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Discussion Starter · #1 ·
Ok guys here's the deal, after saving up enough money, and getting myself into a slight position of power (ok at least in the automotive world) working at a local performance shop, I have decided that enough is enough, it's time to go all the way or go home, and when I mean go all the way, I mean a goal of the at least 250 real tire smoking horse power! In order to do all of this and to make the car as good as it can get I will describe the current mods which I have done to it:

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Throttle Body from a 3.8L Mustang
180* Low-Temp Thermostat
"True" Cold Air Intake
MSD Coil Pack
Double Platium Spark Plugs gapped @ 0.064"
Black Diamond Under-Drive Pully
1989 Escort GT 1.9L HO header
2.5" exhaust piping used
"Racing" Catylitic Converter
Reactive "Tuner" Muffler
Tranny Cooler
Progress Sport Springs (1.5" - 1.8" drop)
Complete Energy Suspension Urethane Master Hyperflex Kit for Escorts
Tokico S/R Struts

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Now with that said I will no outline what I have planned, so I can get some constructive critisism...

The engine I will be using is the 2.0L SPI engine that comes stock in my car, and as that the current one in my car has 130,000 miles on it, I will be rebuilding it from top to bottom as to gain every drop of performance (plus I'm also doing it both as a learning thing, rebuilding it, and as school project). The basic steps, ideas, ect. are outlined roughly below, and will give what I have in mind for this engine:

1.) The engine will be just as durible as the stock engine. So I have decided to impliment such things as oil/cooler/ duel oil filter relocation kit, and a larger radiator plus better fans (electric)

2.) The engine will be built from the bottom up to take advantage of the "Split Port Induction" and as such the cams will have their power begin around 2,500rpms and end ???, plus the turbo will be implimented as to begin boost just as the SPI kicks in.... (Think V-Tech "Escort Style")

3.) The engine will be built with the atitude that "It's all or nothing, the best or go home", so when it comes to suggestions I am all hears...

4.) The engine build up will be well documented as to give back to this community.

5.) Engine management and fuel management have not yet been designed, planned, so that is one area which I will need input...

I know this post sounds really crazy, but I am dead serious, when I say this: THE CAR IS PARKED FOR THE WINTER @ MY GARAGE, READY TO BE TRANSFORMED...

So plz. don't give me any "With enough money you can blah, blah blah"...

I'm looking for the guyz here who are the "Grandfathers" of modding Ford Escorts, I'm looking for input from the people who either have done this before, or have info on doing certain things (tips for say head work, cams, ect.)

I'm also looking for a list of parts to to be formed here on this post along with a list of places (aka links) in which to buy em from... i.e. "Where's a guy to get a decent performance cam shaft other than www.escortfocus.com"

All I can say is this though, this is the project car to put Ford Escorts on the map for performance, and as such I already have 2 local performance shops/garages here willing to sponcer the car with stuff...

So the short of it, I need your help formulating a plan of attack when it comes to designing my 2.0L SPI turbo engine here, and as such I am willing to do the things others have backed off of for it being to exspensive or to crazy, in order to get the most from the engine as to provide the very best documentation of this engine build up for all to use as a reference when it comes to future engine designs for Ford Escorts...

Thank you for your time...
 

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From what I've heard, you'll need aftermarket rod bolts, head studs and possibly pistons. The stock rod's should be fine. Then from there either a lot of N20 or boost with the managment to back it up with some dyno time.

There has been a few 1G Esocrt's in the 250-300whp, might want to track them down.
 

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Discussion Starter · #4 ·
For the cam what do you guys like? Personally I dislike www.escortfocus.com for their extremely high prices, and poor customer service... (personal first hand experience with em has proven that!?)

As I said before, after much research into many different theory's performance and what have you, I would like the turbo to boost the same time the SPI kicks in, so at first I wanted a cam which would give me more low end grunt to make up for the turbo not boosting until 3,000rpms, but I have decided to have all three be "Optimized" for the 3,000 RPM and up power band, since I am also going to swap a 5-speed into my car...

A couple of dumb little questions which the official ford shop manuals do not tell me (Also if anyone has any questions that are found in the "real" shop manual I will be more than happy to answer em'!), is the key differences between years for the 5-speed, if the years are interchangeable, and weather I need a MTX ECU in order to do the swap...

Also does anyone here have first hand experience with any of the "Tuners" available for our cars (not the chip, but the tuner which diablo Motor sports, and super chips sell), and weather I should go with the chip or the tuner... also do you know weather or not they would be able to "Stop" check engine lights for such things as my EGR missing (plz no one yell at me, I live in WI so we don't give a sh*T here), and using ZX2 injectors instead of the 2.0L SPI injectors (Thanks ROb @zxtuner.com for the zx2 injectors!)

