my pu-ka project

Like these ;-)
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Haven't done a thing with the ka since octane in may so this was the evening to get the isdc track day prep started. In fairness the car needs nothing more of a check over and service. Tyres are perfect for the day.
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Next is a quick service and brake fluid change on the mini [emoji3]

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Bit of an upgrade has started on the ka.
After 5-6 years of track work I have decided to retire the 1.7vct puma engine in my ka. It has ran faultlessly since I fitted it with the only failures being a fan belt and a clutch kit.
I have said before that I would be fitting a fiesta St 2.0 engine as I have always found that the chassis was definitely able for way more power than the puma could give, so on Saturday last I dropped the puma lump out and started fabrication on the new 2.0.
The initial spec is as follows!!
2.0 duratec
Cosworth inlet manifold
Four branch exhaust manifold
Fiesta St gearbox with custom ratios
Omex 500 ecu
Should be good for 175-185bhp.
I'll keep ye updated with the progress [emoji106] DSC_1705.jpegView attachment 112198DSC_1713.jpegDSC_1712.jpegDSC_1714.jpegDSC_1715.jpegDSC_1716.jpegDSC_1717.jpegDSC_1718.jpegDSC_1719.jpeg

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Great stuff Dec, in fairness you got your money's worth out of the puma engine, onward and upwards now, best of luck with it????
 
Another bit done this evening, originally when I built the ka running on the puma engine I decided to use a hybrid of the two cars looms to keep it simple and cheap. So this evening I removed all original wiring from the ka and now I'm left with a blank canvas to start the process of getting the loom made up for the 2.0 running with the omex ecu DSC_1732.jpegDSC_1733.jpegDSC_1734.jpegDSC_1737.jpegDSC_1736.jpegDSC_1738.jpegDSC_1739.jpeg

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:clap:Great work dec :clap: Should make a big difference :thumbsup: Love the way you say decided to rip out the old loom and start fresh :doh: sounds like a pain and not something I’d touch :eek7: But sure I guess it’s a lot easier when you know what you’re doing :icon_grin:
great work look forward to the progress :thumbsup:
 
[emoji23][emoji23] I soppose it does like it's a simple job far from it in reality [emoji106]

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A few more developments on the dura-ka project [emoji6]

Removed the engine as I now have the mounts finished up and I wanted to get started on the engine wiring and build a gearbox.

First up was to thoroughly clean the engine with degreaser and then strip any unwanted wires from the engine loom. As I'm running it on an omex I only need minimal engine sensors so a lot was redundant.

Fitted the exhaust manifold and modified the mazda heat shield to fit along with a freshen up with heat resistant black paint.


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Last edited:
Also want to remove some metal from the inside of the right side subframe support as it's very close to the fan belt pulley. While the engine is out I'll freshen up the engine bay.

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Next job on the agenda was to smarten up the engine rocker cover and the cosworth inlet manifold with the now compulsory orange colour [emoji4]DSC_1790.jpegDSC_1791.jpegDSC_1792.jpegDSC_1793.jpegDSC_1794.jpeg

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Good man dec great work as usuall :clap: Looking forward to seeing it out on track :thumbsup:as if it wasn’t quick enough :icon_grin:
 
So after a bit of a headache I finally found a UK breakers willing to post to Ireland [emoji16].

Last Monday my gearbox arrived from the UK in perfect condition from skan automotive.

Got stuck into it on Saturday and fitted my newly lightened flywheel and new clutch kit. Bolted on the gearbox and tidied up the last few bits on the engine mounts. Then I installed it in the ka with some difficulty as the cosworth inlet manifold is a bit bigger than the original one.

Anyway it's in place now and doesn't need to be taken out again so I'm happy with that [emoji106]

Only issue is that the bonnet won't close [emoji23] [emoji23] [emoji23] [emoji23] [emoji23].

I think it's time for a custom bonnet [emoji848]DSC_1798.jpegDSC_1820.jpegDSC_1838.jpegDSC_1839.jpeg

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More pics DSC_1840.jpegDSC_1841.jpegDSC_1842.jpegDSC_1843.jpegDSC_1844.jpegDSC_1845.jpegDSC_1846.jpegDSC_1848.jpegDSC_1849.jpegDSC_1850.jpegDSC_1851.jpegDSC_1852.jpegDSC_1853.jpegDSC_1854.jpegDSC_1855.jpegDSC_1856.jpegDSC_1857.jpegDSC_1858.jpeg

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What do you need a bonnet for :icon_grin: . Great work :clap: Orange looks the part :thumbsup: will be a good bit quicker now at the track day :thumbsup:
 
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