Project Sierra GT 24V

[Remko GT]

HUGE update:
The build is finished. Yesterday we solved the problems we had with the sticking brakes, turned out to be the brakelightswitch keeping the brakepedal pressed down which resulted in the brakes overheating. All's well now. Got all the air out of the cooling system so that's behaving nicely as well. Yesterday's testdrive already showed it goes like stink. Love the way the sound changed pitch over 3500rpm (because of the VIS valve.) Deffo won't be needing a soundsystem for a while    The sound is addictive.

Today it passed its MOT.      
Few advisories,
passenger's side seatbelt damaged, took out pasenger's side seat, pass.  Will replace seatbelt tonight and bolt in the leather Reacaro front seats (after having stood in my bedroom for 5 months...     ) Can't wait to take my car out in these seats.
rear brakelines slightly corroded, corrosion sanded off, pass. Will make new brakelines to prevent further problems with that.
front flexis hitting tyres on full lock, flexis tied to shock, pass.

My m8 is now taking it to a garage have the front wheels properly aligned. We did it with our bare eyes and it was pretty good already, could easily release the steerring wheel when braking and it still went straight ahead. But the steering wheel alignment was off by more or less 20 degrees. Need to get that sorted because it looks awful    

Tomorrow the 1st stage of the re-registration at the RDW (dutch equivalant of the DVLA) and in a couple of weeks to the testtrack for stage 2 of the re-registration. Might just make it before the FSOC national day. Fingers crossed.  

[IansSaph]

Well done mate!
Top job.
Fingers crossed for you.

[capri v8 driver]

sounds good remco.

are you gone out it on the rollers?

greetz paul.

capri v8 driver.

[Remko GT]

Another HUGE update:

Today it passed the RDW technical test with flying colours.      The experts at the RDW checking the car were impressed with the build.    They asked why the rearaxle isn't Polybushed. Because we didn't get around to it yet.
It weighs in at 1290kg so it only gained 120kg over a standard 5dr twinky. And we had it weighed with a full tank, 17x8" OZ rims (those weigh quite a bit as well) the testers said that's quite light for such a car in full road trim (leather seats, the works)
CO was 0.25%, again our theory that the engine is a very low-mileage one seems to be acknowledged.

I haven't had it on the rollers yet. We've done all the tuning ourselves on the road. Can't afford to have it tuned on the rollers. Maybe in a week or 2 it's going to the testtrack in Lelystad. That's going to cost me 630 Euro. Well worth it though.
When we're happy with the results and I've saved some money I will puit in on the rollers for the finetuning.
Yesterday we had it spot on in 2nd gear, 3k revvs, it went like a fucking rocket untill it reached 5k and smothered in petrol again because we haven't adressed the mixture there yet. I shouldn't have it revved it to 5k but it went so fast I couldn't lift my foot of the accelerator fast enough. Can't believe how fast the car is already.  Also the handling of the car is spot on. The car has become exactly what I wanted it to be. I am so happy, I could cry...

[capri v8 driver]

the bob intake make a difference, combined whit the cams and ecu. but if i where you, i would put it on the roller for fine tuning, so you know the fueling and timing is spot on. its well worth the money. but you can do that after you whent to lelystad and if the wallet allows that is.

i hope the test's in lelystad goes as smooth as the RDW technical test.

greetz paul.

capri v8 driver.

[Remko GT]

the bob intake make a difference, combined whit the cams and ecu. but if i where you, i would put it on the roller for fine tuning, so you know the fueling and timing is spot on. its well worth the money. but you can do that after you whent to lelystad and if the wallet allows that is.

i hope the test's in lelystad goes as smooth as the RDW technical test.

greetz paul.

capri v8 driver.

It better make a difference. Otherwise we've completely wasted more than a year getting it to fit and work  

So do I Paul! Really hope to prove you wrong (obviously not personal) about it being impossible to get it re-registered with the BOA. But I think it'll be fine, the technical test is already done, no eyebrows were raised by the RDW ppl when the bonnet was opened (that's the thing that had me worried most) so all is left is the emissions (sound and whatever else they're testing) test and the handling test. Should be fine, I just hope it's on time so we can make it to the FSOC national day and maybe EFE the week after.
And then it's stainless steel exhaust and proper induction kit time. I wonder how much difference that will be.

[IansSaph]

did you ever drive the car as a standard BOA? what have you been driving before to compare its performance to?

The fine tuning and mapping is an expensive and time consuming process it seems.

Happy for you mate.

[capri v8 driver]

hello Remco,

i hope you can prove me wrong and that the RDW is not as stricked anymore as a few years ago.  

greetz paul.

capri v8 driver.

[Remko GT]

did you ever drive the car as a standard BOA? what have you been driving before to compare its performance to?

The fine tuning and mapping is an expensive and time consuming process it seems.

Happy for you mate.

