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Power Adders Superchargers, Turbos, Nitrous, etc... |
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11-18-2015, 10:47 PM | #1 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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sutyak's turbo 2004 Mach 1 build thread
Recently I parted ways with my 400hp turbo Ford Focus and picked up a turbo 2004 Mach 1. It has been through a couple owners, and each before used and abused it accordingly. Now I'll be undoing the past 11 years in hopes of getting it up to my standards.
Here are the overall details according to the seller. So far everything checks out. 87000 miles on the body and about 2000 on the built motor. Motor specs: 8.5:1 compression (I verified cylinder compression before buying) Manley rods CP pistons ARP head studs, rod bolts, cam bolts MMR oil pan Teksid block out of an 01 cobra Stock heads and cams Turbo kit: Hellion single 76mm kit with custom cold side BA5000 MAF sensor Precision PTE 7675 turbo Full 3in exhaust to dump before axle Trans: T-3650 Spec stage 3+ clutch MGW short throw Rear end: Fully built 8.8 with 31 spline moser shafts Factory 3.55 gears New clutch packs Suspension: UPR Tubular k member up front with fully adjustable coil overs Caster camber plates Fully adjustable coil overs on the rear Rear upper and lower control arms from UPR Fuel system: 80lb injectors Lethal performance return style fuel system with dual walboro pumps with adjustable regulator. Tuned by Rev Auto Here are my plans now through Spring 2016: - New driver's seat foam - Rear tires (315/35-17 Nitto 555R) - 4.10 gears - 28" slicks - Full length UPR subframe connectors - Weld torque box seams - Magnaflow exhaust (done) - Fix turbo oil drain (done) - Replace pinion seal (done) - Moser diff cover (done) - Weld axle tubes (done) - Paint rear (done) - Spherical/adjustable Granatelli upper control arms (done) - Replace worn out steering wheel - Remove all unused wires and trace existing wires to nowhere - Rebuild a TR3650. Originally built for 700hp by American Powertrain. Needs a 3/4 syncro I believe. 26 spline - New clutch. McLeod RST or RXT twin disc? 26 spline - Fidanza flywheel - Likely change to smaller turbo for broader power band. Borg Warner S366SX-E 66/73 ? - 2001 Cobra intake cams - Get the tune file from Rev Auto so I can make future tune adjustments myself The short-term goal is to have a strong mid/low 10-second car full weight without a dedicated drag suspension that I can reliably drive to the track and make it home without breaking stuff. Currently makes 667whp and 631 lb-ft torque. I want to keep it around that power level but a broader curve (a full 1,000 RPM earlier). I also don't want to make the car so aggressive that I don't enjoy driving it. How it looks right now, minus the rear:
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) Last edited by sutyak; 01-12-2016 at 10:03 AM. |
11-18-2015, 10:48 PM | #2 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
Oil-covered rear from leaks: Cobra steering wheel for the replacement:
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-18-2015, 10:49 PM | #3 |
it's soo-tack
Join Date: Nov 2002
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Re: sutyak's turbo 2004 Mach 1 build thread
Made some progress today on the rear. I beat out the old/shot bushings, which wasn't as tough as I expected. I used a mini sledge and a punch to dent in the sleeve and then with a few whacks they would pop right out. I'll be installing spherical bushings in the housing, along with some adjustable Granatelli upper control arms.
Next up I replaced the pinion seal, which did not go as smoothly as expected because the first seal I bought didn't fit. A quick trip to the auto parts and that was done. Finally I welded up the axle tubes, which required another trip to the store because I couldn't find the flux core tip for my welder. Tomorrow is the last warm day in sight, so I'll be painting the housing and installing the Moser diff cover. new pinion seal pinion seal done tubes welded
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-18-2015, 11:44 PM | #4 |
Registered User
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Re: sutyak's turbo 2004 Mach 1 build thread
Nice job, great project.
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2003 DSG Mach 1-03 Cobra Term/T56 swap: 2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear Tuned by B.Kurgan 601Hp/558/Tq |
11-19-2015, 09:28 AM | #5 |
Registered User
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Location: Fort Worth, TX
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Re: sutyak's turbo 2004 Mach 1 build thread
If you stick with the dual clutch from McLeod, go with the RXT. I have the RST now and with my measly 500rwhp/460rwtq, I cannot launch with it. It will slip horribly. it is not intended to be a drag clutch by any means. From a roll, it is great however.
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11-19-2015, 09:36 AM | #6 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
Thanks! You're the second person to recommend the RXT. "Measly" 500whp.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-19-2015, 10:21 AM | #7 |
Dark Knight
Join Date: Nov 2009
Location: Albuquerque, NM
Posts: 5,759
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Re: sutyak's turbo 2004 Mach 1 build thread
Sweet. You are going to have a tough time getting the low end torque I think you desire from a single turbo setup without affecting top end power.
