Focus disaster

melbzetec · 02-12-2009, 10:24 PM

The Melbzetec Focus is in a sorry state.

Looks like three piston rings are damaged, and I'm up for an engine rebuild.

(Plus starter motor is fried, but that's another story)

Not easy to rebuild either. Ford don't sell rods and pistons. (Only short motors at $5700!!!!) And it is difficult to get aftermarket pistons that don't either (a.) drop compression, or (b.) raise compression to levels that need race gas.

Looks like custom forged pistons from the US, and about two months out of action (and a BIG hole in the wallet

: ).

Small Ford Sunday is looking shaky this year

stackaj1 · 03-12-2009, 01:35 AM

Thats bad news!! especially after all the work youve done,
seems you will keep it and continue the Melbzetec focus journey, fair call too! must be tempting to get that RS over in Wellington though!!
hope you can get it sorted out without to much hassle.

Velociraptor82 · 03-12-2009, 09:59 AM

That is really sorry news....What happened? What caused the damage? If you rebuild it the same as it was before, could it happen again??

Fredo · 03-12-2009, 10:05 AM

Quote:

Originally Posted by melbzetec

The Melbzetec Focus is in a sorry state.

Looks like three piston rings are damaged, and I'm up for an engine rebuild.

(Plus starter motor is fried, but that's another story)

Not easy to rebuild either. Ford don't sell rods and pistons. (Only short motors at $5700!!!!) And it is difficult to get aftermarket pistons that don't either (a.) drop compression, or (b.) raise compression to levels that need race gas.

Looks like custom forged pistons from the US, and about two months out of action (and a BIG hole in the wallet

: ).

Small Ford Sunday is looking shaky this year

Nooooo!! . . . . really feel for you mate.

:

Will you rebuild to former glory or would you consider stepping over to the dark side (XR5)? :dr_Evil:

Had my fat **** in one the other day and it felt goood. They really are a nice car.

Fredo

melbzetec · 03-12-2009, 10:20 AM

Would love to step into an XR5, but really can't afford it at the moment.

The Zetec is worth bugger all with a busted engine, so I'd get nothing for it without repairing it.

Rebuild will probably cost me about $5000, but it should be stronger (Forged pistons, shot peened rods, ARP bolts) , I'll go with a higher compression (11:1), and take the opportunity to fit the Quaife torque sensing diff I have sitting in the garage.
I have toyed with the idea of a supercharger (I can get my hands on a port and polished Powerworks at the moment), but I'm sick of unreliability, so would rather build a bulletproof NA engine
We're not really sure of what the problems are, or what caused it until we pull the engine down, but compression is gone in 3 cylinders, and really high in the 4th. Go figure. Also hard (impossible?) to start on some days (guess how I fried the starter motor!!) and losing some coolant...head gasket or block?

All in all a PITA

Fredo · 03-12-2009, 10:53 AM

Gotcha Melbz,
Makes my throttle issue very trivial indeed.
Fredo

Tj-zetec · 03-12-2009, 11:57 AM

Crappy, crappy news Steve. (in fact when I saw the title of this thread I was genuinely worried you'd been playing can opener with a truck again)

it seems odd that the engine has lunched three rings at the same time. While we can only speculate, it sounds like something has been getting into the combustion chamber ie a leaking head gasket, or worse, a cracked head.

Wait a minute, you've got higher comp in one piston? And is it low or a complete loss in the other three?
To speculate once again, I suspect somethings amiss in your valve train.

It's also very odd that you can't get rings too. You'd think an engine that is getting on eight years old would have these parts readily available.

Piotr · 03-12-2009, 02:49 PM

V8 Focus

Fast Eddie · 03-12-2009, 03:14 PM

Quote: "V8 Focus".

Or failing that idea, have you contemplated the possibility of dropping a crate engine in it i.e. a Cosworth? Just an idea but nevertheless I feel very sorry for your situation as we all know that your Focus is a work in progress and I've always regarded it as a "work of art". Something that I'd be very proud to own, for sure.

Hope it is all sorted in the long run.

Eddie.

melbzetec · 03-12-2009, 04:00 PM

Rob Herrod has checked the valvetrain and all is in order.

I do have a theory. A bout a week prior to the engine becoming sluggish, I put a bottle of Techron in to clean the injectors.

Now, I'm wondering, IF there was a carbon build up around the rings, MAYBE the techron softened the carbon deposits, exposing the worn piston rings??? Probably not, but just a thought.

Do Cosworth do a crate engine Eddie? I'd love to know. I know they do a Duratec, but not aware of a Zetec.

I can buy a brand new Zetec engine from the States at the moment for US$850, but the shipping would be horrendous, and your only getting a bog basic engine

There are a couple of strong short motors being offered in the US, but they are low compression(for forced induction) and again frieght will be huge.

At this stage, a rebuild looks like the best option

Velociraptor82 · 03-12-2009, 04:40 PM

Quote:

Originally Posted by melbzetec

Do Cosworth do a crate engine Eddie? I'd love to know. I know they do a Duratec, but not aware of a Zetec.

