebuild-able.
Since this motor had no significant damage and very low mileage I'm lucky enough to not need anything professionally machined. That being said I'm still measuring everything and comparing against the Haynes manual.

The cylinders were a bit shiny and I wanted to get that small scratch out of cylinder #2 so I used a 3-blade 220 grit hone to give it a new cross-hatch. I did as little honing as possible and stayed with the 87.5mm pistons.
Following SuperTech's formulas I gapped the top ring to .018" and the second ring I left at .023" as it came out of the box.

For now I'm sticking with the stock head and cams, but I did upgrade the springs and retainers to Crowers in case I want to spin it over 7K. Also if I want to swap out cams later the springs and retainers (the hard part) will already be done. I went with steel retainers vs. titanium after speaking with a representative at Crower. The steel are also significantly cheaper.

I'll be using a TurboSmart dual-stage boost controller, with a toggle switch for the second stage. First stage will probably be around 13-15psi, and second 20-24psi.

My base tune is from Tom, and I tweak it as necessary using the SCT Pro Racer Package. I plan on slowly tuning up to 24psi myself if possible. Chances are good I'll have to hit a dyno rather than street tune like I have up to now.

I'm in no particular rush with this build, so I may not be updating daily like I used to. There's a good chance I'll post a few days and then be silent for a couple months. Family time and home improvement projects tend to come before the car.

So far I've assembled the short block and just finished rebuilding the head with new valve stems seals, cleaned up the old valves, and installed the Crower springs and retainers. At this point I need to think real hard whether or not I want aftermarket cams, but I'm still leaning towards no.
















__________________
2006 sonic blue zx5 GT2871r turbo.
sporadic is online now  
    Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 06-21-2014, 11:40 PM   #2
qweesy
Focus Addict
 
qweesy's Avatar
 
Join Date: Aug 2004
Fan#: 12042
Location: Houston, TX
What I Drive: 2004 focus Duratec 2.3 RS (DEAD)

Posts: 1,353
Points 3,110, Level 34
Points: 3,110, Level: 34 Points: 3,110, Level: 34 Points: 3,110, Level: 34
Level Up 40% Completed
Level up: 40% Level up: 40% Level up: 40%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 4 qweesy Good Standing Member
Buy-Sell-Trade Rating: (6)
very nice
qweesy is offline  
    Reply With Quote Quick reply to this message
Old 06-22-2014, 01:51 AM   #3
ZXthrizzle05
TURBO ZX3
 
ZXthrizzle05's Avatar
 
Join Date: Jun 2005
Fan#: 24434
Location: Marysville, WA
What I Drive: 2007 mazda 3 I sport, TURBO ZX3

Posts: 8,465
Points 50,433, Level 100
Points: 50,433, Level: 100 Points: 50,433, Level: 100 Points: 50,433, Level: 100
Level Up 0% Completed
Level up: 0% Level up: 0% Level up: 0%
Forum Activity 4%
Activity: 4% Activity: 4% Activity: 4%
FF Reputation: 6 ZXthrizzle05 Good Standing Member
Buy-Sell-Trade Rating: (11)
I'm using the 2871r kn built block. Fast early spool to redline. No lag
__________________
FF MODERATOR
RISE AGAIN EGGYOLK302 WHP 274 WTQ ZETEC CREW #271
RIFF CREW
ZXthrizzle05 is offline  
    Reply With Quote Quick reply to this message
Old 06-24-2014, 09:28 AM   #4
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
No updates, but adding photos of the clutch. I have decided to stick with the stock cams after reading negative reviews on the Crower cams, which is what I was looking at.



__________________
2006 sonic blue zx5 GT2871r turbo.
sporadic is online now  
    Reply With Quote Quick reply to this message
Old 06-29-2014, 04:11 PM   #5
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
The motor is all together. Timing the cams and crank ended up being incredibly simple with some good photos. There is a youtube video out there with false information on setting the crank TDC, so I'm adding a photo below of where the crank is supposed to stop against the pin. There is no way to get the cam timing incorrect lining up the slots in the back. Find TDC, back it of some to pull the #1 piston down away from the valves, time the cams, set crank back to TDC, install chain, and done timing.

Timing tool used. The shorter "bolt" is used to set TDC.


Part numbers for crankshaft friction washers and crank bolt


Cams zeroed




Crank at TDC. (There is a youtube video that shows a different TDC point, but this is the correct location!