Also if anyone here could point me to a place which can tell me about setting up a fuel return line would be great!

also some links to the actual sites which sell the parts would be awesome!

Other than that... I would also like to pipe in that I live in Merrill, WI (central WI, 20 min. north of Wausua, WI), and if anyone here is from around here, as so perhaps I could actually check some of the setups which others have up close and personal...

Also when it comes to head work, what would yield me the very best? I have been trying to research the various aspects of head work, but quite frankly, time is beginning to run short for my research, and I am going to need to start here pretty quickly...
 

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Americanzer0 said:
For and using ZX2 injectors instead of the 2.0L SPI injectors (Thanks ROb @zxtuner.com for the zx2 injectors!)
Even Zx2 injectors wont even come close to being what you need for that kind of power, you'll need new one's. Some where around 42lbs or larger.

Americanzer0 said:
Also if anyone here could point me to a place which can tell me about setting up a fuel return line would be great!
You dont need a return line.

You could probly reach your goal with a stock head, just put your money and time into a good turbo and the right managment, in other word's dont buy a old probe turbo or somthing.
 

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Discussion Starter · #6 ·
But heres the thing though reguarding head work, if I can make even more HP with it, why not! Look at this way, I have saved up ovcer $6,000 for mods to my engine, and have decided that this engine is going to be the most powerfull 2.0L SPI here in central WI, plus heres the thing, if I go only "Half-way" whats the point of even trying? As I said before it's all or nothing here, I'm taking it "All the way" onthis one, and I want to pretty much make this engine a corvette killer all around and make the absolute most powerfull that I can possibly make it... so as I said before plz. no "Why waste money one this when you can make less HP with less money blah blah blah!".... so as I say again give me the tips, and I will document the build-up as to provide the Escort commutity with what it takes to make a WRX STi killer! Enough said! Ok!

I've got alot of beer to drink right now so... I'll get back to you after the hang over tomorrow! (Joke)
 

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i never doubted that 20psi would be needed. i think thats a given.

you do realize however that more goes into a car to make it quick/fast than just lots of horsepower under the hood.

you can make a 350hp SPI.. sure ok.. now tell me how you plan on not spinning off the line for the first 3 gears while this corvette youre sposed to be killing just caught up with you and toasted your arse.

youre going to have to look into modifying motor mounts, and other suspension peices to handle the abuse.. as well as heavier duty axles that wont break from every light.
 

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Discussion Starter · #10 ·
Have been thinking on how to go about this engine buildup and I have an idea, but before I go any farther on it I want to hear your opinions on it.... and so it goes!


1.9L SOHC Engine block
2.0L SPI head
2.0L SPI crank
1.9L custom pistons
custom made rods, bolts, ect.

Do you think a combo such as that will allow me to pruduce the maximum power (engine block/head/crank/ect.) as apposed to using the entire 2.0L block...

Plus the 2.0L engine though is in all reality just a bored and stroked 1.9L, so if I use the 2.0L SPI crank which has more counter weights on it, and a longer stroke, theoretically I would have the advantages of a lower compression engine (allowing more boost), but also a slight improvement over the stock 1.9L in displacement, correct?

When it comes to head work, I remember a guy here on either these boards, or ERDT (R.I.P.), having very very crazy cool head work done on his 1.9L (or was it a 2.0L) where he had 2.3L valve springs installed and everything reworked... . which I might look into doing as I remember him claiming an improvent of something like 25hp or something like that...




On another completely different note, I just had a massive brain fart which yielded me this interesting little idea... instead of installing larger injectors and creating a fuel management system to work around them for use in a turbo application, would it be possible to instead use 2 injectors per cylindier and then have the stock ECU control em, aka trick the ECU into thinking it's controlling one set of 4, when it controlling 2 sets of 4... I know it sounds crazy, but at the same time this idea of mine sounds in theory that it would be able to give the needed fuel that the engine needs under high boost applications, perhaps create the fuel line, and what have you above the current location...

Also on another random note to this thread, could someone plz point me to some info on a 5th injector controller, or a 5th injector setup?


And alas, my final random little ramble here is a question regaurding any one here knowing about the 5 speed swap, and weather or not there is a difference between years/models that should be noted, as I have heard that that the early 5-speeds in the EXP's apparently had some crazy gear ratio's that might possibly be used in todays engines/1.9L/SPI... oh well enough random questions and thoughts for a day from me!


