area six jwrc fiesta (urban myth)**NEW PROJECT ** a little update 1/1/16
11-02-2014, 11:31 PM
#642
Advanced PassionFord User
Thread Starter
hi mate no sorry done nothing on the car far to busy getting the house done and its far to cold for working outside.
got some bilstein cases so going to get them cleaned etc and rebuilt .
cheers paul
got some bilstein cases so going to get them cleaned etc and rebuilt .
cheers paul
17-07-2014, 11:48 PM
#646
Advanced PassionFord User
Thread Starter
hi rob hope everything is ok your end , no updates mate as iam spending all my time and money finishing the house off , but its nearly done so the car will be out shortly ,hopefully getting built if i have the funds as iam going to be a dad in november
chesh paul
chesh paul
haha
sent you a pm aswell
18-07-2014, 09:25 PM
#649
Advanced PassionFord User
Congrats on the upcoming birth. My twins are the best thing that happened to me. Cars take a sideline cos you'll not want to miss an hour. Good luck to you and the mrs.
19-07-2014, 08:28 PM
#651
Advanced PassionFord User
Thread Starter
Thanks for the kind words , the car will get built but it may take a while longer lol I've got most of the parts to get it rolling so that should keep me busy for a while
Cheers paul
Cheers paul
23-03-2015, 11:07 PM
#654
Advanced PassionFord User
Thread Starter
Well yes a very important update , Luke was born 7 th nov nice and healthy and is my world , I wish I would of had a kid sooner as he's wicked. Car was tell and truly forgot about for the last 9 months as had to finish the house off which cost me thousands lol and took all my car savings . But at the weekend my mate came around for a brew and gave me a kick up the arse as he said that will be on eBay soon then ha ha . No chance even if I goes into hiding for a couple of years .
So started to strip the front drive shafts down to get them machined to fit the wrc bearings and took them today so should have them back on Friday , then the rears are going for a small tweak then hopefully I can get it built up.
Money will be tight from now on so its as and when I can afford it but I've not given up just more important things in my life
Cheers paul
So started to strip the front drive shafts down to get them machined to fit the wrc bearings and took them today so should have them back on Friday , then the rears are going for a small tweak then hopefully I can get it built up.
Money will be tight from now on so its as and when I can afford it but I've not given up just more important things in my life
Cheers paul
19-04-2015, 04:27 PM
#657
Advanced PassionFord User
Thread Starter
hi guys well finally had 5 mins to myself yesterday so pulled the car out to crack on with some work (its only been a year lol).
first i was getting the front driveshafts machined down as they didnt fit the wrc bearings , so i asked marc with the cossie fiesta and he kindly took his car to pieces and gave me some measurements.
ive found a great little machine shop down the road from work and gave them a drawing ,Ł30 later job done the same day.
unmachined stub axle
machined down , you can see the new lip
fitted to the upright
also recieved a rear wrc top mount plate from mk motorsport a while ago . the idea is to use this as a gearbox lever surround .
i started to make a 3mm thick mounting plate that will be welded to the tunnel with rivnut fittings to allow me to take the top mount plate off.
using the top mount as a template i marked it out on the plate with a 8mm lip for welding.
top mount plate
marked out ready to drill and cut
drilled
all hole lined up
all rivnuts done
bolted down and finishing
next was to remove the battery tray as i didnt like how low it was to the floor of the car as you couldnt clean underneath it and see as the car took me 4 weeks to clean the inside i was expecting it to be rusted and full of mud.
tray remove , no rust thank god but full of mud
next was to remove the fuel tank tray as the tank is small and there will be a pro alloy tank going in soon. iam going to remake it in the same style but bigger to fit the new tank .
next was the tunnel as it had bosses welded in for the gear lever and i had to replace sections as it was rusted through, so i carefully decided which bits i would do and how much metal i would take out as the last thing i wanted was to mishape the tunnel.
the front section cut out
card template made
next job remove all heat insulation from underside of tunnel , this took a few hours as the was ally tale everywhere.
sorry got no pics as forgot to take them but front panel welded in and ally tape to stop rust for the night
dont worry i hear you asking ! whats the big hole for in the tunnel? well it so i can fit a passenger seat . the tunnel is so big theres just no room , so i measured , marked measured to make sure as i defo didnt want to fook this up .