Have any pics of the focus?
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Vortech V2 S-trim, E85, A2A Treadstone, Comp cams, built engine, full exhaust, built rear, built 4r70, more mods. Tuned by me with SCT Advantage |
11-19-2015, 10:31 AM | #8 | |
it's soo-tack
Join Date: Nov 2002
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Re: sutyak's turbo 2004 Mach 1 build thread
Quote:
HERE <- is one of a few build threads for the Focus. It's a long read! (Slicks on front. Just can't see them.)
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
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11-19-2015, 11:27 AM | #9 |
Registered User
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Re: sutyak's turbo 2004 Mach 1 build thread
Man I love the Mach and the focus. Very nicely done on both
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2004 Mach 1 torch red, 5 speed, Borla stingers, off road Mac ss pro chamber, k&n drop in,sct x4 with custom dyno tune 308 rwhp 324 rwtq upr delete puck, MM flsfc, wild rides upper and lower torque box reinforcement kit. MGW shifter with standard handle, speed of sound pillar with dual aeroforce gauges,Bullitts black polished lip 17x8 front 17x10.50 nitto 555r's 315/35/17, smoked tail lights,smoked 3rd brake light. Engine dress up parts. It's only just the beginning procharger coming soon |
11-19-2015, 11:39 AM | #10 |
Dark Knight
Join Date: Nov 2009
Location: Albuquerque, NM
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Re: sutyak's turbo 2004 Mach 1 build thread
Awesome little focus. What did it run?
Were you just picking turbos or did you use compressor maps to predict how it would perform first? That low compression ratio is more suited for a twin screw or twin turbo setup.
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Vortech V2 S-trim, E85, A2A Treadstone, Comp cams, built engine, full exhaust, built rear, built 4r70, more mods. Tuned by me with SCT Advantage |
11-19-2015, 11:59 AM | #11 |
Mach-T
Join Date: Jun 2004
Location: DFW
Posts: 2,865
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Re: sutyak's turbo 2004 Mach 1 build thread
With the goals you are going for I would think twins would be the best path. :smoking:
Twins stay in the back of my mind, I love my setup but the only thing that would make it better would be having a twin setup.
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Darrell Black '04 Mach 1 Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67 (100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88 New build - 750rwhp; not track tested (yet) Mods: Build Log Paint&Body Tuned by Manny @ HPP |
11-19-2015, 12:21 PM | #12 |
Mach-T
Join Date: Jun 2004
Location: DFW
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Re: sutyak's turbo 2004 Mach 1 build thread
After reading your focus build, you clearly have fabrication skills; I stand by my suggestion of twins even more so now.
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Darrell Black '04 Mach 1 Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67 (100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88 New build - 750rwhp; not track tested (yet) Mods: Build Log Paint&Body Tuned by Manny @ HPP |
11-19-2015, 12:25 PM | #13 | |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
Quote:
I agree. I bought the car as it sits and don't really want to open it up in the near future.. I would have gone 9.5-10:1 compression pistons. Pistons in my Focus were 10.4:1. I love my compressor maps. First couple turbos I knew were too small but I was trying a budget build. Third turbo was actually awesome, a GT2871R. The fourth was too big and I knew it, but I just had to try it. That was an HTA 3082R. Finally I went with a GTX2871R and that was perfect all around.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
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11-19-2015, 12:26 PM | #14 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
I'm not ruling out anything.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-19-2015, 07:14 PM | #15 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
Today was painting day. I painted the rear end housing satin black, and the diff cover sonic blue and then cleared it. I'll try to get better pictures when it's all together and out of the garage. The diff cover is just sitting loosely on the rear to keep dust etc. out of the rear. I'm going to give the paint a couple days to set since the humidity and temperature lately are not exactly ideal for painting. The Magnaflow street cat back and Granatelli upper control arms arrived. Ideally I'll get it all together Saturday.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-20-2015, 11:33 AM | #16 |
Registered User
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Location: Jackson, TN
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Re: sutyak's turbo 2004 Mach 1 build thread
Looking good! I bet that beast is a lot of fun to drive.
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2003 Mach 1 Aluminator // Eaton @ 10lbs // T56 Magnum // E85 Build thread: http://www.svtperformance.com/forums...-Picture-Heavy IG: boostedmach |
11-20-2015, 06:43 PM | #17 |
Mach-T
Join Date: Jun 2004
Location: DFW
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Re: sutyak's turbo 2004 Mach 1 build thread
looks good.
