Duratec Clean Up

ozracer · 30-01-2007, 10:08 PM

Hi Guys,

New to the forum but have a 2.0 Litre Duratec out of a wrecked 06 Focus that I am transplanting into a clubman. If you dont know what a clubman is have a look here......... birkin.com.au.

I have started pulling down my motor to eliminate all the crap of it and strip all the un needed stuff out of the loom. I have posted a link to my build diary here if anyone is interested.

http://www.oz-clubbies.com/phpBB2/vi...5053d8d56e334a

I intend on machining down the pulley tommorrow night so should have some more updates by the end of the week.

Regards,

Adam

melbzetec · 30-01-2007, 10:15 PM

Adam, fantastic write up so far. Really look forward to seeing your progress.

eXtremist · 30-01-2007, 10:35 PM

*click* Subscribed

kenny21 · 30-01-2007, 10:46 PM

hey adam where u running this when u finish. I am actually racing a supersports car dunno if u know it, its a red mallock. We are actually racing with the clubmans this year in the cams state championship or are you going to run in the thing that mike barry is organising?

ozracer · 30-01-2007, 11:16 PM

Kenny Im in Adelaide so will get over to Melbourne and PI and maybe Sydney as well but more likely home and Melbourne at this stage. Run it at MSCA Sprints, 6 hour, Hill climbs etc etc and it will be road registered.

MikGan · 31-01-2007, 09:07 AM

Good read, best quote from that page

Quote:

Gotta be thankful for people who bend their nice shiny new cars for our benefit ;)

eXtremist · 31-01-2007, 09:13 AM

Where abouts did you get the engine from?

photn · 31-01-2007, 10:58 AM

A wrecked Focus im guessing!

Piotr · 31-01-2007, 11:04 AM

May I ask you how much it set you back?

31-01-2007, 11:56 AM

Keep in touch! Very interested on sucessfull engine mods you do to this.

Ringo · 31-01-2007, 01:10 PM

your living my dream...building a Clubman....well one of my dreams...the other is building a Cobra (Mrs Ringo has ok'd the Cobra over the Clubman though)

Please whack more about this in Project Cars.

photn · 31-01-2007, 02:26 PM

www.raceline.co.uk offers some good performance intake stuff, TB's and all.

ozracer · 31-01-2007, 06:56 PM

Okay, where to start.

The particular kit that I am using for which I am an agent derives from South Africa. The chasis is dimensionally accurate to the original Lotus 7 which makes it very light. My last car was 550 kilos I am attempting to get this just under the 500 kilo mark. Traditionally in Australia we have used the Toyota 4AGE 20 Valve which still is a fantastic motor. It is imported, makes about 150 bhp has quad tb's and revs like the stink. You can obviously understand these cars are fairly quick and handle senationally given their power to weight, spaceframe chasis and excellent suspension geometry. I just recently sold my car to Sydney it is the red car with the white stripe which you may have seen on the website I referred to in my first post. Essentially times are changing and becasue of emissions restrictions the whole kit car industry has had to rethink on the engines they are using. We are now using the Zetec and the Duratec and a number of other motors Toyota 2ZZ etc. The Zetec will be the most popular but I wanted to put a Duratec together now given the engines fantastic characteristics and it's extremely light weight for obvious reasons. There is another Duratec powered Birkin being built in Perth and one about to be built in Melbourne by Meridien Motorsport the Birkin agents in Melbourne. These are the first Duratec powered clubmans I am aware of. My car will utilise the original ecu and I will modify the original loom by cutting out all the unused stuff. I am researching the software at the moment which will probably be Super Chips Stuff which you may be familiar with from America. This appears to be very good software and capable of switching off certain ecu parameters and modifying the original ecu fairly easily. This can also be done on the zetec which ecu wise is not as complex as the Duratec. As you can imagine these engines are not plentiful given they were only released in June 2006. They are not exactly falling out of trees at the moment given their newness but I believe this will change in the next few years given focus sales figures and Ford's International commitment to mass engine production of the Duratec. So if you are looking for one you really need to sit on the net and scale Australia. There was one in queensland I saw on pickles damaged car auction site last week. Price wise at this stage they are being picked up between $2,500 to $3,500 depending on what you get with the package. I got everything including the throttle pedal, instrument cluster, ecus x 2, starter motor, alternator etc etc.
The motor will be registered in fairly standard trim I will then add quads, cams and remap the ecu which will easily give well in excess of 220bhp (in a 500 kilo toy). This is being achieved very easily in the UK by a number of tuning companies including Raceline as someone pointed out and Webcon. I will be running a dry sump system either Cosworth or ARE which make dry sumps for the american Formula Ford series which run 2.0 litre Duratecs. A number of other ideas are in the works including cooling water rails, light flywheels, clutches etc etc. The engine will be mated to a Ford Type 9 gearbox inported from the UK with a quaife close ratio gear set. Rear end is fully independent with a Subaru Impreza diff centre.

I think that covers everything if not ask away I am more than happy to ask and share the knowledge with you guys as I play with the Duratec.

Is it worth putting this post in the project cars area as well? Do you think some of the v8 scene would be interested in my build or not?

ozracer · 31-01-2007, 07:10 PM

Just to give you guys a further idea of what can be done with a Ford Duratec in a clubman have a look at this internet link from the UK.
A beautiful Caterham 7 very similar in appearance to my car in fact alot of people say you cant tell them apart.

http://www.jackals-forge.com/lotus/duranail.html

Piotr · 31-01-2007, 07:42 PM

Westfield make duratec and Zetec-SE powered clubmans themselves

http://www.westfield-sportscars.co.u...&lid=13&tlid=3

photn · 31-01-2007, 07:53 PM

How much is the Kit car without the engine? and aer there different types of cars you can get?

