Fiesta ST 2.3 Turbo W.I.P

[GazST]

Hey guys I've just signed up onto here. I thought I would start a project thread up and let you all know what I've done to my Fiesta ST within four years of owning it from new. It's taken alot of time and effort to get where it is but thanks to the lads at Pumabuild and alot of other companys it's starting to come together Spec - Oz 17″ Superturismo alloys - EBC rear grooved discs - Gaz Shock coilovers - Goodridge brake hosing kit - OMP strut brace in Performance Blue - Powerflex bushes - W Pro 6 pot calipers and 325m grooved and drilled discs - Rear EBC Green stuffed pads Engine Bay - Performance Blue slam panel - Performance Blue engine bay - Performance Blue underside of bonnet - Pumabuild 2.3 Performance Blue rocker cover - Samco ancillary hose kit (White) - Samco coolant hose kit (White) - Samco induction hose (White) - Washer jet hosing (White) - Intercooler and wiring loom hoses (White) - Sparco motorsport air horn - Radtec power steering tank - Radtec coolant tank with glass level - Auto Specialists stainless steel bonnet catch plate - Auto Specialists stainless steel bonnet hinges - Auto Specialists stainless steel bonnet plates - Auto Specialists stainless steel bonnet stay - Stainless steel brake fluid cap - Fusion stainless steel fuel rail cover - Fusion stainless steel electrical box cover - Auto Specialists stainless steel oil cap - Auto Specialists stainless steel washer cap - Auto Specialists stainless steel wing rail covers Exterior - Carbon fibre pod bonnet pins - Focus RS mkII bonnet vents in carbon fibre - Fiesta JWRC roof vents - Tinted windows - Ultra chrome halo headlights - Ultra chrome tailgate lights - Ultra chrome third level led brake light - Kaylan mudflaps - Wing mirrors in Performance Blue - Carbon fibre front splitter like on the Focus RS - Carbon fibre wing mirror panels - Carbon fibre door pillars - Carbon fibre roof strips - Carbon fibre scuttle panel - Silver front and rear grilles - Performance Blue aerial and base - Performance Blue washer jets - Performance Blue de-lock bezel - Performance Blue front fog and rear reflectors surrounds - Perfomance Blue lower front grille surround - Performance Blue rear valence above exhaust exit ICE & Security - Alpine CDA-9885R headunit - Clifford - Clifford turbo timer Interior - Recaro Sportster SC front seats (with Blue suede centres) - Rear bench retrimmed in Blue suede centres to match Recaro front seats - Front door cards retrimmed with panel in Blue suede with ST Turbo stitched into it - Rear door cards retrimmed with panel in Blue suede - Start Button - Dash board flocked - Sparco pedals - Sparco handbrake handle - Sparco sport LM handbrake gaiter - Gun metal gear knob (numbers in Performance Blue) - Black leather gaiter with Blue stitching Power & Performance - 2.3 American Focus engine - Ford Racing cylinder head ported and polished by Ric Wood - Piper cams spec by Ric Wood for turbo - SuperFlow pistons 9:1 compression - Cortillo rods - Helix clutch - Quaife gearset - Quaife ATB limited slip differential - Titan flywheel - Piper veriner pulleys - Collins Performance dump valve - GT25 turbo - Primary Designs turbo spec manifold - Radtec intercooler - Omex 600 ECU - Race Tech digital dash display - Defi guages temp, water and boost - Blitz boost control - Cosworth billet crankshaft - Cosworth inlet manifold - Cosworth throttle body - Cosworth fuel injectors - Piper de-cat - Piper cat back system - Accel coil pack - Magnecor HT leads - Denso spark plugs Vinyl, Stickers and Badges - 2.3 badge on tailgate - 2.3 conversion Powered by Pumabuild decal on rocker cover - Blue ST tailgate badge - Blue ST badge on front lower grille - Clifford alarm decal on rear window - Clifford decals on rear quarter windows - Blue sunstrip with Powered by Pumabuild on it - Fiesta trophy decal around ST tailgate badge - Ford decals on roof and vents - Ford Team RS decals above front fogs - Carbon fibre Ford oval badges on front grille and tailgate - Fiesta ST decal on bonnet plates - Fiestastoc.com decals on rear quarter windows - M-Sport decal on strut brace - Performance Ford decal below sunstrip - Piper sport decal on rear tailgate - Power by Cosworth decal below ST tailgate badge - Power by Cosworth decals on side skirts - Toyo decals below front fogs - Side strips customed with ST Turbo on rear half

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[pani_k]

Pics of said car plus performance figures!!

