My MG ZS 110 Project Progress Thread

[Tom163]

I thought this time as the project is still new i'd put up a proper progress thread so I can update it every time something happens. I will also be doing video updates through my Youtube through the link in my sig. Anyway here goes....

Picked the car up about 2 weeks ago completely stock with a genuine 24,000 miles on the clock from new. It was made in 2005 but registered on a 54 plate for reasons unknown. The car has the Rover K series 1.6 (108HP) engine as stock and the owner from new added the optional extras of the factory fitted bodykit, Cat 1 alarm and Kenwood audio upgrade...but left out electric windows lol.

The car is mint apart from a few paintwork niggles (been used as a city car), there is some light scuffs and scratches but nothing that can't be removed. Engine wise healthy as the day it came from the factory and the same for the interior of the car.

My goal for this project it to have a fast-road car and also a car that can compete on occasional track days without looking to foolish. I have estimated the final figures of running about 140 BHP and not sure on torque figures just yet also those figures will be achieved without moving from N/A tuning or uprating the liter of the engine from a 1.6. Just yet.

Here are some pictures of how the car stands completely stock-

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4450.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4452.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4455.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/105_0680.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/105_0703.jpg

So thats how it stands at the minute! ready for modding!

[Tom163]

Quick update, since buying the car nothing major has really happened.

I first of all fitted my Competition spec head unit from theloudest.com (Christmas present) which replaced the stock Kenwood unit...although the Kenwood was very good nothing really can match this head unit for quality on stock ICE.

Some features of the head unit-

DVD Player
TV
Colour Screen 3.5'
Ipod connection
USB/Memory Card reader
Bluetooth
Built in Amp
4x80 watt capable
Bluetooth Streaming
etc etc

Installed in my car:
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/105_0696.jpg

Second update, me and a friend took the ZS to have a power dyno run over at Noble Motorsport in Chesterfield. I just wanted to get a base figure to then start modding too insted of blind modifying and hoping I get gains.

The end result was 123.0 BHP at 6729rpm and 108.2 lb-ft of torque at 4960rpm. This was very strange for a car which should only have 108BHP stock so either the dyno was over reading alot or there may be something internally done to the engine already (investigations on going lol). In the very least I know the engine is healthy and ready for modding.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4528.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4524.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4529.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4534.jpg
There is also a quick video on my Youtube (see sig).

Thats all up to yet....comming soon MG TF 135 Fast Road Cams and 160 VVC Inlet Manifold with 1.8 injectors :). Oh and a set of Areo wipers lol.

[Tom163]

Not done an update for a while so here how everything stands up to yet. Nothing really has been done to the car apart from a Steve Cleanz detail, I am still collecting parts in my bedroom lol.

I got some Piper cams from Lee off here, they look very much like Pipers 270's but can't be certain until fitted...at the very least they are 135 profile :) Here they are

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4566.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4565.jpg

Hoping to get them fitted at the beginning of next month :D so will report on the differences.

Also got myself an Exhaust heatshield thingy for the rear bumper but need to modify the bumper to fit it.

Had a nice surprise this morning as I got my brand new XPower Thruflo backbox I got of Ebay (what a bargin!!) the other day....looks sexy with a 3.5" inward rolled tip and a 2.25" pipe diameter so not an overkill and should handle my final power aims perfectly, going to get that fitted soon as I receive my Janspeed Intermediate pipe I got from PTP yesterday :D.

Some piccys-

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF8022.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF8024.jpg
The only markings on the box-
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF8027.jpg

Still waiting for my 160 VVC Inlet mani and Plenum and also Janspeed Center Section which should be here very soon!

Cheers
Tom

[rozzr]

nice, going to be a good project bro!

[Tom163]

Cheers mate, I hope so lol will take time but no expense will be spared!

:)

[Jay-ZS+]

Nice to see a new progress thread, If you do go for the vvc inlet then try a 52mm tb and get the head ported to match the inlet. Otherwise will do very little :)

Look forward to seeing the progress

[Tom163]

Nice to see a new progress thread, If you do go for the vvc inlet then try a 52mm tb and get the head ported to match the inlet. Otherwise will do very little :)

Look forward to seeing the progress

Thanks mate. Yeah been in contact with AA Autosport about a port and polish to match the inlet mani (heard fitting without a p'n'p it can loose power) but the 52 TB will have to come a little later as funds are low this month lol. After buying 135 cams a 160 inlet and some cool areo wipers hahaha.

[BUCKYDEVIL]

Great thread Tom, looking forward to the updates as Im doing some of the same mods.
Best of luck and it sounds like you found a good engine to work with.

[ZS_LEE]

I got 52mm TB's brand new £70 inc postage :)

[Tom163]

Bump for update on page 1 :).

