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Duratec Tuning Modifying the new, powerful 2.3L and its little brother the 2.0L.

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Old 08-13-2009, 11:06 AM   #1 (permalink)
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Default 300+whp Here I Come!

Well as a lot of you know I'm building my motor now (overboosting on several occasions is bad and WILL weaken or damage parts) so I figured I'd give some details of the build seeing as how I purchased all the parts yesterday.

Build List
Siemens 60lb injectors - have come in!
Crank Bolt - has come in!
ARP head studs - have come in!
ARP main studs - have come in!
Supertech .020" 9.1:1 Forged Pistons - have come in!
F2 Forged Connecting Rods 2.3L with ARP Bolts - have come in!
Cosworth 2.3L Timing chain - has come in!
Cosworth Timing Tensioner arm - has come in!
Cosworth Timing chain guide - has come in!
Cosworth Timing Chain Tensioner - has come in!
Ford Racing Cylinder Head - has come in!
12-14psi Wastegate Actuator - has come in!
Cosworth Intake Manifold - has come in!
Clevite HD main bearing set MS-2245 - has come in!
Clevite HD Tri-Armor rod bearing CB-1838HK - has come in!
Fel-Pro bottom half gasket set CS26250 MCEN'9360 - has come in!
Fel-Pro Head Gasket MCEN'9359 - has come in!
PCV Valve - has come in!
Water Pump - has come in!
Weapon R Oil Catch Can - has come in!
F2 BSD - has come in!
Denso Iridium IT27 3-steps colder spark plugs - have come in!
Pennzoil Synchromesh Transmission Fluid - have come in!
0w40 Mobil One Engine Oil with Mobil One High Capacity Filter - have come in!

Already have
FSWerks Stage 2 Turbo Kit with GT2560R (GT28R) Turbo, SS Oil Drain, Water Line
Turbosmart Eboost 2 EBC
Exedy Stage 3 Hypersingle Clutch/Flywheel
Torsen T2 Differential
NGR Type S BOV - Recirculated
Trubendz 2.5" Exhaust with Magnaflow Muffler and Race-pipe

Here are pics of the parts coming in!


























Everything should be all done by 9/6. Parts are getting installed by Twisted Customs in Fredericksburg, VA. I will get it remotely tuned by Randy @ FSWerks. Hopefully will have a dyno within a week after the install. And I'll try and take some pics as parts come in and as things are being installed. Build List parts have been purchased from CFM, F2, FSWerks, Massive, Tousley, Upscale Automotive, Advance Auto Parts, Sparkplugs.com, and Autozone.

I'm hoping for around 315whp/320wtq at around 20psi on 93 octane. on FSWerks' site Chris Holland made 301whp/309wtq with 8.5:1 pistons, and the stock head with 1mm bigger valves at 18.5psi. I guess we'll see!

and soon I plan on finishing getting the boost controller wired up so i can setup the rpm correction factor and have as much boost as possible to redline

here is what I'm hoping my dyno looks like after all these mods. also included a graph for before the engine build as well.


Considering what the gang at CFM rand with a car making this power, I think right around 12.2-12.3 seconds in the 1/4 is definitely possible with slicks and a torque curve like the last dyno.



And if you have anything negative to say, just dont say it.
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Last edited by iceguyb14; 10-10-2009 at 10:43 AM.
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Old 08-13-2009, 11:20 AM   #2 (permalink)
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Default Re: 300+whp Here I Come!

Cossie Manifold FTW.



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Old 08-13-2009, 04:15 PM   #3 (permalink)
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Default Re: 300+whp Here I Come!

yeah i had to get it
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Old 08-13-2009, 04:32 PM   #4 (permalink)
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Default Re: 300+whp Here I Come!

It's lookin like a good build.
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Old 08-13-2009, 04:35 PM   #5 (permalink)
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Default Re: 300+whp Here I Come!

im lookin forward to seeing it finsihed and some a dyno chart, good luck man
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Old 08-13-2009, 04:40 PM   #6 (permalink)
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Default Re: 300+whp Here I Come!

thanks! yeah im pretty excited!

after all this there wont be much more i could do to add power, other than a turbo swap, intercooler upgrade, and cams and valvesprings. and nos of course but not for my dd lol
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Old 08-13-2009, 05:09 PM   #7 (permalink)
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Default Re: 300+whp Here I Come!

so ru sticking with your current GT28R turbo that comes with the kit?
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Old 08-13-2009, 05:58 PM   #8 (permalink)
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Default Re: 300+whp Here I Come!

Pssh... you need to copy their 396whp build. Then shoot for 450! Just kidding, for sure make sure the engine produces lots of midrange torque, I find cars alot more fun when they have lots of midrange torque.

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Old 08-13-2009, 06:05 PM   #9 (permalink)
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Default Re: 300+whp Here I Come!

wow, really looking forward to the outcome of this project! badass that you ended up getting the IM and FR head.
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Old 08-13-2009, 06:11 PM   #10 (permalink)
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Default Re: 300+whp Here I Come!

yeah clint right now i dont have $1175 for the gt2871r i want.

and bix i will eventually be virtually copying that build, cept i have a 2.3L. look at my mod list and their mod list for the 396whp car. and IMO that car was limited by the stock stage 2 intercooler which flows 350cfm, ill be upgrading mine to a one thats a little larger but flows 730cfm. ill also probably get a custom 3" dp made and a trubendz 3" exhaust.
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250whp/245wtq at 11psi...
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Old 08-13-2009, 06:15 PM   #11 (permalink)
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Default Re: 300+whp Here I Come!