[GazST]

Originally Posted by pani_k

Pics of said car plus performance figures!!

The turbo conversion is taking place at Pumabuild at the moment! I currently have a 2.3 engine in the car which is producing 230hp 190lb when it was last on there rollers. Thats all coming out and a new higher tuned Cossie spec engine is going in as it needs to be lower compression for my turbo. Here are a few pics of my car at the moment:-

[pani_k]

Nice! Pretty sure I've seen this at a couple of shows already last year on the pumabuild stand?

[GazST]

Originally Posted by pani_k

Nice! Pretty sure I've seen this at a couple of shows already last year on the pumabuild stand?

Yeah was on there stand last year and will be again this year all finished!

[Graham88]

Like it! Wanna swap engines? lol

[GazST]

Originally Posted by Graham88

Like it! Wanna swap engines? lol

Funny you should say that!! All my current setup including exhaust, gearbox and gearset, Helix clutch, Quaife diff, Titan flywheel, Dreamscience and plus my highly tuned 2.3 Ranger engine which has only done 8k in miles is for sale! If only I could put a for sale thread up on here lol

[pani_k]

Graham, get it bought mate! Would complement the rest of your car soooo well

[alan12112]

Looks Crap

[GazST]

Originally Posted by alan12112

Looks Crap

Oh look what the cat dragged in lol

[COCHYN]

Chuck all the stickers away and its an awsome little car!

[Brian]

Looks very nice


Brian

[Graham88]

Originally Posted by GazST

Funny you should say that!! All my current setup including exhaust, gearbox and gearset, Helix clutch, Quaife diff, Titan flywheel, Dreamscience and plus my highly tuned 2.3 Ranger engine which has only done 8k in miles is for sale! If only I could put a for sale thread up on here lol

How much are you looking for? Pretty serious bit of kit

Originally Posted by pani_k

Graham, get it bought mate! Would complement the rest of your car soooo well

Couldn't agree more, it needs a manly engine!

[GazST]

Originally Posted by Graham88

How much are you looking for? Pretty serious bit of kit

I've sent you a PM buddy.

See link below for parts I have up for sale and available now:-

http://passionford.com/forum/ford-st...0-goodies.html

[jonnyrsturbo]

looks a mint little car that

but not liking the stickers though

[GazST]

Originally Posted by jonnyrsturbo

looks a mint little car that

but not liking the stickers though

The stickers are now coming off Johnny! As got new Focus RS bonnet vents going on and alot of carbon fibre parts. Which myself and Pumabuild have managed to bring onto the ST150 market. If your going to Ford Fair it will be on PB's trade stand your welcome to all come and take a nose.

[GazST]

Right guys! Here is an update as alot has been happening within the last few weeks to the car. I finally sold my original 2.3 engine which was mean't to go in May. But due to reasons out of my control the buyer decided to pull out last minute! I wasn't happy about this as you can imagine as it's totally held up my project as my car was at Pumabuild with the engine still in it until it was sold. So as it went last Saturday to a guy Ric Wood knows who is putting it into an Escort rally car. Things can now start to move with the project as it's in the workshop full time
Now the engine is out the whole engine bay has been stripped right back. So it's ready to go into the spray booth so the complete engine bay can be sprayed in Performance Blue. All the final parts have been sent off too Nur Motorsports to finish off my carbon fibre parts. Which should hopefully be done by the end of this week. As I'm getting front splitter, scuttle panel, wing mirror panels, door pillars and roof strips. Basically all the plastic parts on the exterior will be in real carbon fibre as I think it will finish it off nicely.

