Tonycaterham Posted March 21, 2003 Share Posted March 21, 2003 After having my engine modded by Ammo a few weeks ago, has now be on the dyno at Dennis Vesseys at Barnetby in Lincolnshire. After 3 hours they got power up to 195BHP @ 6766rpm which is the best thay have seen for a zetec of this spec. Spec is as follows: Head ported from 102 cfm to 130 cfm @10". Head skimmed by 0.5 mm. Kent Cams FZ2002 with VS 46 valve springs. ARP connecting rod bolts. Raceco underdriven aluminium crank pulley. Engine running on Weber 45's with 40mm chokes with Weber Alpha Management system Rev limiter set to 7600rpm To say I am pleased is an understatement However sitting in the car on the dyno with an indicated 130mph on the speedo is a 'interesting' experience. I would recommend Ammo capabilites to anyone, unless of course you are competing in Class 4 at the 7 Club sprints, in which case I would propose lots of lead, and a nice block of wood under the throtttle pedal. Tony LA 7's alive and kicking Link to comment Share on other sites More sharing options...
Andrew Russell Posted March 21, 2003 Share Posted March 21, 2003 Tony, That should provide some interesting performance for you! Glad to hear that your up grades are all going well. Best wishes Andrew Link to comment Share on other sites More sharing options...
AMMO Posted March 21, 2003 Share Posted March 21, 2003 Tony I'm glad you are pleased. You may remember I predicted around 190 bhp for this engine. I like to be conservative on power figures. There is plenty of room for further improvement if you fit throttle bodies (maybe with a bit of extra porting), vernier timing pulleys so you can swing the cam timing on the dyno and a more open 2.5" bore exhaust to replace your stock Caterham silencer. Dennis Vessey should be faxing me the before and after dyno sheets sometime today. How much power did the engine make before the mods? Dennis also told me you had a big grin o your face after your road test. Have fun. 😬 AMMO Link to comment Share on other sites More sharing options...
I.Mupferit Posted March 21, 2003 Share Posted March 21, 2003 Tony, Sounds as though you are quite pleased Is it a 2 Litre? Can't wait to get my new, improved Zetec installed and running 😬 Brent 7 not now in so many bits 😬 Link to comment Share on other sites More sharing options...
Tonycaterham Posted March 21, 2003 Author Share Posted March 21, 2003 Ammo, Engine made 165BHP before mods which was spot on for the specification. Engine was dyno'd as Vesseys last May. Brent, It is a 2 litre engine. I am aware you are a fan of the Zetec and are going the Ford axle route which I did last year so would be interesting to compare notes sometime despite the fact that I only have cycle wings, Andrew, Nice to hear from you. How is life without a Caterham? Where did your car go as I have not seen it at any events. Presume any hopes that your wife had about no longer spending hours on Blatchat have been dashed!!!. Tony Link to comment Share on other sites More sharing options...
I.Mupferit Posted March 21, 2003 Share Posted March 21, 2003 Cycle wings eh? Oh well never mind Yes I have now got the Ford axle with disc brake conversion and ATB differential so looking forward to trying it once the engine is back in. Did you modify the transmission tunnel yourself or get Arch to carry it out and have you had any problems since with clearance? My engine now has a DVA head, Piper BP285H cams, ARP bottom end and 45 TB's with Emerald ECU. So looking forward to getting it on the RR to see what it makes. Brent 7 not now in so many bits 😬 Link to comment Share on other sites More sharing options...
julians Posted March 21, 2003 Share Posted March 21, 2003 Thats exactly the same spec as mine ,except mine has a raceline ported head, and is on TB's. I'd be interested to find out how it goes. Link to comment Share on other sites More sharing options...
Tonycaterham Posted March 21, 2003 Author Share Posted March 21, 2003 Brent, Sounds like a nice spec. I did the chassis mod myself I bought the smaller 3 1/2 inch? flange which provides a little more clearance but on right hand corners proposhaft caught bodywork , so I drilled out all the rivets round the rear of the transmission tunnel on the drivers side then repositioned the metal hoop which attaches to the outside of a chassis bracket to the inside i.e nearer the tunnel skin, then using wood dolleys and a trusty old tyre lever gently 'massaged' the tunnel and the rear panel to which the tunnel is rivetted to provide clearance. This was sufficient. I have done several trackdays and sprints with no problem running 205 A21R's If you want to call me to discuss then I am on 07715- 159412. I am intrested in your disc conversion, as I am runnning drums at the moment. Tony Link to comment Share on other sites More sharing options...
I.Mupferit Posted March 21, 2003 Share Posted March 21, 2003 Tony, I had the disc conversion carried out by Steve Perks when he prepared the axle for me. It is a very neat conversion that utilises some beautifully machined aluminium lugs to mount the XR4i calipers on and Escort MK 5? front discs. The only real pain, although not insurmountable, has been the routing of the new De Dion type handbrake cables. I will let you know how it all works out once the car is back on the road. Brent 7 not now in so many bits 😬 Link to comment Share on other sites More sharing options...
JamesA Posted March 21, 2003 Share Posted March 21, 2003 Tony, On the bottom end just ARP rod bolts? Stock crank shaft and connecting rods? 195 HP,,, excellent! Link to comment Share on other sites More sharing options...
