Well its finally here, after waiting for parts and enduring a few setbacks, my ST170 is finally come back to me after being in the caring hands of POWER ENGINEERING for a turbo conversion......... and I couldnt be happier Never did I dare dream it would come out this well, the car is brilliant to drive off boost, it behaives it self in traffic, starts on the button, and its really rather quick too
I'm not gonna go in to massive detail as I'm gonna save it for an article Focus Torque, the clubs wicked cd-rom magazine
First the parts.......
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304Grade stainless steel Power Engineering exhaust, which sounds awesome!
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Krustyatthepod025.jpg
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Krustyatthepod029.jpg
Powers own manifold
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Turbomanagment017.jpg
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GT28R Double roller bearing turbo
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Turbomanagment008.jpg
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http://img.photobucket.com/albums/v237/simon173/ST%20mods/Turbomanagment010.jpg
Omex 710 managment, wiring harness, and map sensor.
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Turboconversion041.jpg
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WRC I-Beam rods (700Lbs/ft capable)
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Turboconversion046.jpg
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WRC Forged Pistons, rods and pistons give 8:8:1 compression
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Dropping the car off.......
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It was hard to say goodbye
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and off Chris goes!
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Chris uploading the latest Omex software......
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while Big Ad looks on.......
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Turbo on and mounted, with bleed valve in place till Omex boost controller is hooked up.
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Breather tank
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Evo 8 Turbo oil return.
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Engine bay nearing completion.
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Yummy fittings used everywhere!
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Forge intercooler.
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Final boost hoses being hooked up All boost pipes reemed by the way.
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Final mapping, Chris, look where your going man!!
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When the car first went in, the idea was to do a low/medium boost conversion using the standard engine to see how the ST responeded. the car was built up and running relitively quickly and sent ove to the rollers to mapped, the intial signs were very promising with 270bhp showing with a rough fuel map and more tuning to go. Plus it came on boost "likea F'ing banshee!!!" according to Chris! After seeing it in action I could see what he meant, the boost was instant and came in really really hard, almost too hard, we feared for traction. But its nothing a particularly grippy set of tyers wouldnt sort out.
But alass, it was not to be.........
Late at night when Chris was working late (8pm, he finishes at 5:30) getting the car finished for me for Trax, the power started to fade on the dyno. After trying everything he knew how and working till 10pm to find the cause. He had to stop and give the car back to work shop the next day for them to strip the engine. To cut a long story short, the variable length runner intake had spat to rubber bungs in the engine and it resulted in a cracked No:2 piston gland The bungs were'nt very well secured and didnt like having boost behind them (we've heard of it happening in standard cars also). No ones fault, just one of those things, although Chris was damn near suicidel when he rang me to tell me, he was cut up than I was.
Rather than replace the internals with standard parts we opted to replace the with WRC forged items, PE were amazing and fiited the parts for free for the trouble, even though it wasnt thier fault it had happened. Now thats customer care
A big thank you must go to Ian Howell and Area Six at this point who was an absolute star, managing to source the parts I needed and ship them to me within a week! Your a star Ian!! Also a thank you to Big Ad for getting Ian to call me in the first place
Chris undertook the rebuild himself, to get the car back to me sooner as the workshop has to undertake routine work as well as project cars like mine. He had it back together and running in no time and ran it in.
Back on the rollers again.......
The car ripped!!! And Chris really liked the way it drove to The mapping was completed again, only for another problem to rear its head. The fuel pump had started varying the fuel pressure due to the origonal ECU being sensitive to barometric pressure, which inturn upset the mapping as the fuel pressure changed. DO-UH!!!
Somehow, I have absoluetly no idea how...........Chris managed to drop the fuel tank out, fit a FRS fuel pump, install a return fuel line to the tank, modify and install a FRS fuel rail, put it all back together, rewire the fuelling module and get it running in one day..........whilst working on his own, with a full days tunng booked with customers!!!!!!! Stunning.
The fuel rail etc etc.....
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With this final hurdle dealt with, the final mapping was carried out and the car was power tested, the water injection fitted and the engine bay tidied up.
The new engine span the rollers up to the tune of 291BHp with 284Ft/Lbs of torque To say I was happy when Chris sent me pic with "Simon291" written on the back of the car would be an understatement, I was stunned! The most interesting bit is that its only running 13PSI!! The only limiting factor we found was the inlet manifold, it cant take lots of boost as its only plastic, but as soon as we change this, its time for more boost............
The finished article......
http://img.photobucket.com/albums/v237/simon173/ST%20mods/Cars016.jpg
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The car feels awesomely fast, and smooth with virtually zero lag It pulls in any gear and just deosnt wanna stop going! I love the way the exhaust sounds, it has this brilliant rally car burble on idle and roar's like hell when its on boost (its scares the hell out of some other road users ) yet is quiet on motorway cruising..... perfect!!
I've not been able to get the car down to Santa Pod yet, but Chris thinks a 13sec capable car and I agree after having driven it. But only time will tell
The biggest thank you simply has to go to PE Chris who worked his socks off to get the car done, often working extra hours for no extra pay. I can not thank you enough Chris you are a legend. I love the car and couldnt be happier
I cant recommend Power Engineering highly enough, I have nothing but praise for them. You guys are the Dons
Thank you to everyone in the FFOC who has been supportive in the whole project
And to Jen(Pinky my long suffering girlfriend who has put up with me talking about it all none stop
P.S Plans are afoot for more power
Hope you like
[EDIT].. made all your pics links for now till you can get them resized.