Engine Bay Stripped





The engine bay has been sprayed but it's currently sitting in the spray booth!

I've also decided to go for a new theme with the car this year. So all the stickers are off my bonnet and will be replaced with Focus RS mk2 bonnet vents and aero catch lockable bonnet pins. My new bonnet vents arrived in the week so Alan at PB decided to pre fit them on Saturday for me.
Focus RS Vents



The bonnet is being resprayed this week! As the car is now being fully worked on daily more updates to follow....

[COCHYN]

So what engine spec is going back in?

[GazST]

Originally Posted by COCHYN

So what engine spec is going back in?

So far the will be my complete engine spec and gearbox etc...

- AP Racing six paddle clutch
- AP Racing flywheel
- 2.3 Duratec short bottom end
- Ford Racing CNC machined ported and polished head by Ric Wood
- SuperFlow low compression pistons
- Piper cams turbo spec by Ric Wood
- Buckets customed to various sizes for turbo spec
- Cortillo rods by Cosworth
- ARP bolts
- M-Sport alloy engine mounts in Black
- Accel coil pack sprayed in White
- Rocker cover in Performance Blue
- Omex 600 ECU
- Race Tech dash with Blue display
- Defi boost, temperture and pressure guages with Blue displays
- Blitz boost control unit
- Collins Performance dump valve in Blue with White hosing
- Piper valve springs
- Piper veriner pulleys in Blue
- Radtec intercooler
- Radtec stainless steel coolant tank with glass level
- Radtec power steering tank in stainless steel
- Primary Designs turbo manifold Zircotec ceramic coated in White
- Primary Designs turbo downpipe
- Primary Designs custom de-cat with larger bore
- Primary Designs cat back with larger bore and 3.5" tailpipe
- GT25 or GT28 turbo
- Quaife gearset cross cut
- Quaife LSD
- Cosworth fuel injectors
- Cosworth throttle body in Power Blue
- Cosworth billet crankshaft
- Cosworth inlet manifold
- Samco coolant hose kit in White
- Samco ancillary hose kit in White
- Samco boost hose in White
- Samco wiring loom hoses, intercooler and inlet manifold and all other hose in White
- Samco vacuum hose in White for washer jet hosing
- Magnecor HT leads in White
- Engine will be custom mapped on Ric Wood's engine dyno

[wide ka]

some engine spec! what kind of power you looking for?

could you have not just got a mazda 3 mps engine for less?

[GazST]

Originally Posted by wide ka

some engine spec! what kind of power you looking for?

could you have not just got a mazda 3 mps engine for less?

Not sure on power until it's been on Ric's engine dyno. All I can say it's going to be one of the quickest Fiesta's within the UK that's for sure.

I decided to go for a highly modified engine using mostly Cosworth parts. It's probably cost me more doing it this way. But I will have a very strong engine and an awesome car to show for it at the end of the project.

[Rick Astley]

So your not going to keep those cruddy, offensively chavvy stickers anymore then?

[GazST]

My full custom exhaust setup has now been finished by the lads at Primary Designs. There work is spot on as always!! I've gone for a manifold built in Inconel and this will be ceramic coated in White by Zircotec once the car is running so will the downpipe. Also have a 2 3/4" bore size all the way along the system. I've decided on a 200 cell sports cat and the tailpipe on the cat back is 3.5" rolled inwards. Will be running a GT28 or a GT30 now. The car is getting flat bedded to Radtec soon to have my intercooler built so things are moving Below is a picture of the GT28 turbo used to build the flanges of the manifold and you can see part of the manifold. Loads of stuff is missing off my engine still which is sitting at Pumabuild's unit and will be installed once Radtec are finished. Will get more pictures of the full system up soon as Scott at Primary Designs has been busy taking progession pictures. Some which will be used in my feature in Performance Ford mag.

[mk2rstaff]

awesome project

[Brian]

Stunning project


Brian

[ADT168]

nice project

[GazST]

Now Primary Designs have finished building my complete exhaust system. Thought I would post a few updated pictures so far...

