sutyak's turbo focus

[sutyak]

For a quick history, this is the car that brought me to SCS:


After a couple years having a blast with it, racking up well over 100 1/4 mile passes (best of 12.65) I sold the Mach 1 and picked up a new 2006 Focus 5 door. You know, doing the responsible thing...
I do miss the Mach 1 and might have to buy another one someday.

It didn't take long to start playing with the Focus, but I didn't mess around. I skipped all the cold air intake junk and went straight to a turbo. Don't mind the external links. They are some extensive reads.
Nearly EVERY piece of this car was built my me, from the motor to fabricating the turbo manifold, intercooler piping, and full exhaust.

Build #1 (2007): Stock motor with custom Thunderbird IHI turbo
Build #1b: Upgraded IHI turbo to a hybrid
Build #2 (2012): Upgraded turbo to GT2871r. Switched to external wastegate.
Current build (external site with many more details)
My PhotoBucket site with all the photos.

Build #3, Current build:
Same GT2871r
SuperTech 10.4:1 pistons
SuperTech rings
Forged H-beam rods
ARP head and main studs
Clevite main and rod bearings
Crower valve springs and retainers
Crane stage 1 cams
Exedy Hyper Single clutch
Torsen LSD
15x8 Weld wheels with 24.5x8 MT slicks
More Prothane suspension bushings
Coilovers? Have them. Not sure if I'll install.
Steeda rear sway bar. Also not sure if I want the extra weight.
Possibly partial new exhaust
Aluminum steering rack bushings
Delrin motor mount bushings?
Extended wheel studs for front wheels
Direct port methanol injection with progressive controller
Dual stage boost controller
Kenne Bell boost-a-pump
Lakewood traction bars
Braided brake lines

Non-performance:
SVT Recaro leather seats front and back
SVT side mirrors
MAP sensor for data logging

Goal: 375whp+ and 11.9 sec 1/4 mile

The motor I'm building is the original out of my car. It suffered an overboost with the IHI turbo and damaged/broke a ring landing and began smoking like crazy. This happened a few years ago, but I'm just now getting around to rebuilding the motor. This is my first ground-up rebuild. With the exception of some very minor scratches (can't even feel it with a fingernail) the motor was fine and fully rebuild-able.
Since this motor had no significant damage and very low mileage I'm lucky enough to not need anything professionally machined. That being said I'm still measuring everything and comparing against the Haynes manual.

The cylinders were a bit shiny and I wanted to get that small scratch out of cylinder #2 so I used a 3-blade 220 grit hone to give it a new cross-hatch. I did as little honing as possible and stayed with the 87.5mm pistons.
Following SuperTech's formulas I gapped the top ring to .018" and the second ring I left at .023" as it came out of the box.

The valve springs and retainers are upgraded with Crowers. I went with steel retainers vs. titanium after speaking with a representative at Crower regarding street vs. track use. The steel are also significantly cheaper.

I'll be using a TurboSmart dual-stage boost controller, with a toggle switch for the second stage. First stage will probably be around 13-15psi, and second 20-24psi.

The motor is built, in the car, and has the first 80 or so break-in miles. I'm currently finishing up an extensive wiring project to install the heated/power seats, MAP sensor, USB ports, meth controller, BAP, various relays, and boost controller. Soon it will be back on the street. After about 250 break-in miles I'll start ripping on it and getting the tune worked out.

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Torsen
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New clutch
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Mocking up the meth nozzles
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Checking cam lobe clearances
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Motor shot
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As it sits now with the winter wheels
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And the turbo

[sutyak]

How it looks at the moment

Methanol controller, because race cars don't need to hold CDs.
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BAP
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Basically how it looks now. Wiring is nearly complete.
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[ERR0RMACR0]

Awesome build, man--looks like you put a lot of work into get everything put together. Looking forward to hearing some numbers on this :)

[sutyak]

Awesome build, man--looks like you put a lot of work into get everything put together. Looking forward to hearing some numbers on this :)

Thanks. It's been a long project over the past 8 years with many different configurations. I'm trying to squeeze as much enjoyment as I can out of this little car. Everything I can do with this to keep myself entertained keeps me from dropping a ton of cash on a new project car, which would probably be a '10-'14 GT500 or '15GT.

