Obsessive Compulsive Developments Ka Turbo

[Natty]

Comments can be made here -----> http://www.bttos.com/modules.php?name=Forums&file=viewtopic&t=18259




Anyway. Little background on the whole thing. Back in the day when hardly anyone was doing Ka Turbo swaps some friend of my ex paid 10k plus for a professional conversions. When i looked at them, they were total garbage and I decided I could do much better, for much less and I decided to tell people how to do these at home using basic tools and complete it with no knowledge of doing anything like this before. It also helped that a guy doing one around the same time, was a fabricator so he could build parts to make it nice and simple.

I sold my Nova
http://img.photobucket.com/albums/1003/SimonKa/custy2.jpg

Bought this of a mate, really nice, basic Ka, well looked after with loads of history
http://img.photobucket.com/albums/1003/SimonKa/100-0028_IMG.jpg

I got it home and the next day totally stripped it
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/ka1.jpg

threw in some buckets
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/ka3.jpg

complete dash change (first person to attempt this :) )
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/100-0061_IMG.jpg

added some racey type stuff
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/dash1.jpg

a fair bit on carbon
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/doorcard1.jpg

The colour plays a big part in the conversion
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/nos.jpg

Then onto the running gear. Luckily I had just bought my own place so the kitchen was used to work in as it was cold out in the garage. Focus rear disc conversion, Gaz coilovers, more bright pink powder coating kept everything clinical clean for my OCD. Oh and a unique set of set of ronal turbo's to make it look spot on.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/4.jpg
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/5.jpg

Bolted it all up, dropped nicely with the arches!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/low1.jpg

As the rear end gear was all pretty special I set about making the front equally uprated to slow it down well!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/100-0045_IMG.jpg

Time to do some engine work
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/engine1.jpg

Mod the Ka gearbox to bolt onto the CVH so I can keep the hydro clutch, two of the mounts, cv's, shafts, gear linkage.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/box3.jpg

Cast engine mount can be mass produced by the lad doing the other conversion, no welding needed, it just bolts into the inner wing and your CVH mount (from escort, not fiesta as in the pic) bolts straight in there. That the mounts all sorted.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/100-0018_IMG.jpg

Now for some boost pipes. All a bit close so yet more custom bits which could be mass produced.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/chargecarrier.jpg

Then a cossie cooler, butchered on some custom cast ends to do the job properly
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/cossiecooler1.jpg

Cooling on the standard rad was going to be rubbish so i upped the core size by 250%, added a fan, altered the mountings so it all didnt take any more room up than the standard setup. I also altered the fittings to suit the Ka Turbo setup. GRS now sell this as the Ka Turbo Radiator.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/radfitted2.jpg

Cooler and rad seem to be sitting nicley enough
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/DSC00749.jpg

Getting an air filter on the car seemed to be a problem and probably a tight fit so I improvised
http://img.photobucket.com/albums/1003/SimonKa/DSC00783.jpg

All coming together nicely now. Looking sweet!!!!!!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/DSC00737.jpg

Had the exhaust made. Also you can make out the Manta mirrors I added too!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/exhauston2.jpg

photoshoped it - the rear track isnt photoshopped. Thats how wide it sat!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/katurbofuture.jpg

Made some back lights
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/lights1.jpg

Starting to look good now
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/oops.jpg

Oh i forgot. I made a loom somewhere along the way. Fiesta loom, extended, and patched into the Ka setup running an ECU for the engine and the the standard one for fuel supply and imobiliser control. I also made it removable for security. Yet more pink too!
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/turbo_wiring.jpg
http://img.photobucket.com/albums/1003/SimonKa/1.jpg

Nearly done
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/DSC00779.jpg

So then it was useable. I drove it for a few weeks, it was amazing. The quickest accelarating car I have been in. Made mincemeat of my mates 2.0 Nova and I never really had to take it over 4k before changing gear.

So then I went and had a stage one chip added and it was even better! Thats where the story comes to an end. After picking up my chip, collecting a mate and driving to my house some guy in a Luton van, towing another luton van pulled into my lane and I had no a choice of under him or onto a grass verge and probably roll.
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/9.jpg
http://img.photobucket.com/albums/1003/SimonKa/my%20ka/6.jpg
http://img.photobucket.com/albums/0903/kachris/skt180/P1010021.jpg

Damage to the wide arch, manta mirror, ronal turbo and the bent coilover meant it was pretty much knackered in addition to the twist in the chassis leg, door pillar and a few other bits. I replaced most of the other bits but I couldnt replace the Ronal as they were pretty much one off's and weren't made anymore so I broke it and bought my Audi with the money.