I drove Marty's 24v, Damo's 24v and Mads 24v. Never drove mine with a standard 24v, we immediately started modding it. The car was built to see if we could pull it off more than the actual result. (although I have to admit it's nice to have a fast car as result)  It was more or less a study project. Can't half start counting how much I've learned.
Before I got into Sierras I was driving a really fast roadbike.

The thing is, I don't really need every single last pony squeezed out of it. It's a road car so if it picks up nice and crisps, revvs nice and smooth and goes like stink I am satisfied, I never go to pubs to brag about it anyway  So most of the tuning can be done on the road, saves me a bundle.

@Paul, it seems the RDW is indeed less strict than a couple of years ago.   Although I've heart ppl claiming certain parts of the inspection has become more strict. I think mostly because of stolen engines etc. I think my inspection went easy because the car has been mine over 3,5 years, which idiot would stick a stolen engine in a honoust shell? I'd like to think that declaration Ford sent me helped as well.

[cossiemk2]

Good work Remco.

It's a good thing you went to the RDW.
Although the Sierra came in V6 form it's good to have it tested.

The number of cylinders isn't an issue on MOT (APK) right now but its good to have an official report on it. As the Sierra came in 2.9 you shouldn't have any problems.

My Mk2 Escort was SVA'd on a 2.0 V6 and now sports a 2.9 24v on a supercharger.

As long as the build was made as it came "from factory" its fine.

What sort of tests do you have to do?

I had the Capri V6 brakes and a proper "original" exhaust times 2 it past with flying colours.

Had to pass the brake test and the dB test.

You shouldn't have any problems with both.

Handling isn't an option as the Sierra came in V6

[Remko GT]

Well, the technical tests are done. Yes, the handling is an issue. Powerincrease is over 40% so needs this test. Only the sound level and handling still need to be tested. The testers were very happy with the declaration I got from Ford with the power and other details on the BOA. Couldn't fool them though, they immediately recognised the 24v and the BOB plenum. But they were really impressed with the build quality. Not a single remark except: "Good work boys!" They really appreciated the fact we upgraded everything and made a couple remarks on how much was spent on the car on all the right places. Although the completely standard exhaust caused quite some hilarity.      
When they tested play on the transmission and suspension it was a lot better than a new sporty Merc behind my car. The Merc was dancing in its suspension, on mine only the tyres flexed a bit and probably the turrets. Solid as a rock  
They were also grinning when they noticed my rearwheels were turning the same direction, again, getting the thumbs up from the testers.  
The guy aligning it the day before was baffled    
The best part is, the RDW even let us keep the registration papers. Usually they take it and you're left without them till you get the new one after the final tests in Lelystad. I guess they are already sure it will pass the test easily. Otherwise they'd never let us keep the papers. The tester was really a nice bloke. Must be a petrol-head as well. I am so pleased with the result      
Some details:
front axle weight: 710 kg.
Rear axle weight: 580 kg.
I guess next couple of mods will be sticking the battery and the washer fluid in the boot to try to even the balance a bit. Although I must admit, the balance isn't that bad.
What I am also very happy with is the ride-height. I was afraid the rear would be too high but since we've driven it and give it a bit of stick the clearance on the rear is now slightly less than 2 fingers between tyre and arch and front slightly more than 1 finger.

[Remko GT]

After a couple more months of hard work due to to oil-leaks, breather problems and timing-gear worries we finished putting it back together. So here are the piccies, enjoy:

While the plenum was off, we decided to repaint it because we weren't happy with previous result. Had them blasted and then repainted them:

So now the engine is back in 1 piece, the VIS is still missing on this piccie:



Damo sold me his RS500 splitter so when they were over a couple of weeks ago we fitted it:


Because the MS ECU wouldn't fit the original ECU bracket we made our own, on it is also an additonal fusebox and the LC-1 WB Hego controller:

I will also be fitting racing harnasses. I mock-fitted the one I already bought (still need to buy the second but need to save up 1st because they are bloody expensive)
How cool is this going to look:


And a couple of random interior shots, I don't mean to brag but I haven't seen many Sierra's with a better looking interior:
The retrimmed headliner:

Interior shot:



And how we've secured the sapphy rearseat:

Part of it has been grinded out of a sapphy to make things a bit less complicated. It's a lot more sturdy then the standard hatchback rearseat securing, which frankly, is pants. The rear seat in a hatch always sort of callapses where it is devided. I didn't want that so we started welding. Original rear self won't fit anymore but I don't really care because that is pants as well. always sagging like hell and no good to put speakers in because it's far too weak. I haven't bothered making one because that will only add dead-weight. I haven't  a stereo in it anyway.

Tuesday night we spent getting a bit of the accelaration tuning right. We did manage to improve it but to speed things up I've decided to get it done on a RR so it will be ready for the tests once again. I plan on heading to Nieuwegein end of February and get it on t he test-track as soon as possible so I can finally drive it on the road legally and mod a bit more without having to keep an eye out on keeping it standard-ish for the tests. Saturday, Februari 21st it will hit the rollers with a guy who's had a bit of experience with MegaSquirt. I don't expect a lot improvement over a standard engine (if anyting) because it's still too heavily restricted by the exhaust and by the induction but as soon as it through all the test, first thing we're doing is removing the cat, the airbox, the middle dampers and the standard 2.9 backbox for something more fleeflowing. It will need another mapping session then, but so be it.

