Project Ugly Horse

For those who don't follow Autoblog, a friend of mine is documenting a really cool build over there.

Project Ugly Horse started off as a plan to stuff a 2.3 turbo and manual trans into an old four-cylinder automatic Fox body Mustang. Zach accidentally stuck a bunch of junkyard upgrade parts in the suspension, such as big brakes and IRS along with the planned transmission. All pretty interesting, done by a guy with non-godlike fab skills in a normal home garage. Total GRM.

Then it gets interesting. Ford Racing called up and raised the stakes, in the form of a 2.0 EcoBoost that should have landed in a Focus ST. There are quite a few hurdles to overcome, but now we get to find out what challenges are involved in a direct injection crate motor swap.

This is going to get good.

http://www.autoblog.com/tag/ugly+horse/

I've been following this project and really like it. I hadn't read the eco boost update, that's exciting.

Wow! This should be very interesting...

looks awesome, maybe Ralph Gilles needs to catch wind of my projects

I've been following this as they update. It's been pretty interesting to watch especially since I don't expect too much out of AOL sites.

moparman76_69 wrote: looks awesome, maybe Ralph Gilles needs to catch wind of my projects

Mine too.

I wished they had covered more ground with this update, the others have been really good, and it's pretty cool watching a Fox pick up some of the best available factory hardware on its way to something that should be very nice to drive and enjoy. Nice motor, too, now let's see some info on what it takes to get moving.

I think this most recent update brings you to the present. The parts have arrived. Now Zach is in investigation mode, trying to figure out just what needs to be done and formulating a plan. Like "how the heck do I attach this thing to a transmission?"

Neat for him, but I wonder if he knows what he's getting himself into. Without an engine controller that also plays nice with the throttle control and two cam controls, he's in for some major headaches. You'll notice there's not a lot of support for direct injection out there, especially for po'boys. I wonder what the Radical SR3 SL uses?

I'll be following this closely to see what happens! With Ford involved, I wonder if they'd let it fly when he puts injector bungs on the intake, locks the cam phasers, and puts a cable throttle on it. Hopefully not, and hopefully he figures out some engine management that is not ludicrous expensive.

Bryce

I doubt he's going the Megasquirt route. That would be pretty dumb. Modern OE processors are a whole lot cleverer and powerfuler. I suspect a better option would be to adapt the ST engine management (or some other 2.0 EcoBoost application) and overcome problems involving anti-theft. That's what you'd do if you were swapping an Explorer V8 into an old Volvo or a Camaro LS1 into an MG, to pick a random example or two. It's what we'll be doing in 15 years when there are Focus STs parts cars.

I'm not sure DI is going to be a problem. I think they use a "low" pressure feeder pump to the engine, then a mechanical pump to ratchet it up to the crazy DI pressures. That's how the new Chevy LT1 works. Which means all the DI hardware is self-contained.

I can't wait to hear the details. He tells me the trans and the oil pan have been figured, but he's being cagy on details. The engine IS used in RWD form in Australia.

Well, I sure wonder what Ford has in mind. Whether or not they offer assistance of any kind, it seems like they must've been able to see a path to success from where they were sitting. Why donate a crate engine to a public display of the incompatibility of modern engines and the DIY auto enthusiast?

Keith, I'm not following your injector control story. While I agree the high pressure pump is mechanical, I'm talking about controlling injectors. The DI setup requires very different controls than typical port injectors.

I agree that he's probably best off hacking a stock ECM to work, but that's also Pandora's box with so many missing computers/parts. I can't imagine Ford would let him fail, but it sounds like they also haven't offered any solution. Like I said, I'm watching!

Bryce

I would be shocked if Ford would give him an engine, knowing he was going to write about it, and not be pretty damn sure he was going to end up with a running driving car. A story that ends with him saying that the engine sucks and is completely unusable wouldn't be good for anyone.

I get this feeling Ford's secretly testing the viability of this project via Autoblog to A- gauge interest in an Ecoboost crate- and B- to test the viability of a reissue of ye olde SVO. If this works and people like it, i'd not be surprised to see an SVO 4 banger somewhere around v6 territory in the near future- which is freakin AWESOME!

I love this build! Thanks for sharing, Keith!

Hey Guys.

I guess this just goes to prove you never know where your ratty Fox Body will show up...

I wish I had answers for you when it comes to why Ford chose to get behind this thing. I've never built a car for an audience before, and honestly, my wrenching skills are mediocre at best. I can pluck and plug engines and gear boxes, but this is something of an entirely different flavor.

Fortunately, it looks as if I shouldn't have too much trouble getting it bolted in and functional over the next few months. Many of the initial issues I laid out in the first post now have theoretical solutions. Now it's just down to spending the money and the hours.

Aside from a few freebie or discounted parts, this project has come entirely out of my pocket, which means it's been a bit slow going. The addition of the EcoBoost certainly complicates things, but, as you say, makes it all the more interesting just the same. Stay tuned. It's going to be a lot of fun.

I'll definitely keep an eye on this.

Keith-

What vehicle is this in down in Australia that's RWD?

Ford Falcon. Mated to a 6-speed auto, alas.

Bryce - it's almost going to have to be an OE PCM. I don't know Ford hardware the way I know GM hardware, but the GM computers are so thoroughly broken into they might as well be aftermarket - but they have OE-grade operating systems and control a lot more than a MS with a bunch of add-on boxes would. Standalone may not be a big problem, the PCM will probably be able to run the engine without too many helper boxes. After all, you're asking it to do a subset of its usual role. Putting an older/different engine in a new car is a different and harder challenge, as a lot of the subsystems require that communication. But Zach's Mustang is from a simpler time, when you didn't need computers to run the windows.

I doubt Ford set Zach up to fail with this engine. They know it's possible. And I'm pretty sure I've heard rumors of an upcoming Ecoboost 4-cylinder Mustang somewhere, this really would be a clever way to introduce the idea.

Alfadriver, where are you? Want to weigh in on this?

That is so, so awesome. I hope it works amazingly well and opens the path for more of us to play with these little motors.

Awesome build. Just finished reading the whole things and will be waiting patiently for the next installment.

I was always a fan of Ugly Horse simply for the total GRM vibe and the IRS/focus on handling. The EcoBoost is such a cool addition though! I'm now glued to my seat so I can copy it nut-for-nut, but in an 87 TBird Turbo Coupe...

I think it's absolutely brilliant on Ford's part. Rather than spend lots of money and engineering staff support in developing RWD uses for this engine, they simply gave away the engine, etc. Probably to the tune of <$2000 at their cost, and let the guy do it for free

ransom wrote: Well, I sure wonder what Ford has in mind. Whether or not they offer assistance of any kind, it seems like they must've been able to see a path to success from where they were sitting. Why donate a crate engine to a public display of the incompatibility of modern engines and the DIY auto enthusiast?

It'll get publicity in the enthusiast circles, which isn't such a bad thing. Certainly makes them look good and it's not much skin off their back--despite being a HUGELY generous gesture.

Pretty neat project.

Yeah, I've been following this on autoblog. Things just got very interesting.