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.

http://i229.photobucket.com/albums/e...928_144957.jpg

http://i229.photobucket.com/albums/e.../IMG_72191.jpg

http://i229.photobucket.com/albums/e.../IMG_02201.jpg

How it looks right now, minus the rear:
http://i229.photobucket.com/albums/e...1/P1030961.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

http://i229.photobucket.com/albums/e...1/P1030972.jpg

Oil-covered rear from leaks:
http://i229.photobucket.com/albums/e...115_171223.jpg

http://i229.photobucket.com/albums/e...115_171248.jpg

Cobra steering wheel for the replacement:
http://i229.photobucket.com/albums/e...116_140007.jpg

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.

http://i229.photobucket.com/albums/e...118_115649.jpg

http://i229.photobucket.com/albums/e...118_174923.jpg

new pinion seal
http://i229.photobucket.com/albums/e...118_175734.jpg

pinion seal done
http://i229.photobucket.com/albums/e...118_180736.jpg

tubes welded
http://i229.photobucket.com/albums/e...118_214350.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

Nice job, great project.

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.

Re: sutyak's turbo 2004 Mach 1 build thread
 

Thanks! You're the second person to recommend the RXT. "Measly" 500whp. :23:

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?

Re: sutyak's turbo 2004 Mach 1 build thread
 

Yeah it's certainly going to be a challenge. I went through 5 turbos before I found the perfect one for my Focus. I hope I can find the right one for the Mach 1 with fewer tries.

HERE <- is one of a few build threads for the Focus. It's a long read! :)

http://i229.photobucket.com/albums/e...419_070202.jpg

(Slicks on front. Just can't see them.)
http://i229.photobucket.com/albums/e...15_burnout.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

Man I love the Mach and the focus. Very nicely done on both

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.

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.

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. :)

Re: sutyak's turbo 2004 Mach 1 build thread
 

12.4 @ 115
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.

Re: sutyak's turbo 2004 Mach 1 build thread
 

I'm not ruling out anything. :)

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.

http://i229.photobucket.com/albums/e...119_115347.jpg

http://i229.photobucket.com/albums/e...119_151813.jpg

http://i229.photobucket.com/albums/e...119_165500.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

Looking good! I bet that beast is a lot of fun to drive.

Re: sutyak's turbo 2004 Mach 1 build thread
 

looks good.

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!

http://i229.photobucket.com/albums/e...121_160702.jpg

http://i229.photobucket.com/albums/e...121_160519.jpg

http://i229.photobucket.com/albums/e...121_160549.jpg

http://i229.photobucket.com/albums/e...121_161217.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

Nice build! Makes me want to take out my rear end and clean it up.

Re: sutyak's turbo 2004 Mach 1 build thread
 

Sweet! I'm following along. :thumbsup:

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.

http://i229.photobucket.com/albums/e...125_163518.jpg

http://i229.photobucket.com/albums/e...123_153526.jpg

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

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.

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.

http://i229.photobucket.com/albums/e...128_133524.jpg

http://i229.photobucket.com/albums/e...128_163654.jpg

http://i229.photobucket.com/albums/e...128_164102.jpg

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. :claus:
http://i229.photobucket.com/albums/e...129_151539.jpg

Re: sutyak's turbo 2004 Mach 1 build thread
 

That rear end just looks sexy, love the blue

ASh