Paul Hunt's Zetec SS1

 

08/31/08

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Paul's 2.0 Zetec SS1

Paul's SS1 has had a ground up rebuild, but went with the CVH engine's successor, the Ford Zetec (Zeta).  In this case, it's in 2.0 litre guise as originally found in the Mondeo.  As the engine was designed for a FWD transverse installation, transposing it to a RWD in-line install has provided a few little niggles along the way.

Fully stripped and rebuilt chassis

Rolling chassis, but missing something...

Carefully rebuild a 2.0 Zetec..

Fully built engine

At least it drives!

Gets a bit windy at 70mph, though...

Paul has created a spec sheet for the work so far:

Engine Bay

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2.0ltr 1993 Ford Zetec (Zeta) engine

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Head flowed, ported, balanced & smoothed chambers by Andy West at CHD

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Kent FZ2001 cams

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Kent high performance hydraulic tappets

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Competition valve guides

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Heavy duty mains bearings

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Heavy duty big end bearings

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ARP high tensile conrod bolts

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Competition piston rings

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Dynamically balanced crank assembly by Wilcox engines

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Balance conrod/piston assemblies by Wilcox engines

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Lightweight Zetec flywheel (1.6 zetec)

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Twin 45 DCOE 152’s

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3D mappable Alpha ECU

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16mm length induction trumpets

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Pipercross air filters

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Twin return spring throttle linkage

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Custom engine mounts

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1.8ltr Zetec ally sump pan + pick up

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1.8ltr Zetec dipstick tube, top mounting tube/bolt and dipstick

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Custom stainless steel water pipe (thermostat housing to top hose)

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Custom Stainless steel water pipe (rad bottom hose to water pump with take of for header tank and take off for thermostat bypass)

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Samco silicone reduction hose (water pump to custom pipe 32mm)

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19.1mm rubber hose (thermostat bypass to custom water pipe)

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1.8ltr escort Zetec water pump

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Rover 400/600 cooling fan mounted using custom bracket

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Spare thermostat housing outlet blocked using copper pipe stop ends

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Mocal Remote oil filter

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Mocal sandwich plate to allow take off for remote filler

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Oil pipe and fittings for remote filter

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Silicone hose for rad to expansion tank

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Custom alternator bracket using old LH engine mount, upside down on RHS of engine under inlet manifold

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Spigot bearing from CVH sierra

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Custom full length 3” bore, stainless steel exhaust system & tubular 4into1 manifold. Built on the car by Andy at Gran Fabrications. Routed over the LH chassis rail, collector in the wheel arch & then routed under the trailing arm. Straight through stainless silencer at the rear.

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 Engine rotated about crank axis to sit more upright for inlet clearance.

 Chassis & Body

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Car rebuilt on late SS1 galvanised chassis

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Painted using chassis paint and etch primmer

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All bolts, nuts & set screws replaced with stainless, usually socket screws

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Extra rear wing supports added to allow wheel/arch clearance

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15” 7J multispoke alloy wheels with 185/50/15 goodyear eagles. 34 offset + 10mm spacers

Fuel System

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Facet Competition Silver Top fuel pump

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10mm ID copper full length fuel lines

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Malpassi Fuel King filter and pressure regulator

Drive Train

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RS Turbo friction place

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Lightweight Zetec clutch cover

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Extended spigot bearing

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Starter motor spaced forwards

Brakes

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Custom copper brake pipes

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Goodridge stainless steel braided flexible hoses

Interior

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Full set of Smiths instruments

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Corbeau Pro-Race Kevlar composite shell bucket seat (not yet fitted – waiting for harness)

All finished, roof off...

..or roof on, it still looks standard from the outside

The aforementioned Rover Fan conversion

A very neat installation

...and that wonderful exhaust

Note the alternative routing for the exhaust, not over the driveshaft as normal

 

Paul still has a list of "to be continued"..

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Single layer carbon fibre bonnet, boot and hardtop (acquired carbon matt, in process of making moulds)

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Inboard coil over front suspension (designing new upper wishbone… slowly)

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Aluminium front brake callipers and large diameter vented discs

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Roll cage (any advice much appreciated)

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Limited slip differential

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Turbo induction system  (now I wonder why...?)

 

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This site was last updated Tuesday, 21 March 2006

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