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Restorations, Rebuilds & Projects. Restoring her to Concourse? Just getting her running again? Or got a mad project? This is your room.

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Old 21-06-2009, 09:38 PM   #1
M K
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Default Mk6 JWRC fiesta cosworth

well most of you knew my old car and if you didn't here is a couple of shots of it

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Well after a year out and going semi sensible with an e46 M3 coupe i have decided its time for another project and obviously it has to be bigger better and faster than the last so after toying with escort cosworth group a shells and focus cosworths etc i decided on the mk6 fiesta with the jwrc kit the same as the likes of pat and liam dorans rallycross cars as i just love the look of them with the kit and the big bhp 4wd cosworth set up,

well its gonna be long, expensive, very testing and did i mention very expensive :blub: but here goes..............

i did look into getting a new shell from fords but for the cost and then having to buy sill little things like dash/lights/brackets etc i ended up sourcing a complete 53 plate tdci 1 owner from new lol for £900, that is completely rot free and has them bits on it already so away we go, let the build commence :cool!:

here is the future beast
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started to strip it pretty much straight away but as it still drives and has tax and mot for 2 months i might go and get the rear quarters put on and the wrc sill tubes fitted while i can drive it there,

Click the image to open in full size.

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Click the image to open in full size.


i have been too and fro as to whether it should be 2wd or 4wd but i just don't think it would be as drivable as rwd car with no overhang at the rear but the pro's are 2wd transmission for big bhp around the 450-500bhp is cheaper but a 4wd set up would handle like its on rails but be a lot more expensive slightly heavier and more complicated to work on so i am still undecided on that as yet, any opinions please post them up :cool!:

will talk a bit more about desired spec and plans soon.

:cool!:
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Last edited by M K; 25-02-2013 at 06:07 PM.
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Old 21-06-2009, 09:45 PM   #2
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Nice one Marc good luck with it

If it turns out any thing like your Mk2 it will be a monster


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Old 21-06-2009, 09:59 PM   #3
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Oi Kinsey....so much for the M3 ya douch!

Glad you stuck with the blue oval, looking forward to seeing your plans unfold. Good luck!

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Old 21-06-2009, 10:00 PM   #4
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Should be mint mate....

How much are you thinking?

PM if you like
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Old 21-06-2009, 10:26 PM   #5
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hi mate nice to see your not hanging about and getting started , also good to put a face to the name as i remember your fiesta , a very nice car , any info i can help with i will glady pass on , good luck!
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Old 21-06-2009, 10:42 PM   #6
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Oooh, very exciting. Keep us informed.
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Old 22-06-2009, 07:00 AM   #7
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Good to see you getting stuck in Marc
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Old 22-06-2009, 08:14 AM   #8
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Will be watching this eagerly. Id say go RWD but with a proper wrc style cradle set up
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Old 23-06-2009, 07:20 PM   #9
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Will be watching this one closely aswell



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Id say go RWD but with a proper wrc style cradle set up

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Old 23-06-2009, 07:31 PM   #10
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Awesome, once you're done, feel free to practice on mine after lol
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Old 23-06-2009, 07:40 PM   #11
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sweet m8 i was gna do a fiesta mk6 van 4x4 bout desided on a focus 4x4 keep up the postz
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Old 23-06-2009, 09:08 PM   #12
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Richie did you get my pm? About cradle costs?
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Old 23-06-2009, 09:22 PM   #13
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£900

will be watching this so keep us informed
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Old 23-06-2009, 09:23 PM   #14
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no doubt this will be a proper car!! did you sell the mk2?
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Old 23-06-2009, 10:15 PM   #15
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Sold it off in parts for 16.5k
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Old 23-06-2009, 10:28 PM   #16
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sounds cool project marc, they look awsome with the wrc kit on
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Old 24-06-2009, 11:53 AM   #17
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Quote:
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Richie did you get my pm? About cradle costs?

Yes mate, replied
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Old 24-06-2009, 12:48 PM   #18
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o no, more trailoring for me then
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Old 24-06-2009, 01:32 PM   #19
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£900 for the car was a bargain, it was on ebay for £950 start - reserve not met so i emailed to see and she said £1200 so i said il give you £900 if you deliver it to my house and they said ok, women was 60yrs old and came on her own to drop it off then i dropped her at the station to get back to portsmouth

RESULT.....


RICHIE. - cheers mate, will no doubt be speaking to you alot more in the coming months lol,

still undecided as to whether its going to be 4wd or rwd so have to hurry up and make a decision so i can start collecting parts etc,

i want to collect everything so when i sub out the shell fab work i can get it back rolling with all the proper bits fitted rather than on dummy/temp standard crap,

my list of bits to get of the top of my head are -

COILOVERS
WRC ADJUSTABLE TOP MOUNTS
GEARBOX
REAR DIFF
FRONT DIFF (if 4wd)
BEAM/OR HAVE CRADLE MADE
FRONT AND REAR HUBS ETC
DRIVESHAFTS
PROPSHAFT/S
COMPRESSION STRUTS
STEERING RACK/COLUMN ETC
JWRC BODY PANELS
DRIVERS SEAT
PEDAL BOX
WHEELS/TYRES

and proberly a load more i havent thought of and thats just to get me a basic rolling shell

i have only bought 1 thing so far as im gonna get them fitted now so its easier for me to do a few bits at home

wrc sill stands and fitting kit

Click the image to open in full size.