[zxgto06]

Nice car! Awesome seeing a build out of the mainstream

[SlowSix]

love it. I love builds that aren't your typical stuff. Any idea what the car weighs?

[sutyak]

love it. I love builds that aren't your typical stuff. Any idea what the car weighs?

Stock it was 2650lbs according to Ford. I haven't weighed it since then, but no doubt I've added weight from the intercooler pipes and 3" turbo back exhaust. The leather power seats certainly won't help. I'd figure 2750-2800lbs now. Race weight without seats, spare, and my 160lbs self would still be at least 2800lbs. For the track I'm heavily considering a straight dump after the crossmember. That will save weight and help spool.
On my to-do list is to buy a TIG welder this year and start working with aluminum. The first project will be aluminum intercooler piping instead of stainless steel, and possibly a full aluminum exhaust.

[SlowSix]

Stock it was 2650lbs according to Ford. I haven't weighed it since then, but no doubt I've added weight from the intercooler pipes and 3" turbo back exhaust. The leather power seats certainly won't help. I'd figure 2750-2800lbs now. Race weight without seats, spare, and my 160lbs self would still be at least 2800lbs. For the track I'm heavily considering a straight dump after the crossmember. That will save weight and help spool.
On my to-do list is to buy a TIG welder this year and start working with aluminum. The first project will be aluminum intercooler piping instead of stainless steel, and possibly a full aluminum exhaust.

pretty light. Aluminum intercooler piping would definitely help. Never heard of anyone doing an aluminum exhaust though.

[sutyak]

pretty light. Aluminum intercooler piping would definitely help. Never heard of anyone doing an aluminum exhaust though.

I agree it's rare, but it's certainly done. I doubt I'll go to that expense when I can just dump it at the track. Another Focus owner with a 600hp build did a 4" turbo back aluminum exhaust, which is where I got the idea.

[SlowSix]

interesting. There is a guy on moddedmustangs with a turbo focus. Not sure how fast it is though. are you running pump gas or e85 ?

[sutyak]

interesting. There is a guy on moddedmustangs with a turbo focus. Not sure how fast it is though. are you running pump gas or e85 ?

Pump (91 or 93) plus 50/50 water/methanol injection (4x 1.5gph nozzles). I'll be tuning without the WMI initially so I can really see how much timing I can add with the WMI. With 10.4:1 compression and up to 24psi, I'm assuming the WMI will be necessary. I built the motor expecting to run WMI.

[gmkillr]

Cool project man! Good luck with everything!

[yeahloh95]

very cool project i would love to have a turbo on my focus

[sutyak]

Thanks guys. I'm hoping for a 11.9 run this year after I get used to launching a FWD and tweak the suspension and traction bars. A track rental would be ideal where I could make adjustments at the track and get more than two runs in.
If anyone hears of a track rental at PRP, Mason Dixon, or Quaker City (I guess Quaker City is still around?) let me know!

[Tom]

Get that focus some medicine, it's going to be sick!

I can't wait to see it run.

[phillysrt4]

unequivocally some of the best sport compact turbo porn i've seen in a while! I might be taking up an offer to get a focus wagon and I would be hard pressed not to follow in your footsteps lol! :)

[bgblockelcamino]

awesome build. Been building aluminum exhaust for a while. I have a 4 inch downpipe back out fo aluminum and weighs 9 lbs. well worth the effort for weight reduction. have built a few others with good results too and several thousand miles on them

[sutyak]

unequivocally some of the best sport compact turbo porn i've seen in a while! I might be taking up an offer to get a focus wagon and I would be hard pressed not to follow in your footsteps lol! :)

Thanks! It's been a fun build. I can definitely overwhelm you with turbo Focus information if you do pick one up to play with. While cheaper than a lot of cars to modify, it's still been a money pit.

[phillysrt4]

right on... im going to swing a PM your way with a question

[Cam99]

Sweet build!