Joined
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10 Posts
Hello,
First off I would like to introduce myself. My name is Cory and I am a Senior mechanical engineering student at Rose-Hulman Institute of Technology. I have been passionate about cars my entire life. Once I got to college, that really took off. I was a member on University of Pittsburgh's FSAE team working on intake and exhaust design as well as being the head of forced induction. After I transferred to my new school I joined the supermileage team, immediately taking over the engine program. I do work for Castellano Performance Engineering (www.cpeturbos.com) in Chicago and R Sport International (www.r-sportinternational.com) in Portland, OR. I work mostly on Volvos and Vipers (weirdest combo ever), but am looking to get into the V8 Rx7 scene as well. I am pleased to be here. Looks like you guys have a nice little forum.
My room mate has a 2001 Ford Zx3 with the 5 speed manual tranny and Zetec engine. He keeps complaining that it is slow and I said, "Well why don't we do something about it?" I suggested a home made turbo system and he asked how much a bare bones system would cost. I said I thought I could do one for 600 dollars, depending on the tuning required. I read the intro threads to forced induction on the Focus and thought I would run some things by you guys.
My plan was to use the factory tube manifold and a cheap turbo from a Volvo (I can get them very easily), or WRX. Those can be had for 50-100 dollars in great shape. I would obviously have to put some flexible bracing on the turbo so that the manifold isn't taking the entire weight. My friend, Chris, owns an exhaust shop and could probably do a turbo back, 2.5 inch system for 200-250 dollars. For intercooler and intake pipes, I figured I would get one of those ebay kits for 140 dollars. I know lots of people that run them and have success. I can get oil lines from CPE for cheap. This leaves about 150-200 bucks left for odds and ends and engine management.
I have to be honest, I am surprised there are no tuning solutions for the Focus that don't require a box. This is the largest hold up. Our goals are to run about 7-10 psi. So, instead of doing a predator or other such solution, I have started considering doing an extra injector and variable resistor on the IAT sensor controlled by a pressure sensor and PIC controller. I saw that the stock fuel pump is nothing to get excited about, but will it be able to feed 7-10 psi's worth of power? I understand that the Focus doesn't have a return style fuel system. I take it the pump is PWM to keep a constant rail pressure? Are there any obstacles I am going to run into with an extra injector?
My roomy has also been reading around and said someone apparently did a system for $250. Does anyone on here know about this?
Any advice you have to give is appreciated.
First off I would like to introduce myself. My name is Cory and I am a Senior mechanical engineering student at Rose-Hulman Institute of Technology. I have been passionate about cars my entire life. Once I got to college, that really took off. I was a member on University of Pittsburgh's FSAE team working on intake and exhaust design as well as being the head of forced induction. After I transferred to my new school I joined the supermileage team, immediately taking over the engine program. I do work for Castellano Performance Engineering (www.cpeturbos.com) in Chicago and R Sport International (www.r-sportinternational.com) in Portland, OR. I work mostly on Volvos and Vipers (weirdest combo ever), but am looking to get into the V8 Rx7 scene as well. I am pleased to be here. Looks like you guys have a nice little forum.
My room mate has a 2001 Ford Zx3 with the 5 speed manual tranny and Zetec engine. He keeps complaining that it is slow and I said, "Well why don't we do something about it?" I suggested a home made turbo system and he asked how much a bare bones system would cost. I said I thought I could do one for 600 dollars, depending on the tuning required. I read the intro threads to forced induction on the Focus and thought I would run some things by you guys.
My plan was to use the factory tube manifold and a cheap turbo from a Volvo (I can get them very easily), or WRX. Those can be had for 50-100 dollars in great shape. I would obviously have to put some flexible bracing on the turbo so that the manifold isn't taking the entire weight. My friend, Chris, owns an exhaust shop and could probably do a turbo back, 2.5 inch system for 200-250 dollars. For intercooler and intake pipes, I figured I would get one of those ebay kits for 140 dollars. I know lots of people that run them and have success. I can get oil lines from CPE for cheap. This leaves about 150-200 bucks left for odds and ends and engine management.
I have to be honest, I am surprised there are no tuning solutions for the Focus that don't require a box. This is the largest hold up. Our goals are to run about 7-10 psi. So, instead of doing a predator or other such solution, I have started considering doing an extra injector and variable resistor on the IAT sensor controlled by a pressure sensor and PIC controller. I saw that the stock fuel pump is nothing to get excited about, but will it be able to feed 7-10 psi's worth of power? I understand that the Focus doesn't have a return style fuel system. I take it the pump is PWM to keep a constant rail pressure? Are there any obstacles I am going to run into with an extra injector?
My roomy has also been reading around and said someone apparently did a system for $250. Does anyone on here know about this?
Any advice you have to give is appreciated.