[Maxxed_Ross]

Thats the same exhaust I had on my old 180 (I had 2 of them!) Just be extra careful with the Xpower writing as it's very very prone to scratching and coming off totally!

[Tom163]

Yeah figured as much lol only printed on aint it. Mite get it embossed on when the original wears off.

What is the sound like by the way mate? seem quite rare as there is no videos anyware and very few pics of them fitted.

Cheers
Tom

[Ritchy]

ive got an xpower one as well, no writing on it though and its slightly shorter than the mk2 exhaust but it looks good still, its a sporty sound not too loud, it isnt noisy on the motorway which is good

[stokey-leroy]

how much did aaa quote you for port and polish bud? Ive got an alloy inlet mani sitting in the garage but dont want to fit it if it will be loosing power!

[Tom163]

I am not going with AA Autosport for myne mate, i'm going with Dave Andrews from DVA Power.

I got quoted the following from Dave-

Strip head, clean and re-assemble £90
Stem seals and oil seals £47
Fettle inlet ports to match VVC plenum £60
Light fettle around valve seats and throats £100
Cam ladder sealant £4

Also those prices were with me removing the head from the car first.

Cheers
Tom

[Jay-ZS+]

How much is your insurance gonna be once the engine work is done? I was put off modding the Kseries any furthur by my insurance and Im 23.

Your getting your work done by the right guy thats for sure! ;)

[Maxxed_Ross]

Yeah figured as much lol only printed on aint it. Mite get it embossed on when the original wears off.

What is the sound like by the way mate? seem quite rare as there is no videos anyware and very few pics of them fitted.

Cheers
Tom


Well mine was on a V6, but it sounded mental at full blast. it's got quite a loud bass tone

[ZS Phil]

Awsome project, you sound like a sensible guy who will take his time and do the job properly... just the way to do it. Hope all goes well for you.

[Tom163]

Cheers lads :)

How much is your insurance gonna be once the engine work is done? I was put off modding the Kseries any furthur by my insurance and Im 23.

Your getting your work done by the right guy thats for sure! ;)

They are quite understanding to be honest mate and are fair with the price increases. Its all good though as i've got a crap but well paid job and no bird at the minute so that free's up alot of funds hahaha.

[Tom163]

Exhaust Updateeyy-

Got all my parts delivered yesterday so went about fitting everything. Looking at the old mild steel system it was way past due a replacement :O Very rusted with a massive hole in the silencer too.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100408_132735-1.jpg

I originally wanted to remove the old system before going about cutting up my bumper but the rusted solid bolts said different lol so while I was waiting for my blowtorch to arrive I decided to cut the bumper to MG's factory measurements...quite risky not knowing how the new box would line up but did it anyway.

I did all the marking with crayons and used a hacksaw and a dremel tool to cut it and I amazed myself how good and clean it came out in the end....all done with the bumper still on the car too! preparation was key to not cutting to much lol.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100408_132650.jpg

Rough cut-
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_141712.jpg

All cleaned up-
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_141645.jpg

After all the cutting I used the blowtorch to cut the old system off as it did'nt want to come off normally, I think that was the easiest part of the whole day. Then came the time to fit the new Janspeed Intermediate pipe and also the Xpower Thruflo box. All bolts were supplied so ready to go!

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_144658.jpg

Fitted I was very happy to see it sat rite in the middle of my cut in the bumper :D:D and looked rite good!!

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF8042.jpg

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF8048.jpg

Finally went onto fitting the heatshield itself. It was very easy as the bumper was cut, all I had to do was mark and drill 4 holes for the bolts and put them on.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100408_133218-1.jpg

And finally all done-

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_161903.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_161917.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_161929.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/P100415_162716.jpg

Hopefully coming next month, bigger brakes and cams fitted. Oh and Waxoyl!! before anything else hahaha.

Cheers
Tom

[Tom163]

Videos coming soon :)

[tb steve]

very well done :)

[Tom163]

Thanks mate :)

[Ritchy]

looking good:)

[Stephen]

Looking good mate. looks like a good fitment too

Any chance you could get a vid of how it sounds. I have a janspeed xpower backbox but i want the Janspeed Intermediate pipe to go with it if it makes any difference etc.

Stephen

[RudeDogg1]

Thats the same exhaust I had on my old 180 (I had 2 of them!) Just be extra careful with the Xpower writing as it's very very prone to scratching and coming off totally!

chrome polish took mine off :0(

[Tom163]

Will get you a video tomorrow mate.

