Been a while since I posted on here. As some of you know I used to own the Ford Racing Ka prototype but as some of you also know I owned a race prepared Fiesta XR2 until recently. I sold it last week so on Friday night we were on a boat to the Isle of Man to pick up the 2006 Manx Rally International winning Ford Ka.
A full ex works left-hand-drive challenge spec car, it has (well 'had', but we'll come to that!) around 110bhp from the 1.3, courtesy of a trick head, strengthened bottom end, high compression internals, Ford Racing ECU/throttle body, Janspeed manifold etc. This is all mated to a newly rebuilt Quaife short ratio gearbox with LSD and all the bells and whistles.
The car also has Proflex WRC spec remote reservoir coilover suspension, fully rose jointed with a hydraulic fly-off handbrake, seamwelded lightweight shell, multipoint cage, kevlar underbody and sill protection, wide arches and a whole load more. I'll update this will a full spec if people are interested, but this at least gives you an idea as to the preparation and rally pedigree of the car.
The car is FIA homologated for international rally use, being an actual Ford Factory rally car, and has a box full of homologation papers, build spec, regs and loads of really interesting stuff! It's like owning the FRK again, only it's been on steroids since then!
On test driving the car, I was amazed at how hard it is to drive - the steering is so direct, the clutch either 'in' or 'out' and the suspension is so hard and bouncy, and the driving position really makes you feel like you're bolted to the car. It's a proper rally car, and my first experience of driving a factory competition car. A get the feeling that getting to grips with this car will be a rewarding experience! I drove a few of the famous Manx International stages before returning to the UK, where things went a bit iffy.
After a weekend with no sleep, and a long journey with my ears ringing (thank god we have an intercom for on the stages!), the car lost power and the temperature spiked before coming to a stop, about 20 minutes from home on the motorway. I said to my Dad, who had pulled the van up behind; "this is serious". I was right.
On closer inspection today, and after suspecting that the concerning level of crank case compression pointed to piston trouble, it turns out that 3 of the cylinders have little or no compression, with a hole in the top of Piston no. 3. Not good. Basically, this is what I think happened; the car has been stood for a year or so since its last International outing on the Manx and in that time the fuel has crystalised in the injectors, causing a slight blockage. This meant that certain cylinders would be running lean and with such a highly tuned engine the tolerances are very tight. That explains the heat spike and also why there is so much compression in the crank case.
Not good, given that this engine is only one event old and cost £2000 to rebuild. These things happen, and it's an opportunity to strip the car down at least while and get to grips with everything else whilst we rebuild the engine. I'm not too bothered because I got an ex works international spec car (there are very few of these KAs in the world!) with a comprehensive spares package for a VERY good price.
Now that the introductions are out of the way, here are some pictures...
On way to first in class on the 2006 RBS Manx International:
The car attracted a bit of a crowd on the ferry at times, was a great feeling!!
25 Speedline Corse lightweight competition wheels (most brand new), 14"/15" with a selection of mostly new forest/different compound tarmac tyres :cool: These, and spare engines, competition brakes/clutches, spotlights, LOADS of mechanical spares and engine bits, different gearing settings for the forest - literally a van FULL! The tyres are all Pirelli P-Zero rally, this car really has not had anything but the best!
Plans (following the engine rebuild of course) are to compete in a selection of events next season, with plans to contest a championship the year after.
My brother Mike will be co-driving and just a quick pic here of the dream team :thumbup:
I'll update as I progress with bits and pieces that I'm doing besides the engine, but suffice to say from my time so far behind the wheel I cannot wait to get this car back on the rally circuit. It's a proper piece of kit, and has a prestigious international rally history which is really exciting!
Yeah I will selling some of the spares, at least one set of Speedline Corse competition wheels (14") with PZero road legal rally intermediates.
Plus the original Ford Racing engine, which had apparently done 6000 miles and has the alloy sump etc. Comes as you see above, not sure of spec or how long since it was fitted but it turns round freely etc.
And any other bits after I've gone through everything. I'll put on Ebay and put the links up on here
YAY, A PROPER KA!!! Seen plenty of these in action out on the stages back in the challenge days (& seen a few rolled & stacked by over-enthusiastic numpties at the Jim Clark & the UK Rally Challenge at Knockhill). Have you any events in mind for next year? Maybe see ya out on the stages bud. (I'll be one of the friendly chaps with a clock & a brightly coloured tabard)
(I'll be one of the friendly chaps with a clock & a brightly coloured tabard)
One of the legends of the sport, no less!
Yes, a proper Ka - I've wanted one for as long as I can remember. Bit disappointing about the engine but we'll get that sorted asap. I would welcome advice btw as to possible causes so that I can ensure I don't let it happen again when I've finished rebuilding it...the engine was running beautifully (or so it seemed) and then all of a sudden lost power.
It has burnt a hole in the top of piston 3, with 2 and 4 not far behind. The engine was only rebuilt one event ago by a top rally engine specialist in the North West (most unhelpful and blunt when I spoke to them to confirm the spec I have to say though!) but hasn't really been run for around a year. Here are the possible causes that have come up:
- crystalised fuel in a few of the injectors, causing a slight blockage and the mixture to run lean
- Water getting through the bonnet vent directly onto the airfilter cone and getting sucked into the induction system, again causing a bad mixture (not very likely but possible?)
I believe my engine has a MAF sensor, so I don't know how the air/fuel mixture could be adjusted - used to carb engines you see!
What 'could' it be, and how can I ensure it is set up properly next time?
what you say about water in the air filter might not be far off. we had a peugeot 206 at work not long ago, had been in an accident at some point which broke the airbox and ducting, and it was never replaced, water was slowly collecting in the ducting and as the throttle was opened it was sucking up the water, suffice to say the bottom end didnt last long and i was the unlucky 1 that had to stick another engine in it.
however saying that it didnt melt any pistons, the bottom end was just shot and it blew a nice hole through the block.
pistons only normaly melt due to it running lean, fuel acts as a coolant, if theres not enough fuel then the combustion chamber and cylinder will get too hot and it will just melt or blow a hole in it.
it wont help either if that timing was advanced too much, any signs of it suffering from detonation? is the head pitted at all?
Maybe try Ian Forgan at Mercury Classics in Fife - they used to run Kas as far as I remember (& still rallying Fords on tarmac events). OR Chris Birkbecks of course.
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I love it! I'd like to know the spec on that car 