^^ sweet!

I want to build another sleeper and the focus seems like it would be a nice little design.
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Old 08-13-2009, 06:49 PM   #12 (permalink)
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Default Re: 300+whp Here I Come!

yeah QJKXBM i had to get a new head and if i was gonna spend money on it i figured i should get the FR head now. and i wanted the cossie IM bad and to me its worth gaining the amount of hp i will with it.

and my car used to be a sleeper. now with the front bumper showing everyone the intercooler, its not as much as it used to be.. lol. still though its a focus so people always underestimate it
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Old 08-13-2009, 09:22 PM   #13 (permalink)
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Cool Re: 300+whp Here I Come!

Dude, why would anyone hate on your car? The nothing to hate when you're shooting for 300WHP.
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Old 08-14-2009, 01:34 AM   #14 (permalink)
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Default Re: 300+whp Here I Come!

I'm def excited to see the end result. Then bigger intercooler and turbo
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Old 08-14-2009, 02:11 AM   #15 (permalink)
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Default Re: 300+whp Here I Come!

hey jeff, you will want to upgrade all those hose clamps with ones that are a bit more substantial... either beefier worm clamps or some t-bolt clamps if you wanna spring the money. otherwise, you will be blowing off IC piping left and right.
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Old 08-14-2009, 03:59 AM   #16 (permalink)
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Default Re: 300+whp Here I Come!

Ask most people who use the T-bolt clamps and they will tell you they are a real pain in the ass. Right Paul? Or ask Vik.

Vik will have to verify, but I don't think we had any issues until we were getting up to the 26-30psi range with the GT2871R when testing. One of the pieces of plumbing popped off. That was crazy.
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Old 08-14-2009, 10:48 AM   #17 (permalink)
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Default Re: 300+whp Here I Come!

so i should be alright with the clamps i have now running 18-20psi with the gt2560R?
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Old 08-14-2009, 11:22 AM   #18 (permalink)
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Default Re: 300+whp Here I Come!

I've upgraded some of the clamps to stronger worm clamps (my old evo piping clamps) and they've held up. some of the original clamps blew off at the 11psi a few times and another broke when doing the original install upon tightening down. so i'm using a combo of original and upgraded. just soemthing to think about, since when IC piping blows off your engine will usually completely die. of course, it will usually occur at the most inopportune time as well. also, depending on where the pipe blew off, it can be a PITA to fix it on the side of the road. so just something to think about. worm clamps at home depot are pretty cheap. t-bolts, not so much.

as my rule of thumb, the decent normal-width worm clamps are good up to 20psi, above that, t-bolts have been recommended. I have come to these conclusions from my prior experience w/ my evo. The most common pipes to come apart always seemed to be the one just pre-intercooler and also the one at the throttle body. I've noticed the same occurrence with the focus.
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Old 08-14-2009, 12:44 PM   #19 (permalink)
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Default Re: 300+whp Here I Come!

^^^ I agree as well. The standard clamps we use are good for up to around 20psi if they are tightened properly and fitted well over the hose & the hump section of the metal tubing. We only use higher quality clamps when absolutely necessary like our STC car which was running more like 26psi. However I hate t-bolt clamps unless you have room for them and the kit is designed to accept them which our kit doesn't fit well with these clamps. I suggest a high grade worm drive clamp. They are expensive but they are twice as strong as the standard worm clamps we use and they fit nearly the same.

Thanks,
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Old 08-14-2009, 12:45 PM   #20 (permalink)
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Default Re: 300+whp Here I Come!

hmm so where can i pick up some t-bolt clamps
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Old 08-14-2009, 04:16 PM   #21 (permalink)
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Default Re: 300+whp Here I Come!

looking forward to this, i'll be keeping my eye on this here, cause FF is turnning into a pissing contest,lol.
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Old 08-14-2009, 05:10 PM   #22 (permalink)
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Default Re: 300+whp Here I Come!

looks like ill get the high grade worm drive clamps. how many do i need? since im not with my car right now..

and yeah bdnld4482 i want to beat tom so bad.. lol. but lets keep that out of this thread.. lol.
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Old 08-15-2009, 03:45 PM   #23 (permalink)
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Default Re: 300+whp Here I Come!

i have the exact same clamps that came with the kit from the beginning, anywhere from the 11-si when my motor was stock to 18-20psi with my built motor on the GT28R and the GT28RS turbos under track conditions and street driving. they'll hold up fine
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Old 08-15-2009, 05:04 PM   #24 (permalink)
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Default Re: 300+whp Here I Come!

I bought my T-bolt clamps from CXracing.com. They are a couple dollars apiece and have worked great so far, I can at least vouch for them to about 11psi and half of the pipes are not bead rolled. That's the other thing--if you look for the DSMtuners link on how to make your own bead roller you can use the cheapest clamps you can find and it should still be fine.
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Old 08-16-2009, 03:00 PM   #25 (permalink)
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Default Re: 300+whp Here I Come!

All of FS pipes are bead rolled, that's why the kits clamps work so well.

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