Cheers
Tom

[Tom163]

Few videos-

http://www.youtube.com/watch?v=FRwAVwZZ-So

http://www.youtube.com/watch?v=iZjkWb67H90

http://www.youtube.com/watch?v=lAgtaiwPO8s&feature=related

http://www.youtube.com/watch?v=W5BghKf8fcQ

[Ritchy]

http://www.youtube.com/watch?v=lsvhYHwqR0k

that was mine when i had the open cone on it still, was really loud, yuou really need big speakers to hear what it was like, sounds a lot quieter without it now

[Bobdope2002]

youve got a break light out kidda

[BUCKYDEVIL]

youve got a break light out kidda

Well spotted Bob-3rd Video at 39 secs shows your brakelights out mate.
Car is coming along nicely mate, That exhuast sounds great.

[Stephen]

Sounds awsome mate. Bit louder than mine.

Time to save the pennies :)

[RudeDogg1]

nice car but wouldnt it of been better to get a 1.8 to mod it dont cost much more than a 1.6. Either way uve got a nice car its comming along nicely

[Tom163]

Thanks! :)

youve got a break light out kidda

Never noticed that before hahha will check now...cheers.

nice car but wouldn't it of been better to get a 1.8 to mod it dont cost much more than a 1.6. Either way uve got a nice car its comming along nicely

Na mate the 1.6 is better than the 1.8 for tuning because of the shorter crank making it rev free-er etc. Thats why they use the 1.6's in the Kit Cars like Caterhams and that :).

Cheers
Tom :)

[Murray]

The backbox really does change the way the whole car looks now. I like it even more, those MK2's do look mean with the wide arches.

Also looking forward to seeing how much gain can be had from the future mods.

[Maxfly]

looks and sounds cracking there!!! coming on very well:)

[Andyf]

Lovely car mate, it sounds lovely and you've done a great job on the exhaust. I have a Janspeed on my MK2 and it is too far over to the left which is really annoying!

[Tom163]

Cheers lads, much appreciated :)

[Tom163]

Update-

Brake light fixed...that is all!


lol

[RudeDogg1]

lol

[Tom163]

Update-

Done a bit since last update. Received my Inlet Manifold after 5 week wait. Planning to fit it later in the build along with a VVC head and a nice 52mm TB hopefully.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF9004.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF9003.jpg

I also recived my EBC vented discs and Jurid brake pads for a bargin price and also a set of calipers and carriers from a MG ZS 180 to upgrade my car from solid 262's to vented 282mm brakes.

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF0007.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF0010.jpg

And all fitted and Hammerited in Lotus Yellow (not to everyones taste)

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF0021.jpg

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF0024.jpg

Comming down from higher speeds is ace but braking from 30/40 it feels a bit spongy so think I may have to bleed again even though i did it and renewed the fluid at the same time as fitting lol.

Cheers
Tom

[Jay-ZS+]

Looking good tom like the yellow with the blue looks good. The brakes will take a while to bed in.

[p_b82]

Was just going to say - give the brakes a chance to bed in.

It might also be the EBC disks, as i also think they are bit 'soft' when stopping from slow speeds but are fine under hard braking when pressing on a bit *shrugs*

[gsinclairzs]

I thought this time as the project is still new i'd put up a proper progress thread so I can update it every time something happens. I will also be doing video updates through my Youtube through the link in my sig. Anyway here goes....

Picked the car up about 2 weeks ago completely stock with a genuine 24,000 miles on the clock from new. It was made in 2005 but registered on a 54 plate for reasons unknown. The car has the Rover K series 1.6 (108HP) engine as stock and the owner from new added the optional extras of the factory fitted bodykit, Cat 1 alarm and Kenwood audio upgrade...but left out electric windows lol.

The car is mint apart from a few paintwork niggles (been used as a city car), there is some light scuffs and scratches but nothing that can't be removed. Engine wise healthy as the day it came from the factory and the same for the interior of the car.

My goal for this project it to have a fast-road car and also a car that can compete on occasional track days without looking to foolish. I have estimated the final figures of running about 140 BHP and not sure on torque figures just yet also those figures will be achieved without moving from N/A tuning or uprating the liter of the engine from a 1.6. Just yet.

Here are some pictures of how the car stands completely stock-

http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4450.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4452.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/DSCF4455.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/105_0680.jpg
http://i72.photobucket.com/albums/i163/dooley_2006/My%20MG%20ZS/105_0703.jpg

So thats how it stands at the minute! ready for modding!



Lovely looking car! Like the colour.:smile2:

[Tom163]

Thanks all for the comments, I think the brakes are getting slowly getting better....just a thought, when I was putting the pads into the carriers they were very stiff and took quite abit of effort to get them in. Is that normal or should they be able to move freely when seated in the carriers?

Cheers
Tom

[Jay-ZS+]

Bit of copper grease should slide in although can be quite stiff if theyve been painted.

[Tom163]

Bit of copper grease should slide in although can be quite stiff if theyve been painted.

Wont cause any problems with them being stiff will it dude?

Can't hear any noises coming from them just a little paranoid.