THE END .........



Until ....


Basically when mine got crashed into I was just starting to build one for a mate. He pretty much bought all the cool stuff off my car. A few years on and he is bored of it so i've gone halves and bought it with Natty.

http://img.photobucket.com/albums/1003/john2184/P1010089.jpg
http://img.photobucket.com/albums/1003/john2184/5a729e8a.jpg
http://img.photobucket.com/albums/1003/john2184/P1010024.jpg



So basically Sy built himself a show worthy Ka Turbo, and then to prove a point built another little flying sleeper, with a £3000 budget this time for a mate.

The lad he built it had it about a year, and although its pretty much mechanically sound, its ain a bit of a poor state of affairs.

So now its under the new ownership of Me and Sy, and we're gonna bring it back to its full chattering glory and mainly use it to thrash about as a second car for us both.

This won't be any where near as high spec as his previous Ka, this is just a small budget blaster for us to enjoy and upset other road users :lol:

First job this weekend is to relocate the battery to the boot, then drop the engine and box as it needs a new clutch release bearing.

[SyKaTurbo]

And clean it!!! :lol:

The basics were build a Ka turbo to get it on the road for under 3k including uprating the suspension and brakes aswell as buying the Ka all in that budget. We did that and evolved it with better specs to what it is now.

Basic spec on this car at the moment

Engine:
1600CVH
0.5mm oversized pistons
Piper Cam Kit
Piper Pulley
Fully rebuilt head
Modded Cossie Intercooler
GRS custom rad to my specs with Pacet 10" fan
Superchip 165 chip and 13psi boost
Poorflow exhaust.
Lots of custom bits to get it to bolt into the Ka nicely

Suspension:
G-MAX

Brakes:
Puma conversion

Wheels:
Ford Racing multispoke wrapped in Yoko A539

Interior:
Sparco Corsa Seats
Willians Harnesses
Flocked Dash
Smiths Rev counter, oil pressure, boost and water temp guage
Air charge temp guage.

[SyKaTurbo]

Right, a little update but not many pics at the moment.

Got this at home on my drive now. Been OCD'ing it like taking the back lights off to detail behind them. Also removed most of the wiring loom ready to be redone and make sure its working properly. I'll be dropping the engine out to clean it and refit it all next weekend.

Also bought stuff to stick the battery in the boot to make weight distribution even better and give me more room in the bay.

Also took all the dash out to remove the foam insulation from the bulkhead. This is a pig of a job as the loom is all attached to the dash and the whole steering column needs to be removed. I was going to leave it out but the dash frame adds strength to the steering column so might be partially going back in.

Just thinking braking options at the moment. I want something effective and trick looking. I may be running braided lines through the car and running a bias valve for the rears. Uprating the rears to Focus discs and then putting something special on the front.

[SyKaTurbo]

Okay some pics

Battery relocation stuff
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00182.jpg

Flocked Dash removed to get access to sound deadening and all the wiring loom for lightening. Was going to leave it out but the steering column needs it for strength.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00183.jpg

Me hard at work
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00184.jpg

Took some nitromors to my nitrous bottle
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00188.jpg

Stripped the strengthening from the Ka Dash to put back in to support the column but also the center is nice and flat to panel and mount the guages in.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00198.jpg

Nice and lightweight dash. Just need to sort all the loom out now and get a load of P clips so I can attach it to the frame.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00206.jpg

Gaffa taped the dials to the frame for now lol
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00207.jpg




Brake Theory. I want to use Porsche calipers so got hold of some discs that would fit my car. ST170 300mm and Mondeo V6 278mm. Also grabbed some Porsche Boxster Front and rear pads to see how they would sweep.

300mm Discs
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00196.jpg
Rear Pads are way to small for that disc and the Fronts look okay but the caliper may catch.

278mm Discs
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00197.jpg
Front pad is waaay to big but the smaller one seems fine so time to buy some Porsche Boxster Rear Calipers.

http://i9.ebayimg.com/05/i/000/8e/87/5359_1.JPG
The good thing about these is the fluid transfer tube and bleed nipples can be switched so the calipers can be mounted which ever way I need.