tunnel cut out
i used a 1 inch wide piece of metal and bent it around the original curves of the gearbox tunnel and the made it so i could fit seat rails to the passenger side. this gave me the measurements i needed to make the sheet metal and i fit perfect first time. the only problem i had was my bender can only bend upto 60cm and i need about 65cm so i was going to have to make a end box.
sheet metalwork bent and drilled for spot welds
fitting to the car
end box made at rear of tunnel
front section the same as steven mackays fiesta as i like the way his looked as i copied
front section made and welded up
and finally all welded up and cleaned ready for a coat of red oxide primer
coat of red oxide to stop the rust for the time being.
thats all for now but trying to get as much done as possible while the sun out lol, next is the other side of the tunnel and the square hole then thats it .
also spoke to bilstein about rebuilding my suspension and a small amount of machining on the rear drive flanges.
cheers for looking
paul
first i was getting the front driveshafts machined down as they didnt fit the wrc bearings , so i asked marc with the cossie fiesta and he kindly took his car to pieces and gave me some measurements.
ive found a great little machine shop down the road from work and gave them a drawing ,Ł30 later job done the same day.
unmachined stub axle
machined down , you can see the new lip
fitted to the upright
also recieved a rear wrc top mount plate from mk motorsport a while ago . the idea is to use this as a gearbox lever surround .
i started to make a 3mm thick mounting plate that will be welded to the tunnel with rivnut fittings to allow me to take the top mount plate off.
using the top mount as a template i marked it out on the plate with a 8mm lip for welding.
top mount plate
marked out ready to drill and cut
drilled
all hole lined up
all rivnuts done
bolted down and finishing
next was to remove the battery tray as i didnt like how low it was to the floor of the car as you couldnt clean underneath it and see as the car took me 4 weeks to clean the inside i was expecting it to be rusted and full of mud.
tray remove , no rust thank god but full of mud
next was to remove the fuel tank tray as the tank is small and there will be a pro alloy tank going in soon. iam going to remake it in the same style but bigger to fit the new tank .
next was the tunnel as it had bosses welded in for the gear lever and i had to replace sections as it was rusted through, so i carefully decided which bits i would do and how much metal i would take out as the last thing i wanted was to mishape the tunnel.
the front section cut out
card template made
next job remove all heat insulation from underside of tunnel , this took a few hours as the was ally tale everywhere.
sorry got no pics as forgot to take them but front panel welded in and ally tape to stop rust for the night
dont worry i hear you asking ! whats the big hole for in the tunnel? well it so i can fit a passenger seat . the tunnel is so big theres just no room , so i measured , marked measured to make sure as i defo didnt want to fook this up .
tunnel cut out
i used a 1 inch wide piece of metal and bent it around the original curves of the gearbox tunnel and the made it so i could fit seat rails to the passenger side. this gave me the measurements i needed to make the sheet metal and i fit perfect first time. the only problem i had was my bender can only bend upto 60cm and i need about 65cm so i was going to have to make a end box.
sheet metalwork bent and drilled for spot welds
fitting to the car
end box made at rear of tunnel
front section the same as steven mackays fiesta as i like the way his looked as i copied
front section made and welded up
and finally all welded up and cleaned ready for a coat of red oxide primer
coat of red oxide to stop the rust for the time being.
thats all for now but trying to get as much done as possible while the sun out lol, next is the other side of the tunnel and the square hole then thats it .
also spoke to bilstein about rebuilding my suspension and a small amount of machining on the rear drive flanges.
cheers for looking
paul
19-04-2015, 05:09 PM
#659
Advanced PassionFord User
Thread Starter
02-05-2015, 11:16 PM
#666
Advanced PassionFord User
Thread Starter
only a few little updates, wanted to spend 3 days on the car but the weather has other ideas . today was a shitter , crap weather , derby county lost 0-3 to reading which means no play offs after being top for most of the season lol.
so decided to go down to the shed and make some little parts ready to be welded in to the shell.
first was to cut some plates for the seat bars , these where made from 3 mm thick steel
2 for the tunnel and 2 for the sill side of the car
next i wanted to make some plates to cover up the crappy threaded bushes that have been welded to the side of the tunnel . first made cardboard template then made a metal one , holesaw some holes , swaged and job done.