Turbo manifold made from Inconel



Complete turbo manifold which will soon be ceramic coated in White





Under section of the system which has been built using 304 stainless





Really pleased with the work the lads at Primary Designs have done it's top notch!! The car is now with Radtec who have started building my intercooler. So finally everything is starting to come together

[GazST]

Popped down to Nur-Motorsports one night last week and saw the mdf mould of my front splitter. This is the first stage of producing a front splitter. My mate Noel wanted me to see it before it was done into a solid plastic mould which is the next stage before it's made into carbon fibre. It's abit of a process but Noel was saying he wants everything to look right as he believes in making high quality parts in carbon. Plus I've known him for years and he wouldn't be on my xmas card list if I hated it haha....

Splitter design in mdf



I've decided to make the sides of the mould more curved from the design above just to suit the style of the ST150 front bumper. Which has now been done and made into a solid plastic mould which I saw on Saturday. I was going to take a picture of it and post it up. But it's currently covered in wax! It's going to look awesome as I've put it upto my bumper at the unit. Now I had two opitions how the splitter was produced as could of gone for the complete under section like you see on the picture of the mould. Which would of been clamped onto the front bumper. Most of the motorsport guys who use Nur-Motorsports go for that opition. But I've decided to cut that section off and have it fixed onto the front bumper with clips. I thought this would be best as I don't know if it would of hit my intercooler which Radtec are currently building. I've now removed the plastic strip under the bumper and clips which it was attached on too as that way I get a flush finish upto the bumper.

I had an issue removing my wing mirrors from my panels. As it looked like a complete unit! I've now taken them off and the panels and bracket part is moulded already. So all the above will be made into carbon fibre this week finally so will be ready by the end of the week. The scuttle panel, front wing mirror covers and b pillars have been finished. The plastic roof strips are something which were do one weekend when I have the car back. At the current time these will not be made for anybody else as there so busy!!! But within the next month these will be available to purchase from Pumabuild including ST225 and Focus RS MK2 parts including front splitters.

It's a shame my car is not finished yet as Nur-Motorsports had a feature today with Redline magazine at there unit and Noel wanted my car in it. This should be in the next issue and your see his Peugeot 306 Cosworth, 700bhp Supra which is an animal!! Plus his Skyline R34 all full of carbon fibre parts. His business own all of them plus a Porsche 993 GT2. As you c0an see he likes his cars

We also talked about fitting the RS concept kit onto my car today. I ruled this out a while back as I found out with suspension and arch work plus fitting the bodykit it would of worked out being about Ł5,000!!! Which is just out of my budget and is crazy money. I mean it would buy you another ST150 lol... But for the work involved to do it properly that would be the rough figure. But one of Noel's best mates used to work for Team RS and could do the arch work he has already done alot of work on Nur-Motorsports cars in the past. For the suspension this could be done by another lad who works for him who used to be part of the Renualt rally team and worked on suspensions. His work is unreal!! That could all be done for mates rates and I was shocked at the price in a good way! So I might have to think about doing it in the future now.

[luke89]

sounds awsome mate just notist ur from Reading, when its done any chance of haveing alook over? is nur the people that done the black skyline?

[GazST]

Bonnet sprayed with Focus RS Mk2 vents fitted!!



All my carbon fibre parts are finally finished Will get more pictures uploaded soon.

[CozzyKing]

Originally Posted by GazST

Bonnet sprayed with Focus RS Mk2 vents fitted!!



All my carbon fibre parts are finally finished Will get more pictures uploaded soon.

Looks like a sweet little project you got there, would love to see some performance figures once it is built, hope we don't have any problems with split engine blocks with this one though

[GazST]

Popped down to Nur Motorsport as Noel wanted me to see my parts finished in carbon before they were despatched out to Pumabuild. The finish is to a very high standard and the front splitter will look awesome once fitted onto the bumper. Which was done this week and he has also done my wing mirror caps in carbon which I didn't know about! They will be a straight swap for the original Ford part but I'm not sure weather I'm going to put them on yet. As I'm getting my complete mirror housing sprayed in Performance Blue.