I did look up the cosworth website not that long ago to look for just that. I browsed through their catalogue but sadly couldn't make sence of their products.

The Zetec engine has been around a little longer that the Duratec and since it's not aluminum like the duratec, it can be pushed harder. I'd be surprised if they don't do one.

I suppose you'll just have to ring. The focus community are dying to know....

Piotr · 03-12-2009, 06:56 PM

It might be worth taking a look at shipping from the US. I was quoted 130pounds for shipping a new duratec crate motor from the UK

melbzetec · 03-12-2009, 07:36 PM

That's good info Piotr.

Thanks. Reputation points for you!

leakey · 03-12-2009, 10:16 PM

There's a Zetec engine on ebay at the moment.

http://cgi.ebay.com.au/2-0Lt-Ford-Fo...item3efab9de16

819_FLY · 03-12-2009, 11:12 PM

Caterham R500 Engine Perhaps????

Sucks about your misfortune mate, seemed like it was supposed to last a little longer then it has. Hope you can get it sorted soon.

melbzetec · 03-12-2009, 11:22 PM

Quote:

Originally Posted by leakey

There's a Zetec engine on ebay at the moment.

http://cgi.ebay.com.au/2-0Lt-Ford-Fo...item3efab9de16

Thanks Leakey. He's asking a bit much though. Going rate for a Focus engine is about $650 (albeit with more k's)...but you really don't know what problems you're buying.

But really appreciate the heads up

melbzetec · 03-12-2009, 11:39 PM

whoo hoo! The God's may be smiling! Just found this on UK ebay.

http://cgi.ebay.co.uk/ws/eBayISAPI.d...MakeTrack=true

Brand new Zetec short motors. 10 available. Under 280 quid.

Have just sent a message to get a cost on freight

Buzz Box · 04-12-2009, 02:02 AM

Quote:

Originally Posted by melbzetec

whoo hoo! The God's may be smiling! Just found this on UK ebay.

http://cgi.ebay.co.uk/ws/eBayISAPI.d...MakeTrack=true

Brand new Zetec short motors. 10 available. Under 280 quid.

Have just sent a message to get a cost on freight

Well you wouldnt have to worry about reliability if you brought 10 motors lol

:

Fez WQ · 04-12-2009, 02:23 AM

http://cgi.ebay.com.au/2-0Lt-Ford-Fo...item3efab9de16

Focus motor for you maybe

melbzetec · 04-12-2009, 07:50 AM

Quote:

Originally Posted by Buzz Box

Well you wouldnt have to worry about reliability if you brought 10 motors lol

:

Fast Eddie · 04-12-2009, 03:01 PM

Steve, Have a look through www.streetperformance.com

There MAY be something of interest in there. Just a though.

melbzetec · 04-12-2009, 03:35 PM

Thanks Eddie. Good site

DZFord · 04-12-2009, 08:30 PM

Hi mate, shattering news. The short motor from the UK looks good, I only hope freight doesn't blow a hole in the wallet.

Here's another thought - is there are stroker kit for the Zetec?

Cosworth definitely don't do Zetec engines, just 2.0L and 2.3L crate engines. It would be a dream to have one of these under the hood - high compression ratios (up to 13:1), but backed up by Cosworth's forged internals.

FORD5 · 04-12-2009, 09:00 PM

sorry to here the focus is down and disabled, best of luck bud

Fast Eddie · 08-12-2009, 02:25 PM

Any more development/s on sorting out your "problem"???

melbzetec · 08-12-2009, 04:47 PM

I've just ordered a brand new short motor from the UK.

Great price 280 pound. Air freight a frightening 370 pound. But all up about A$1200. (Not bad compared to Ford Australias $5700 price!)

Rob Herrod is reorganizing the workshop at the moment (new dyno I think) so really doesn't have room to hold the car. This way, it is a straight swap in and swap out, and now worries about rebuilding the bottom end.

I've also got a 2001 US Intake manifold coming (flows a little better), and will probably get a different custom tune from the states (one of Tom's tunes for anyone that frequents Focusfanatics).

I'll take the opportunity to get the Quaife LSD fitted when the motors out.

Doubt whether it will be done by Christmas however

Velociraptor82 · 08-12-2009, 06:54 PM

Quote:

Originally Posted by melbzetec

Doubt whether it will be done by Christmas however

Maybe not christmas but how about feb 7th?

Sounds like the engine was a bargin. I'm sure you'll be happy once you get it back on the road.

melbzetec · 08-12-2009, 07:41 PM

Half a chance for Feb 7.

Photn.....where are my brake knuckles??? :P

Woodsa · 08-12-2009, 09:43 PM

did you check the head gasket and head stuff first... could just be a rooted gasket? and water in the 4th? just an idea..

Fast Eddie · 09-12-2009, 03:20 PM

Good to hear there's some progress with the car. Are you planning on re-installing the Ford Racing Head??

Also, you'll have to let us know what you think about the Intake Manifold in comparison to the Pipercross Viper jobbie as I might be interested in one myself if it's a good fit and easy to install.