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Darrell Black '04 Mach 1 Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67 (100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88 New build - 750rwhp; not track tested (yet) Mods: Build Log Paint&Body Tuned by Manny @ HPP |
11-21-2015, 07:01 PM | #18 |
it's soo-tack
Join Date: Nov 2002
Location: Fairmont, WV
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Re: sutyak's turbo 2004 Mach 1 build thread
Rear is together with spherical bushings installed. 2qts 4oz of 75w-140 oil plus friction modifier in. I was hoping to get the exhaust in today, but spent most of the day cleaning out 700lbs of scrap metal from the garage. Time well spent, though!
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-23-2015, 01:13 PM | #19 |
Never Satisfied
Join Date: Sep 2007
Location: San Antonio, TX
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Re: sutyak's turbo 2004 Mach 1 build thread
Nice build! Makes me want to take out my rear end and clean it up.
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P1 8psi @ 6k PA Transmission DD 3,600 Stall BBK LT's w/ 3in Collector Custom 3in X-Pipe Custom 3in CB w/ Pypes 3in M-80's Built Rear w/ 4:10 415/383 PB 11.80, @ 119 with a 1.71 60ft Tuned by http://www.southtexasperformance.com/ Built WAP Block, 10.5:1 compression, 14psi, E-85 Coming soon. |
11-23-2015, 02:29 PM | #20 |
Lorraine's driver
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Re: sutyak's turbo 2004 Mach 1 build thread
Sweet! I'm following along.
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11-26-2015, 10:07 AM | #21 |
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Re: sutyak's turbo 2004 Mach 1 build thread
I'm not impressed so far with the Granatelli uppers. They are too narrow, and needed washers at the top and bottom to fill the gap. They should be fine now, but they'd be extremely sloppy without the washers.
The exhaust is on and the rear is mostly in before I ran out of time last night. The Magnaflow street cat back is shockingly quiet at idle, but when revved up it becomes very obvious it's a straight-through design and gets pretty loud. More pictures once everything is together this weekend.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-29-2015, 07:53 AM | #22 |
Soldier for Christ
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Location: Willis, TX at The Daddy ASh Ranch
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Re: sutyak's turbo 2004 Mach 1 build thread
very nice mach,
good luck on your goals, look forward to seeing how it comes along rearend looks beautiful ASh
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2001 lazer red v6 Mustang coupe sold in Aug 2006 2004 screaming yellow 5.0 sc Mach 1 sold in Oct 2012 2013 grey 6 speed coupe GT Mustang Sold in Feb 2014 2013 RED Dodge Charger R/T Sold Nov 2014 2002 custom Blue 02 Auto Trans AM Sold June 2015 1998 Cobra Black Sold summer 2016 Current 2009 Ford F350 FX4 March 2017 (work truck) 2003 OW 5.0 Mach 1 Aug 2020 ASh |
11-29-2015, 01:00 PM | #23 |
Registered User
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Re: sutyak's turbo 2004 Mach 1 build thread
Awesome looking mach build. I'm headed that was as in a turbo setup with mine. I have a V1-si kit on it now and looking to go the other direction. Looking forward to seeing your build progress.
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04 Competition Orange Mach 1 |
11-29-2015, 03:31 PM | #24 |
it's soo-tack
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Re: sutyak's turbo 2004 Mach 1 build thread
The rear is in and all front and rear oil leaks are fixed. Unfortunately it's time to put it away for the winter, so I haven't driven if further than the end of the driveway to turn it around and back it right back into the garage. It's been washed, waxed, and covered. The car will sit on stock wheels/tires for the winter. I do plan on working on the transmission over the winter, so this thread won't be completely dead.
Don't mind the messy garage. I'm in the process of getting it cleaned up from quite a few car projects this year. With the wife's commuter car; a 2002 Toyota Echo. The family hauler is a 2006 Ford Freestyle and has to stay outside with the snow.
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mark 2004 DSG Mach 1. Built motor. Turbo. 667whp 2006 Sonic Blue Focus. Built motor. Turbo. 12.4 @ 115mph (sold) 2003 DSG Mach 1. 12.65 @ 106 (sold) |
11-29-2015, 08:02 PM | #25 |
Soldier for Christ
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Re: sutyak's turbo 2004 Mach 1 build thread
That rear end just looks sexy, love the blue
ASh
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2001 lazer red v6 Mustang coupe sold in Aug 2006 2004 screaming yellow 5.0 sc Mach 1 sold in Oct 2012 2013 grey 6 speed coupe GT Mustang Sold in Feb 2014 2013 RED Dodge Charger R/T Sold Nov 2014 2002 custom Blue 02 Auto Trans AM Sold June 2015 1998 Cobra Black Sold summer 2016 Current 2009 Ford F350 FX4 March 2017 (work truck) 2003 OW 5.0 Mach 1 Aug 2020 ASh |
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