So, the session booked for the 21st we will just make sure it's drivable, picks up nicely, doesn't knock and stays in 1 piece. Tbh, it scares the hell out me having to let anyone else tinker on my car.....

[cossiemk2]

What will you be doing in Nieuwegein then Remko?

I live there so you could pop round.

[Remko GT]

The technical test it passed last year has expired so have to get it redone. Had good experience with the people there so figured I might as well go back there.
I reckon we're not living too apart then, I live in Mijdrecht, aprox 20km down the A2 and exit Vinkeveen.
Unfortunately, when I take it to the test it will be on a workday so can't come round but would need to get back to work asap.
We could meet some other day, maybe some day in the weekend when the car is road legal?

[Remko GT]

double post

[capri v8 driver]

its a wise move to spend some time on the rollers. let us now the results.

good luck whit the rdw test.

[Remko GT]

Good and bad news

Bad news 1st. Got fucked conrod bearings. BUGGER. Our own fault  probably. Taking out engine and replace the bearings.

Good news: all the mods have made an approvement. Even though my engine is heavily restricted (exhaust and induction) it still made 289Nm @4400rpm. The graph showed a torque line everyone would want. Went from 1800rpm in a straight line upwards to 4800rpm with an increase in slope around 3100rpm (the VIS works). We couldn't map it properly above that because of the conrod bearing playing up and the fact my MAP reading is fluctuating heavily over 5k rpm because of pulses in the plenum. AFR was all over the place. Going to make the MAP connection directly behind the TB.
We decided to tune it with safety for the engine in mind and for drivability rather than getting as much power from it as we could. Didn't go berserk with spark advance to keep it within safe regions. Ended up with 174bhp @4100rpm. With more spark advance it might have made 10-15bhp more. Considering the exhaust is a fully standard XR4x4 exhaust, catalytic converter still in place, double middle damper and standard backbox, the inletpipe is 60mm bore I am well chuffed. According to the tuner it could make 250bhp/350Nm with a proper induction kit and freeflowing exhaust. Over 270bhp with different cams.

So all in all, not all bad. Something bad was bound to creep up after all the smooth sailing on my project.

[Remko GT]

BOA Crank and block are knackered. Hidden dirt in the engine has ruined my bottom-end   There were a couple more issues that would've ruined the engine anyway so I think I got away lucky. Heads and cams are okay as well.
Pistons and conrods are still ok., so I will probably buy nice pistons and use the conrods out of the BOA.

Last night we stripped down the BOB block Aaron got me last summer. Thnks god the crank in that is still fine. Very minor scratches but that's to be expected with a used crank. Going to look into getting it polished or polish it ourselves. Basically, yesterday my new engine was born. Now we are really going to build the BOB/BOA hybrid. Been doing some calculations and I think I can scrape a budget of 2.5k Euro together in 2-3 months to rebuild the engine. I hope that will get me a more or less brand new engine bottom-end.

Anyone ever polished his own crank? Good results? Any hints/tips? What have you used? Clean linnen and a VERY mild polishing medium?

So now I am looking into the differences between the BOB and the BOA.
Tonight we will find out whether the BOA oilpump sprocket fit the BOB oilpump drive shaft or whether the shafts need to be changed over.

Anyone need BOB parts? All the guides out the BOB engine we stripped last night seemed fine.

[Marc]

I wouldn't polish the crank. IMO polishing removes material making the crank too thin. If work needs to be done on the crank I think it would be best to have it reground and fit oversize bearing shells.

[Remko GT]

Oilpump driveshafts differ. Inside the block the shafts are the same but the way the sprockets bolts to it is different. You cannot bolt BOA drive sprocket to a BOB oilpump drive shaft so yesterday I unbvolted a couple to find a decent one. The one that came out my engine had, not suprisingly, a couple of fine grooves in them. Luckily I had a couple more blocks to take parts from.

My mainquestion now is:"What pistons will I use?" I am thinking towards getting standard pistons but slightly oversized.

[Remko GT]

Update:

Yesterday I received my Wilwood adjustable rearbrake proportioning valve, rear brakes have been useless so far. The standard proportioning valve was one from a drumbraked braking system. Reduces the pressure going to the rearbrakes way too much so needed sorting. I think this will do the trick. Just a matter of reshaping some brakelines and some test to find the right front-rear bias.

This week I am removing an engine from a donor car to replace the broken engine. Should be in start next week, maybe even before the weekend. Maybe it's running again next week.  

While I drive the car with this engine, I am going to get my engine rebuild with a BOB block, forged pistons and a girdled bottom-end. So here's hoping the temporary engine stays in 1 piece long enough..