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PostPosted: Sat Nov 16, 2013 6:22 pm 
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Joined: Mon Apr 16, 2007 3:17 pm
Posts: 366
Location: Essex U.K
Drives: Xr2i 1.8 turbo
Hey guys,
its been a while since i asked a question but this issue im having has got me stumped,

Im in the process of building a forged zetec turbo lump, however im am cutting a corner by using audi 1.8t 20v turbo pistons, paired upto some ebay special forged rods
(which appear to be identical to all the other rod manufacturers)

[eBay]http://www.ebay.co.uk/itm/Ford-Escort-Focus-Fiesta-RS-2-0-Zetec-ZVH-Turbo-Forged-Steel-Connecting-Con-Rods-/330979616344?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4d0fec2658[/eBay]

i picked up a set of Audi 1.8t 20v pistons with the 20mm gudeon pin, 0.787" for you imperial bastads (i kid of course)
the pistons are 80.95mm (pretty standard piston size designed to fit a fresh 81mm bore
the gudgeon pins are also the same size as any zetec forged piston i can find
woosner
mahle
superteck
je
etc etc
on measuring the pins with my digital verneir they are indeed 19.99mm +- 0.1mm

the bloke in the machinists shop (Specialised engines in gray) who deal with mostly ford engines said
"oh right yes we've had a few lads use those pistons"
so i thought great, this isn't something unknown or unheard of, plus theres that guy in the ford mag who done this exact same conversion, (but he had his std rods machined out)

whats got me stumped is

as far as i can tell all forged zetec turbo pistons come with a 20mm wrist pin it seems to be pretty standard
all the forged zetec rods some with a 20.64mm little end

so that leaves us with 0.64mm clearance, 0.0252 inches 25thou whatever you prefer

now maybe im being stupid but when the piston and rods are assembled you can clearly feel that 25thou of clearance

now i know they are supposed to be "floating pins" but with that kinda clearance my concern is that these rods are going to get smashed to pieces within minutes of starting the lump up,

so i was wondering if someone could help clear up this confusion i have and clarify if yes 25thou of clearance for a fully floating piston is correct and the engine oil would take up the slack
or no thats way wrong

those of you who have built forged zetec lumps what size gudgeon pins were in the pistons you bought and what size were the little ends on the rods

im itching to build this lump but have run out of fund to buy a new set of wOOsner pistons at £550

this is the last piece of the puzzle

any info would be greatly appreciated
i am itching to build this lump and chuck it in, the pistons rings have gone on my decomp plate zetec turbo (after 2 years of abuse at about 230bhp)[i was expecting the decomp plate to go first]
Cheers
Dom

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PostPosted: Fri Nov 22, 2013 10:53 pm 
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Joined: Mon Apr 16, 2007 3:17 pm
Posts: 366
Location: Essex U.K
Drives: Xr2i 1.8 turbo
Just a quick follow up on this

turns out standard uk spec zetec e gudgeon pins are 20.63mm

st170 pistons run a 20mm gudgeon pin
but the rod length is to long to run VAG 1.8t pistons
also US zetec engines run a 20mm gudgeon pin,

rods were sent to machinist and rebushed to 20.01mm for 80quid

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PostPosted: Sat Nov 23, 2013 8:01 pm 
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Joined: Mon Apr 16, 2007 3:17 pm
Posts: 366
Location: Essex U.K
Drives: Xr2i 1.8 turbo
the guy who originally sold me the rods has had 3 sets made up especially for those who wish to build a 1.8 zetec turbo using the Audi Pistons
[eBay]http://www.ebay.co.uk/itm/Ford-Escort-Focus-Fiesta-RS-1-8-Zetec-ZVH-Turbo-Forged-Steel-Connecting-Con-Rods-/231100325477?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item35cea71e65[/eBay]

these are probably a one off, they are abit pricey but rated to 600bhp, the audi 1.8t 20v pistons can run inexcess of 400bhp so for as little as £400 you can build your self a strong bottom end

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