[SyKaTurbo]

Oh bollocks. Just ordered a set of plexiglass (sp) windows :oops:

[SyKaTurbo]

Decided as there is no dash to direct air flow through the car that I would just remove the whole heater matrix. Its a big heavy thing.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00211.jpg

Also bolted the battery box into position. Made sure it wasnt going anywhere under heavy braking and that in a crash it wouldnt be affected by impact.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00212.jpg

[SyKaTurbo]

Right. Been tinkering again this weekend.

First off - Porsche Brakes. I went and picked up my Boxster rear calipers and instantly thought " oh bollocks. These are pretty big and never going to fit behind the 15s" Anyway. Got them home and had a play

First off, tried them for size on the disc. Seem a good fit
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00229.jpg

The try the pads in there for the sweep. Still all good
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00230.jpg
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00231.jpg

Disc on the hub with the caliper placed over. Very close round the back so the brackets will be small. Gonna need to think about that one.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00232.jpg

Wheel over the caliper and disc. Seems a very snug fit. Very tight up to the back of the spokes and a snug fit on the internal rim.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00235.jpg
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00236.jpg
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00237.jpg

Overall i'm very happy about how they will fit. Just need to knock some wooden brackets up for machining and have the custom lines made and they will bolt straight in.



RS Turbo engines in a Ka may have been done a few times now but Porsche brakes! I doubt that one lol.

[SyKaTurbo]

Little update. I decided to chop all the loom to bits in order to remove every piece of loom that was no longer needed so in the list of stuff that went

Electric Window
Heaters
Central Locking
Boot release
Reverse Light
Interior Light
Headlight adjust
Every wire from the old ECU
Imobililser (sp)
Clock
Headlight loom passenger side!!!!!!!
and a few other bits

I had to totally rewire the headlight loom in but I have have routed it better in the engine bay so its lighter and neater.

I got the loom halved I reckon. I just need to reattach my engine loom now.

[SyKaTurbo]

http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00255.jpg
Battery now secured. Not heatshrinked fittings and wingnuts for true OCDness lol

http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00254.jpg
loads less loom now. Still need to tidy the fuse box area.

http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00245.jpg
Bit of removed loom

http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00264.jpg
sat on my drive

[SyKaTurbo]

Just ordered a Escort Cossie fuel pump so I can safely juice the engine when on full chat.

Was also tempted to order a blank fuse box and relay box to rehouse my Ka one and neaten it all up. Parts will be about £50 so might leave that till end of the month! :(

[SyKaTurbo]

Right, another update

Got home and decided to take the engine out to clean it as it was a bit oily.

While it was out I changed the clutch, cleaned the inside of the bellhousing and changed the release bearing. Then cleaned the engine bay.

Normally this wouldn't be too bad but I did it on my own. Usually I get a extra pair of hands. I also usually do it on the flat covered surface and usually with a couple of jacks. I only used one jack last night.

Engine out. Nice and simple to remove it. Used a space saver to hold it steady and the wood makes it easier to slide around and comfy to lie on.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00265.jpg

This will be the reason the car was grinding and not going properly. Tut tut. Too many hard launches John!
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00266.jpg

New Black Diamond Power Clutch. Was going to paddle clutch it but thought i'd try a work product out so I can tell the public if I actually think they are any good.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00267.jpg

New clutch bolted on
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00270.jpg

I just took my time and before i knew it 10pm was here. I started about 7ish though so i didnt do too bad
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00271.jpg

Engine back in, just needs a wipe over and it
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00273.jpg

[SyKaTurbo]

Posties been

Cossie fuel pump to get my juices flowing
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00274.jpg

Battery distribution box.
http://www.twistedstyling.co.uk/NewGallery/albums/userpics/10009/normal_Dsc00275.jpg

[SyKaTurbo]

Right, a little update but no pics as I have been too dirty while working.

The interior is pretty much done. The battery is all fitted and working, the interior loom is all neat and tidy, just need to make a custom fuse box now.

I should have my Porsche brakes bolted up and bled by next weekend hopefully.

The starter and alternator as fitted and wired in so I can start on the engine loom, coolant, and boost pipes. Then its all pretty much done.

Anyone fancy buying it lol?