AMMO Posted March 22, 2003 Share Posted March 22, 2003 James You can go 200 bhp + on the stock bottom end with ARP rod bolts. Once you start talking over 110 bhp per litre it's wise to start thinking about steel cranks, rods and forged pistons. Tony's engine will be tractable at low speeds and can be used as an everyday means of transport. It also has the ability to run on low octane fuel but should use high octane fuel for track use. Although these engines are a little on the heavy side they are good value for money and are boringly reliable. Dunnells have been building these engines for quite a while. All the time they have been building them they have only ever had two come back. On both occasions the customers had run them low on oil. I have an 1800 Zetec in my Caterham which made 177 bhp at a recent dyno session. A great little motor. Hoping to bump it up to around 190 bhp with fuel injection and a few other mods. Get in touch if you need any information. AMMO Link to comment Share on other sites More sharing options...
cdg Posted March 22, 2003 Share Posted March 22, 2003 Just as an aside... The Zetec in my mates Chevron sports racing car has just made 257bhp on the engine dyno. It's a stock bottom end apart from forged Accralite pistons, and uprated bolts, but obviously with a heavily modified head. Midrange is VERY strong. Redline is only 7500rpm. Built by Solus. Chris. Link to comment Share on other sites More sharing options...
JamesA Posted March 22, 2003 Share Posted March 22, 2003 Oh, one other question, are you running the stock compression ratio, in the US it is 9.3 : 1. Is it the saeme for the UK? Link to comment Share on other sites More sharing options...
AMMO Posted March 22, 2003 Share Posted March 22, 2003 James Stock Zetecs are 10:1 in the UK. AMMO Link to comment Share on other sites More sharing options...
yankeedoodoo Posted March 25, 2003 Share Posted March 25, 2003 Is that 195HP measuered @ the rear wheels or flywheel? Or is it a formula used to estimate HP @ the rear wheels? It's an excellent figure!!! What is your max torque figure and how does it perform from idle to 4000RPMs? Nice work AMMO!!! Link to comment Share on other sites More sharing options...
Threeracers Posted March 25, 2003 Share Posted March 25, 2003 Can I ask those who have added Piper 285 cams, which Zetec you have (series 1, 2 or 3) and if you uprated your springs and retainers with the cams? I have a 2 litre series 3 Zetec (solid followers) and I am just about to go down the same route of porting and changing cams. Its an extra £150 or so for Piper springs and steel retainers and I am inclined to fit them just to be on the safe side. Mark Link to comment Share on other sites More sharing options...
julians Posted March 25, 2003 Share Posted March 25, 2003 Not sure what series zetec I have (but I think it a 94 engine), it has hydraulic followers. When I fitted the 285 cam I didnt change anything else. Its been fine now for about 2 years and around 7000 miles (2000 or so of those are track miles) Link to comment Share on other sites More sharing options...
Threeracers Posted March 25, 2003 Share Posted March 25, 2003 You have either a series 1 or 2 Julian. They were made up to April 98 and used hydraulic followers. From May 98 onwards the series 3 used solid followers. I think the series 1 had “DOHC 16V” on the cam cover and the series 2 had “16V Zetec” but I am not positive. Mark Link to comment Share on other sites More sharing options...
Mike Molloy Posted March 26, 2003 Share Posted March 26, 2003 Zetec Thread Hijack... A friend is building a Westfield and is looking for a 2 liter Zetec. Any advice on the best places to get one? (Has to be pre-95, apparently.) Ta, Mike. Link to comment Share on other sites More sharing options...
Matt Seabrook Posted March 27, 2003 Share Posted March 27, 2003 I have a 2000cc Zetec making 210bhp in a 600kg Westy it will pull from 1500rpm (full throttle) in 5th gear. These engines are very under rated. I am now looking to go for steel rods and forged pistons. Not sure if this is going to be strong enough for 250bhp but I would just like to wipe the of some of the Vx boys faces. I know it will not produce as much power ultimately as the Vx but will make more power the my driving ability will cope with 😬 Link to comment Share on other sites More sharing options...
AMMO Posted March 28, 2003 Share Posted March 28, 2003 Matt On top of the pistons and rods you will probably need bigger valves and porting. Mechanical profile cam with solid followers (possibly oversize). It may be possible to convert the hydraulic followers to mechanical. The valve springs are a bit of a problem. The only reason you need bigger followers is to accomodate dual valve springs. I have been testing various springs on my RIMAC machine to see if there is something available that would save the expense and aggro of machining the head. I think the touring car guys use a single Schmitthelm spring. Probably very expensive. There are dual springs that will fit under the stock follower. You would have to modify the retainers, remove the standard stem seal, provide an spring seat and either run with no stem seals or find a stem seal that fits inside the inner spring. This may need the guide to be modified. It may be possible to make a piloted tool to do this in situ. However you do it it involves a bit of aggro. If you would like me to research it for you I will. AMMO Link to comment Share on other sites More sharing options...
Matt Seabrook Posted March 28, 2003 Share Posted March 28, 2003 Hi Ammo thanks for the help. This is going to a bit of a long temp project, as I know it will not be cheap. I have been looking into getting proper solid lifters for this sort of spec anyway. Do you think the crank will be up to the job at this level? I have also been looking at piper or Kent cams could you take an educated guess which cam profile would be best I do not want to completely destroy the bottom end performance. I have also thought about boring the engine out to 2070cc (86.5mm) as I think this is as big as the engine will go correct me if I am wrong. I Know the valves will need to be bigger and I am hopping by over boring the engine it will give the valves a bit more room as I know that the valve area is a bit of a problem with Zetecs Link to comment Share on other sites More sharing options...
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