Sleepers Zetec Sleeper

Larger 4 cylinder engines, body mods, major brake and handling modifications.

Sleepers Zetec Sleeper

Postby Sleeper » Tue Jan 10, 2017 9:27 am

Dear All
Hope you don't mind but thought it might be a good idea to document the progress as this is a long term project, and this section seems as good as any...

Thanks
John

Purchase price of a 2005 Focus 2.0 with 75,000 mls on the clock £250:00 ,engine and all ancilleries (ABS) stripped out and the carcase left for the scrap-man
DSC01736.JPG


Alternator replaced with a 100A bosch,power steering and aircon binned ,sliding tensioner pulley fitted ( correct water pump rotation ) and a new 6pk1115 belt fitted
2017_0110sleeper0002.JPG

John
Last edited by The vast minority on Sat Jan 21, 2017 6:39 am, edited 1 time in total.
Reason: Placed photo in line to eliminate white background and dotted lines
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Re: Sleepers Zetec Sleeper

Postby Nourish » Tue Jan 10, 2017 10:10 am

I like your Idler pulley solution - I was thinking along those lines but yours is much simpler - very good!
Why have you changed the alternator - and why not use the std belt tensioner? - Can you post a picky of your tensioner?
Cheers
Martin
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Tue Jan 10, 2017 11:19 am

Martin
Was advised ( correctly ) the standard alternator was controlled by the Ford ECU,tossed it in the bin and made a new fixing for the Bosch
Thought of the standard belt tensioner but couldn't find anywhere nice to fix it.
As for the tensioner what you see is what you get,a foot of 1 1/4" angle steel with two slots in it,tapped for the M10 bolt with locking nut and turned down the heads of the bolts just in case the belt flaps around...

John
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Re: Sleepers Zetec Sleeper

Postby qwertyhenry » Tue Jan 10, 2017 2:50 pm

hi m8 have a look at this build tread my m8 st170
viewtopic.php?f=48&t=2882
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Wed Jan 11, 2017 8:49 am

Yes,that was one of my many hours of research but I'm not going racing , just need a mild mannered daily driver street sleeper,hence will be keeping the standard induction system and exhaust manifold mated to a Type9 gearbox,quaife ATB and escort back axle,driven by the Megasquirt Ms1.

John ;)
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Re: Sleepers Zetec Sleeper

Postby Nourish » Wed Jan 11, 2017 9:18 am

Hi John - I meant a picture of your Alternator tensioner!
My plans too are to use the std intake and ECU although I'll be using the ST170 engine and the exhaust manifold won't fit.
Sounds like you're not using the Focus ECU - take a look at this if you haven't seen it before
https://www.locostbuilders.co.uk/viewth ... tid=179921
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Wed Jan 11, 2017 11:46 am

You would wouldn't you,that was the most complicated bits of metal welding/drilling.there is no alternator tensioner it's just a two piece bracket,the idler pulley is the tensioner....when I've got the Moggie gearbox out ( noisy 1st ) I'll dismantle the mounting and post a piccie.
John ;)

P.S Using the donor ECU is far too complex.especially as one has a running Megasquirt ECU on a similar Ford ( Ford Lotus 1600 Twincam,throttle bodies ,Wasted spark 36-1 etc...
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Re: Sleepers Zetec Sleeper

Postby jonathon H » Fri Jan 20, 2017 11:43 pm

This is how we run our Zetecs, std alternator and pump
DSCF0001.JPG
Last edited by The vast minority on Sat Jan 21, 2017 6:37 am, edited 1 time in total.
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Re: Sleepers Zetec Sleeper

Postby 200272 » Wed Feb 22, 2017 12:07 am

You can use the standard alternator, it defaults to 14 volts max output when the ECU is disconnected.
I've been doing this with no issue in my van.

Also using standard inlet but on an Omex.

Loving the idler/tensioner idea.
The Bean: 1972 2002tii (ish), 5speed E21 O/D, 6 series Recaro interior.
Green Bean V8 M60 conversion

Sideways!
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Wed Feb 22, 2017 9:15 am

Ooops , too late now it's in the bin,but replaced by "cheap as chips" 100Amp bosch unit,hopefully using the existing Ignition telltale..
John ;)

P.S. Haven't thing moved on,my old lucas alternator was rated ay 37Amps.
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Tue Apr 18, 2017 8:00 pm

Update
I've not been sleeping but life has got in the way...anyway,managed to fit two 10inch fans into the gap between the rad and grille,one controlled by a thermostat the other manual.

2017_0418twinteninchfans0006.JPG


And the redundant regulator box has come in handy for extra fused relays,one for accessories the other ignition,with tell-tale LEDs

2017_0418regulatorbox0005.JPG



The dash panel insert is also coming on

2017_0418dash0002.JPG


( after numerous attempts )

2017_0418dashpatterns0001.JPG


John ;) ;)
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Re: Sleepers Zetec Sleeper

Postby woodywoodchipper » Thu Apr 20, 2017 2:51 pm

neat idea with the regulator ;)
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Sun May 14, 2017 9:11 am

and the bell housing has been modded to fit the Blacktop Zetec with the starter motor in the correct place..

2017_0514bellhousing0001.JPG


John ;)
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Re: Sleepers Zetec Sleeper

Postby jonathon H » Tue May 16, 2017 7:59 pm

For interest we are about to look into the manufacture of the high mount starter bell housing. We use an alloy one with our Midget zetec conversions, and feel that this high mount type should be useful for many other marque conversions.
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Re: Sleepers Zetec Sleeper

Postby Sleeper » Tue May 16, 2017 8:55 pm

I agree,firstly I picked up a Morgan alloy bell-housing but wasn't sure about its strength with the steering rack cut-out,and after seeing a picture of one on the web decided that was the way to go...no costly does-it/doesn't it fit starter motors,just the standard Blacktop article in the standard Blacktop place.

john ;)
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