Timing chain on. Remember to install a new friction washer between the sprocket and crank, and another between the sprocket and crank pulley.


How I locked in the crank in order to torque the crank bolt.


Assembled and ports taped off


It will be a couple months before I get the new motor into the car. After remodeling the bathroom I'll get back to this.
__________________
2006 sonic blue zx5 GT2871r turbo.

Last edited by sporadic; 06-29-2014 at 07:07 PM.
sporadic is online now  
    Reply With Quote Quick reply to this message
Old 06-29-2014, 05:01 PM   #6
sailor
Crankshaft
 
sailor's Avatar
 
Join Date: Jun 2008
Fan#: 57268
Location: Williamsville, NY
What I Drive: 2004 Pitch Black ZTS 2.3 5spd.

Posts: 16,625
Points 11,855, Level 71
Points: 11,855, Level: 71 Points: 11,855, Level: 71 Points: 11,855, Level: 71
Level Up 52% Completed
Level up: 52% Level up: 52% Level up: 52%
Forum Activity 99%
Activity: 99% Activity: 99% Activity: 99%
FF Reputation: 79 sailor Excellent Standing Member
Buy-Sell-Trade Rating: (0)
Great Pics! Those are the kind we can use for reference - Tx.
__________________
"Rubber Side Down"

S.R. #275
sailor is online now  
    Reply With Quote Quick reply to this message
Old 06-30-2014, 11:09 AM   #7
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
Some other goodies the car is getting along with the new motor:
15x8 Weld wheels with full slicks
More Prothane suspension bushings
Coilovers
Steeda rear sway bar
Possibly partial new exhaust
Aluminum steering rack bushings
Extended wheel studs for front wheels
__________________
2006 sonic blue zx5 GT2871r turbo.
sporadic is online now  
    Reply With Quote Quick reply to this message
Old 07-02-2014, 07:47 PM   #8
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
Here is the part # for the ARP extended lug nuts that fit the Focus. 100-7708 12mm x 1.5
They say late model GM, but they certainly do fit. With a vise it only takes a few minutes to pop out the old ones and press these in.

__________________
2006 sonic blue zx5 GT2871r turbo.
sporadic is online now  
    Reply With Quote Quick reply to this message
Old 07-02-2014, 08:19 PM   #9
1turbofocus
FF Affiliate
 
1turbofocus's Avatar
 
Join Date: Oct 2003
Fan#: 1123
Location: Belmont, NC
What I Drive: 2000 ZX3 / 2002 SVT Turbocharged

Posts: 22,194
Points 51,296, Level 100
Points: 51,296, Level: 100 Points: 51,296, Level: 100 Points: 51,296, Level: 100
Level Up 0% Completed
Level up: 0% Level up: 0% Level up: 0%
Forum Activity 29%
Activity: 29% Activity: 29% Activity: 29%
FF Reputation: 154 1turbofocus Excellent Standing Member 1turbofocus Excellent Standing Member
Buy-Sell-Trade Rating: (28)
If you havent bought the wheels yet I have a nice set of bogarts front and read with good slicks and skinny rears I will sell

Tom
__________________
Focus-Power: Your #1 Source for Ford Focus Speed, Tuning & Performance!

Customer Support
AIM: hpdyno
Email: hpdyno@aol.com
Phone: 704-249-3745
Site: focus-power.com

Elder 1turbofocus
1turbofocus is offline  
    Reply With Quote Quick reply to this message
Old 07-02-2014, 10:20 PM   #10
sporadic
Focus Addict
 
sporadic's Avatar
 
Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,289
Points 12,643, Level 73
Points: 12,643, Level: 73 Points: 12,643, Level: 73 Points: 12,643, Level: 73
Level Up 49% Completed
Level up: 49% Level up: 49% Level up: 49%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
Quote:
Originally Posted by 1turbofocus View Post
If you havent bought the wheels yet I have a nice set of bogarts front and read with good slicks and skinny rears I will sell

Tom
Thanks Tom, but I have a set of Welds with some slicks already. I could use the skinnies but probably won't bother to be honest.
__________________
2006 sonic blue zx5 GT2871r turbo.
sporadic is online now  
    Reply With Quote Quick reply to this message
Reply

Bookmarks & Social Networks

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Display Modes

Posting Rules
You may post new threads
You may 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 01:16 AM.


Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Privacy Policy : Advertise Information

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 Audi S3, Ford Fusion and Acura TLX. 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. Challenger Hellcat - Charger Hellcat