template
and the finished product , not bad with a vice and a small metal bender
hopefully more updates on monday
cheers paul
so decided to go down to the shed and make some little parts ready to be welded in to the shell.
first was to cut some plates for the seat bars , these where made from 3 mm thick steel
2 for the tunnel and 2 for the sill side of the car
next i wanted to make some plates to cover up the crappy threaded bushes that have been welded to the side of the tunnel . first made cardboard template then made a metal one , holesaw some holes , swaged and job done.
template
and the finished product , not bad with a vice and a small metal bender
hopefully more updates on monday
cheers paul
03-05-2015, 08:50 AM
#668
10K+ Poster!!
Wow!
Why is it that metal with swaged holes just look soooo cool
Why is it that metal with swaged holes just look soooo cool
03-05-2015, 12:35 PM
#670
Advanced PassionFord User
Thread Starter
i never get any marks but i always clean my metal work with a scotchbrite pads so cleans up really well unless its a deep grinding mark.
cheers paul
03-05-2015, 04:15 PM
#672
Advanced PassionFord User
Thread Starter
buy some scotchbrite pads mate i use them for mild steel which it cleans up great and also when i build my stainless steel exhaust manifolds it gives them a slight brushed effect , and i guess you would get the same effect on alloy.
cheers paul
cheers paul
03-05-2015, 05:10 PM
#673
PassionFord Post Troll
It just wouldnt be the same without our local derby mate 
Works great mate you got skills
Works great mate you got skills
03-05-2015, 05:22 PM
#674
Advanced PassionFord User
Thread Starter
23-05-2015, 05:07 PM
#675
Advanced PassionFord User
Thread Starter
a few little jobs finished off last weekend .
first was finishing the tunnel mods ie cutting all the rusty parts out and replacing them as standard as possible as i like the tunnel and dont want plates welded all over the shop.
cutting the sequential gear level hole
i then made a plate with the original lines as close as possible
fitted into place as tight as possible
then tacked in to the shell
you can see the major rusty section of the gearbox tunnel , mud , water and heat dont mix very well with metal
section cut out
you can see how bad the metal was
front section made again following the original lines as much as possible
rear section made
both sections tacked in (ran out of gas )
next i decided that the one thing that let the car down when looking at it was the fact that it had no front rollcage stiffeners . this proved to be a little bit of a problem as the cage is that tight and well fitted to the car that it looked like i wasnt going to be able to fit one in but finally i got there.
picture with no stiffeners
cardboard template made
transfered on to metal with hole cut
one made
trial fitted and looking much better
close up picture
both stiffeners made , they wont be weld in to the shell until glass come out for painting etc
also welded in seat bar plates and the swaged brackets but forgot to take pictures so will get some up when i work on the car again
and just a few random pics of the shell
cheers paul
first was finishing the tunnel mods ie cutting all the rusty parts out and replacing them as standard as possible as i like the tunnel and dont want plates welded all over the shop.
cutting the sequential gear level hole
i then made a plate with the original lines as close as possible
fitted into place as tight as possible
then tacked in to the shell
you can see the major rusty section of the gearbox tunnel , mud , water and heat dont mix very well with metal
section cut out
you can see how bad the metal was
front section made again following the original lines as much as possible
rear section made
both sections tacked in (ran out of gas )
next i decided that the one thing that let the car down when looking at it was the fact that it had no front rollcage stiffeners . this proved to be a little bit of a problem as the cage is that tight and well fitted to the car that it looked like i wasnt going to be able to fit one in but finally i got there.
picture with no stiffeners
cardboard template made
transfered on to metal with hole cut
one made
trial fitted and looking much better
close up picture
both stiffeners made , they wont be weld in to the shell until glass come out for painting etc
also welded in seat bar plates and the swaged brackets but forgot to take pictures so will get some up when i work on the car again
and just a few random pics of the shell
cheers paul
23-05-2015, 07:46 PM
#679
Advanced PassionFord User
Thread Starter
they was all ground back before proper welding anyway and it looks as good as new (i will get some pics )
cheers paul
23-05-2015, 07:48 PM
#680
Advanced PassionFord User
Thread Starter