Front Splitter





Wing Mirror Panels



The edges around the wing mirror bracket are yet to be smoothed off!! The bracket will be sprayed gloss Black

Scuttle Panel



Also got a few pictures from Radtec today with updates on my intercooler and radiator. Both parts are finished but before the intercooler is bracketed onto the car there waiting on silicon. Unfortunately this is having to be made special as the plenum side is a 135 degree bend reducing elbow!
Radtec ST150 intercooler





Radtec radiator which is an exact copy of ST150 part. But it has high performance core with double the depth.

[Paul_RS]

Fantastic project!

[cboi23]

Have you got any pic of the underneath of the bonnet or could you tell me how they were put in as I want to do this to my white fez ST cheers

[cboi23]

Sorry was talking about the focus rs vents previous post didnt make much sense!

[00fergie]

any updates?

[jacko]

where did you get those seats there same as mk2 rs focus and i want some

[CozzyKing]

There are some really great parts getting fitted to this motor, keep up the good work mate

I would also like to know where you got those seats from as I would love to get some for one of my projects.

[Brian]

Looks stunning


Brian

[GazST]

Update...

Not been on the forum for ages... The project is still on going and nearly finished! Had so many delays with custom parts being designed but the complete build is fantastic! My PD manifold and downpipe have been ceramic coated by Zircotec in Performance Colours range Sterling Silver. Bailey Motorsport are designing all my tanks there work speaks for itself! Radtec have modified my sump and done all the pipework/braided hoses for the project. My interior is finished which a complete flocked dash, pillars and sunvisors. The roof lining is now suede Black and really looks impressive! Also decided to have some more carbon parts made RS MK2 bonnet vents and bonnet trim. Anyway that's enough typing I will let the below pictures do the talking!

New 2.3 turbo spec engine being built up!



Purchased a new set ajustable coilovers from Gaz Shock decided on the Gold range.



Primary Designs full system fitted





Now the engine was finally built up was time to put it into the engine bay





Flocked dash, pillars and sunvisors also suede Black roof lining





As I've got alot of carbon parts decided on RS carbon vents now! Had my JWRC roof vents also produced in carbon.



Carbon wing mirror cap and base panel



Also purchased my Defi gauges and control unit





Had my Superturismo WRC alloys powder coated in gloss Black to match the OZ GT range. Thought this would suit the carbon Black on Blue theme!



Also had the rear beam powder coated Blue and front suspension arms and cross member powder coated Blue, Red and Yellow. Now looks like Noddys car from underneath haha...



Had my rear Ultra Chrome tailgate lights tinted





Mean while the engine was starting to come together more...



Radtec modified 2.3 sump



At this stage just connected the front bumper so you get the idea what it will look like with the Radtec intercooler fitted.



Bulkhead ceramic heat wrapped in ZircoFlex





We noticed the engine was sitting flush on the M-Sport alloy mounts before it came out. To have the bulkhead wrapped and all hoses/pipework on the bulkhead ceramic coated. So Alan at Pumabuild made some custom plates for the mounts to make the engine sit flush. Here are the mounts, plates and finished result!

M-Sport alloy lower gearbox mount you can see the different need to made the engine level by the spacer!



M-Sport alloy engine mount you can see the different needed by the bolt



PB custom mount plate





Finished result



The reason why we have coated the pipework/hoses against the bulkhead your see the manifold runs very close below!



Radtec have yet again helped out again with the custom work on the pipework and made all braided hoses. with heat protection.

Now starting to look more like a car again...



Engine bay is starting to come together too!



At the moment the stage were at is Radtec have had the car for the last three weeks finishing off all pipework and hoses so everything is running where we want it to be. Now it's back at the unit the Omex management is ready to be installed with the Race-Tech Dash2 display. Once that's done basically the tanks can be fitted and ready to start up... The car should make FITP and with be covered feature in a Ford mag hopefully the issue before the show.