31-01-2007, 09:41 PM

Quote:

Originally Posted by ozracer

Is it worth putting this post in the project cars area as well? Do you think some of the v8 scene would be interested in my build or not?

Yes pretty please!

Remember CAPA has been able to flash tune the original ECU sucessfully, perhaps a trip to Melbourne with the car on the trailer may be something to concider.

ozracer · 31-01-2007, 11:24 PM

Thanks Guys glad to see some interest I really love this Duratec motor it really is an impressive.
I haven't had a look at the ports in the head yet but I was reading an article in an english magazine recently (Race and Track Magazine) on Duratec performance and accessories available for it and they quoted the Duratec Head is something Formula 1 Designers would drool over. I guess this is why it responds so well to tuning.

Piotr:- Yep Westfield in the UK do. The Duratec is becoming the staple engine for all kit car manufacturers in the UK at the moment. However the Duratec has been their since about 2002 when it came out in the Ford Mondeo. The other thing is that it is very easy to get a motor through their SVA Test in the UK with after market ECU's and the like they dont have the same restrictions as we do here.

Photn:- Re pricing of the kits have a look here birkin.com.au
It is all explained. Depending on how much you can do yourself really effects the final price of the kit. Anything from $35,000 to $55,000 depending on how bannanas you want to go. These are road registered cars though. I drive mine to the race track, race and then drive home. My Toyota powered 4AGE routinely was blowing Porsches and WRX's to the weeds they are a very quick car.

Black LS:- Re CAPA they are actually in the Riverland 2 hours from Adelaide so even better but as I said am looking at buying the software so we can tune it ourself. Haven't committed to anything yet but this looks the most promising.

XR5-Boy · 01-02-2007, 01:49 PM

Welcome to the forum dude. I'm a big fan of the Elfin's. I managed to take an MS8 Streamliner for a spin around the Phillip Island circuit. It was magic!

It had the GEN III engine (yes, i know that word is blasphemy in here) but it went like a rocket! Hopefully the car turns out for the best

kenny21 · 01-02-2007, 02:25 PM

Oz racer, i myself love the duratec and the mugen honda (for a race engine) and wanted to put one in ma Supersports Mallock i dunno if you have herd of mallock but its a big company in england that makes race cars. Anyways the only problem i have is that being a front engine car the exhaust is on the right on the duratec which means it would go straight through ma legs haha, how did you go about this problem? We ended up goin with the new Suzuki Liana 1.8 and destroking it to 1.6 cause thats wat our rules allow and that head is amazing. Its got bigger inlets then the cosworth and man does it breath well. 13:1 pistons, gapless rings, tighe cams and came out with 218HP, so in the end it worked out to prob be as good as the duratec.

ozracer · 04-02-2007, 05:39 PM

Bump Update 4/2/2007

http://www.oz-clubbies.com/phpBB2/vi...afd73cf9a4d7aa

fou_bleu · 04-02-2007, 05:45 PM

good! I would have prefered the 2.5L 5 cylinder engine out of the XR5T, but it's still a great project!!!

ozracer · 04-02-2007, 07:29 PM

This motor will make heaps of power well over 200 bhp. The turbo motor wont fit anyway its too big for the engine bay and that sort of power is not really needed it's bloody hard trying to get it to the ground in a 500 kilo car.

04-02-2007, 10:12 PM

Ozracer, The Oz LS Focus (aside from the XR5) is built in South Africa, and I was under the impression out engine was manufactured in Mexico although I'm probably wrong.

ozracer · 04-02-2007, 11:14 PM

Hmm interesting when I spoke to the guys at a local Ford Service centre they told me it was manufactured in Europe. All Duratecs from europe are manufactured in Valencia Spain. But if what you are saying is right they are manufactured in South Africa then they probably do come out of Mexico. I will do some research and check up on that one.

kenny21 · 05-02-2007, 01:25 AM

hey oz, so how u get around the problem of the exhaust coming out the right hand side? Or is it just that with the PRBs that u can mount the engine in front of the cockpit enough that the exhaust clears your legs?
Cheers
Alex

ozracer · 05-02-2007, 04:39 PM

Its not a problem at all the exhaust are made for the Duratec at the factory in South Africa. They go over the top chasis rail and down no issues whatsoever

melbzetec · 05-02-2007, 06:22 PM

Adam,

Picked up a pamphlet at Small Ford Sunday from Eurospeed Motorsport. They are developing a whole range of fitting kits and custom engine kits for the Duratec...... for Escorts, PRB, and clubmans, plus lots of ancillaries (alternators, water rails, manifolds, throttle bodies, ecu's, harnesses, sensors, gearboxes, housings etc etc)

It all looked good, and prices seemed ok as far as I could tell

Their website (www.eurospeed.com.au) has none of this info on it yet, but if you're interested, the guys name is Geoff Gillespie, 0409 275 149, sales@eurospeed.com.au, and I'm sure he could send you a pdf of his pamphlet

ozracer · 05-02-2007, 10:01 PM

Thanks for that much appreciated I have bought type 9s from him before wasnt aware of all the other stuff though maybe he is bringing in some of the stuff from Raceline Ill contact him thanks for that.

Piotr · 05-02-2007, 11:41 PM

The engines built in Mexico are slightly different to the engine built in Spain. The Mexico engines are used in US, brazilian and argentian Focus's (Any maybe some more american countries). They have less power 100kw and a 10.1compression ratio compared to 107KW and a 10.8Compression ratio.

We have the engines built in Valencia

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