Thanks for all of your guys help on my little project here! Thanks for you time reading this post too!
 

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You deffinately could do the 1.9 block if you wanted to but if you are going with custom pistons, use the 2.0 block and make pistons for that. Just have them use the dish design for the new SPI pistons because you'll get that extra .1L worth of displacement. You're going all out with this so stick to the biggest and best. :wink:

Headwork is a deffinate must. I'm going to be getting mine done hopefully this next spring/summer if my finances permit. Add on the turbo and you'll deffinately flow enough to support 300+hp.

If you can get beefier rods made, go for it. The weak link in the motor at that point assuming you did the pistons and rods and got some nice bearings and bolts would be the crank. Not sure if you could get a custom crank made but if you could then it would be that much better.

PonyExpress is the guy with the crazy headwork on his 1.9L I'm modeling mine after his and would suggest you do the same or even take it the next step and get bigger valves machined in.

For management, I would really look at the MegaSquirt II or MegaSquirt Ultra (when it comes out). It will let you fully control the timing and fuel maps and adjust for boost. Also will let you run any injector you want. I would say go with at least 67lb injectors. That's 700cc/min. With 4 of those babies, you can support 350hp at only 85% duty cycle. Gives you some nice wiggle room. If you would like more fuel injector info let me know.

The other option is Haltech, SDS or whatever else.
 

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I also would agree that since your getting aftermarket pistons, just have them made for the 2.0 SPI, and dont make things more complacated by throwing a 1.9 block into the mix. You might want to keep the high compression, you'll need it to spool that big turbo your gonna have.

And, I also will agree with the injectors, dont make things more complatated by useing a 5th injector, or 8 injectors. Just use 4 big ass ones, and since your gonna need real engine managment anyways, you'll have no problem getting them to run right. I'd say dont go any smaller then 42lbs.

Depending on the year of your car, if you do go with a stand alone, you will need to convert to the return fuel system. But, if you just go with the MIC setup, you can keep it simple and keep the non-return system, just need the right sized MAF and a custom chip-keep it simple.


I would'nt even think about trying to make a 1G tranny fit in a 3G, wayyy to much work for what you'll get out of it.
 

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300hp on a 5 speed would be alittle much. you would need 4 speeds, front end SLAMED on the ground.and some weight on the front tires which btw will be about 12''across. but hey if you do it i want a ride.
 

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The tranny might hold 300hp but the axles won't. As to the needing to possibly switch to a return style fuel system, you won't have to with MegaSquirt. As long as the injectors are large enough, you won't need to turn up the fuel pressure. Thus no need to switch.

You will however probably need a custom fuel rail made to support the flow required by whatever you do use. MegaSquirt or other, the old rail probably won't support 300hp. I've looked at the design of mine and it just doesn't lend itself to flowing well. The way it's got the injector connectors pressed into it, it creates restrictions all over the place. The end cylinders will be getting some nicely whipped fuel, "IF" it gets any at all. Ok, ok. I may be a little extreme on that. It will still get fuel but you'll start to run lean.
 

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drivinonthinice said:
As to the needing to possibly switch to a return style fuel system, you won't have to with MegaSquirt. As long as the injectors are large enough, you won't need to turn up the fuel pressure. Thus no need to switch.
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Can the MS read the 98+ electronic FPR and send the varible power to the fuel pump to maintain a regulated fuel pressure?
 

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Oh shoot I totally forgot about that. I was somewhere in left field thinking that it would send the constant 42psi if no vacuum was connected for some reason instead of not doing anything at all since the ECU is no longer. Sorry bout that. Yeah you would need a return system. I'll read up and see if it can control the system the 98+ uses.

*bangs head into wall*
:eek:
 

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Discussion Starter · #17 ·
Ok, so If I go with a "Chip", I would much rather go with the "Tuner" (hand held version of it, so ican do well, the custom stuff more easily...) and well where would one go to find it, I'm trying as we speak, but am coming up, well with nothing, I'm think they would have to probabley "Custom" make it?
 

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Well I think us Escort guys kinda got the shaft on the chip solution. The Focus SPI guys can get the SCT Pro Racer package but I haven't heard of it working on a Scort ECU yet. Maybe we could steal a Foci ECU and chip that? Although it's a bit impractical cost wise. MegaSquirt is cheaper and for only a few hundred more then the chip and tuner you could get a Haltech or something.
 

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gosh I wanted to just turbocharge my cort and run low boost with stock internals, guess what...it would cost me in excess of over $2000 (parts and labor) to get a whimpy setup like this, I got discouraged but I do hope that you will pull through with this project!!
 
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