[Jay-ZS+]

I did exactly the same with my 120 when I got 180 brakes, Painted them and the pads were stiff, so Dave ground the pads down very slightly to loosen them up. Just on the edge where they slot into the caliper.

As long as the pads can slide within the caliper will be alright, otherwise could stick in worse case

[Tom163]

Not had any sticking just wondered if that could be causing the spongy feel if the piston is taking longer to reach the pads if they are stiff in the carrier.

[coreygraham180]

if you don't mind me asking do have a running total and what effect it has had on mpg..... just that i am 17 and if u do get the 140 bhp might do a verrry similar project /???


plus a starter button ...lol

[Pandy]

Nice project dude :thumbsup: Coming on well.

I have a very similar setup in my 114 GTa, it has a 1.6k fitted with a pair of VVC Exhaust cams (similar to 135's i believe but not as good), VVC inlet (not port matched), 52mm tb, ITG panel filter, Scorpion cat-back s/s exhaust.

Its a big improvement over a stock 1.6, have yet to get it rolling roaded as i need a new distributor drive peg but i recon its around 120-125bhp if im lucky

[Tom163]

if you don't mind me asking do have a running total and what effect it has had on mpg..... just that i am 17 and if u do get the 140 bhp might do a verrry similar project /???


plus a starter button ...lol

Hi mate, what exactly do you mean running total? (BHP?) the engine will not be done and running 140/150 BHP for a while yet mate as I dont have the cash to do it all in one lol.

MPG has not really changed at the minute with the exhaust system, panel filter etc but it will i'm sure it will when start modding the internals. At the minute I get about 100 ish miles from ?20 town driving mostly.

I will definitely get 140/150 BHP out of her just depends how much money I need to throw at it! will definitely be different. I had a push start on my 25 and was really fun haha.

Nice project dude :thumbsup: Coming on well.

I have a very similar setup in my 114 GTa, it has a 1.6k fitted with a pair of VVC Exhaust cams (similar to 135's i believe but not as good), VVC inlet (not port matched), 52mm tb, ITG panel filter, Scorpion cat-back s/s exhaust.

Its a big improvement over a stock 1.6, have yet to get it rolling roaded as i need a new distributor drive peg but i recon its around 120-125bhp if im lucky

Thanks mate, have you ever thought of going the VVC head route and blanking it off? you will see better gains from all the mods that way. So much better than other heads.

Cheers
Tom

[coreygraham180]

Thanks mate, have you ever thought of going the VVC head route and blanking it off? you will see better gains from all the mods that way. So much better than other heads.

Cheers
Tom


so is the bore of the cylinders of the 1.6 and 1.8 the same and just a longer stroke??????

[Pandy]

Thanks mate, have you ever thought of going the VVC head route and blanking it off? you will see better gains from all the mods that way. So much better than other heads.

Cheers
Tom

Yeah i did think about it, aswell as a 1.6 VVC but to be honest my engine isnt the best out there as there are a few mounting bracket holes that are damaged so ill probably upgrade again next year which doesnt warrant fitting a vvc head to this engine

[Tom163]

so is the bore of the cylinders of the 1.6 and 1.8 the same and just a longer stroke??????

Not sure on the bore mate but I do know the 1.6 has a shorter crank which makes it more rev happy than the 1.8 which is why alot of the Caterham/kit car guys choose the 1.6 to tune over the 1.8.

[Tom163]

Yeah i did think about it, aswell as a 1.6 VVC but to be honest my engine isnt the best out there as there are a few mounting bracket holes that are damaged so ill probably upgrade again next year which doesnt warrant fitting a vvc head to this engine


Yeah that fair :)

[coreygraham180]

Not sure on the bore mate but I do know the 1.6 has a shorter crank which makes it more rev happy than the 1.8 which is why alot of the Caterham/kit car guys choose the 1.6 to tune over the 1.8.

had a bit of a look in to it and got the bore's and stroke's of the engines


1.8vvc 80.00x 89.30


1.6 80.00x 79.00


so technically it should be a stright swap of head no alteration to it????

[Tom163]

had a bit of a look in to it and got the bore's and stroke's of the engines


1.8vvc 80.00x 89.30


1.6 80.00x 79.00


so technically it should be a stright swap of head no alteration to it????

All the K series heads are interchangeable mate but the VVC 'super cylinder' head needs a blanking kit so solid cams can be fitted. Also the VVC head is near enough the exact same as the VHPD head which costs ?????...it has alot bigger valves and a much better combustion chamber.

So its as follows-

The 1.4 head has the smallest valves and the porting is not great

The 1.6 and 1.8 non VVC heads are near enough the same with bigger valves etc

The 1.8 VVC head is the best as above...the best base for modding.

Cheers
Tom