22.5" high so give plenty of room for working under the car without getting in the way like normal axle stands, a must have imo
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Old 24-06-2009, 02:00 PM   #20
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A high lift jack is more of a must have with those type of stands

Good project - looking forward to seeing it progress
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Old 24-06-2009, 02:13 PM   #21
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Quote:
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A high lift jack is more of a must have with those type of stands

Good project - looking forward to seeing it progress
thats very true tony been looking at a few lately, would you recommend any high lift inparticular?

i have 1 of them alloy racing style jacks and think there crap and no where near enough lift anyway
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Old 24-06-2009, 05:41 PM   #22
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Quote:
Originally Posted by M K View Post
wrc sill stands and fitting kit

Click the image to open in full size.

22.5" high so give plenty of room for working under the car without getting in the way like normal axle stands, a must have imo
Alright Marc,

Where abouts did you purchase your wrc stands from?

Cheers

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Old 24-06-2009, 05:57 PM   #23
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http://www.motorsport-tools.com/inde...roducts_id=633

http://www.motorsport-tools.com/inde...roducts_id=635
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Old 06-07-2009, 10:37 PM   #24
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Any Updates?
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Old 06-07-2009, 10:46 PM   #25
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Hello fella
bit slow at the mo as I need to shift the m3 to release funds to really get going but I have got a few
more bits like
weld in sear bars
cossie mt75 box
front diff and prop
hi spec monster 6 pots with 360mm discs

I have stripped the shell a bit more and currently making up a dolly to move the shell around on,

when the m3 has gone it will really get going
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Old 06-07-2009, 10:54 PM   #26
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know this is gona be awesome just like the fiesta.good luck with the build
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Old 09-08-2009, 08:05 PM   #27
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Thought id throw an update on here although progress is still very slow at the moment,

things are happening tho and im currently in talks with MDV who are a very reputable motorsport engineering firm responsible for the 1st doran fiesta rallycross cars and more recently well known is a complete re desing of the suspension and aerodynamic package on the pikes peak 1150bhp rs200,

the idea is to create the best possible shell i can and then i can build up form there when funds allow as its looking like the shell fab and re worked wrc derived wide track suspension set up is going to cost more than first thought so the build is gonna be done in two stages first being a complete 4x4 ready shell built to the best possible spec with wide track wrc rear end and custom wide track front end so as far as chassis and geometry goes i have the best set up from the start, as i know from many cars including my last that the suspension design and set up is more important than anything else imo,

so the shell will be going in soon i hope for the following

fitting of jwrc kit and steel arch liners for strength.

fully mig welded t45 cage including roof x, door x, rear x, harness bars, full front and rear triangulation and rear diff and cradle tie ins.

large style turrets for adjustable alloy top mounts for wide track suspension.

chassis mounted engine mount brackets.

full 4x4 tunnel modification.

rear subframe mounts incl rear floor modification.

steering column mounting.

floor mounted pedal box fitting.

full re worked wrc rear cradle and links.

custom rear uprights to suit wrc rear links set up.

modify front subframe to suit 4x4 installation and accept wide track adjustable tca's and comp struts configuration.

fully adjustable wide track custom tca's.

fully adjustable wide track custom comp struts.

fully adjustable custom track rod ends.

Now i have been to visit MDV to discuss all these options with peter bennett and look at a white rwd focus rs hey have built for a customer that has their wrc rear end set up etc and its very impressive and the quality of the work reflects the price tag it comes with but you get what you pay for imo.

my full jwrc kit was ordered through mdv about 2 weeks ago so should be here soon consisting of

full jwrc rear quarters
jwrc front wings
jwrc front and rear bumpers
jwrc full carbon front splitter

again these are from msport contacts and are of a kevlar glass mix and are very good fitment which again reflects in the price compared to the likes of the pumaspeed kit which from what i have seen are very poor quality and fit.

so there should be news on the shell work soon once we have finalised a price for the work, but the shell is now completely stripped ready to go off and be transformed,

Click the image to open in full size.

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also picked up a cosowrth 7.5" rear diff so i now have a front diff, rear diff and cosworth 4x4 gearbox to dummy up for the chassis work and have hopefully sourced some hubs shaft and props and a steering rack to use for the dummy build

Click the image to open in full size.

and i also need to order my 4x4 bells for the brakes i picked up for the front which should stop me nicely although i admit there not my 1st choice but were so cheap i have to try them

Click the image to open in full size.

hopefully some proper progress reports soon with some serious work underway
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Old 09-08-2009, 08:10 PM   #28
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http://www.mdvse.com/default.asp

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Old 09-08-2009, 08:26 PM   #29
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looking good mate!
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Old 09-08-2009, 08:52 PM   #30
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Good progress marc
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Old 09-08-2009, 10:12 PM   #31
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good project, the only advise i will give you is dont scrimp on the drivetrain, hibs/flanges/control arms etc std items are just pure road use, and serious usage and you end up replacing bits constantly, i did it with my last rally cars and just ended up with more maintenance costs after every even than if i had bought pukka parts originally.

just take your time and do it right.
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Old 09-08-2009, 11:05 PM   #32
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Got to get me some of those sill stands
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Old 09-08-2009, 11:10 PM   #33
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good look with the build mate
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Old 09-08-2009, 11:33 PM   #34
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looks good mate
what colour will it be?
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Old 10-08-2009, 10:58 AM   #35
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good project, the only advise i will give you is dont scrimp on the drivetrain, hibs/flanges/control arms etc std items are just pure road use, and serious usage and you end up replacing bits constantly, i did it with my last rally cars and just ended up with more maintenance costs after every even than if i had bought pukka parts originally.

just take your time and do it right.
I know what you mean mark but there are certain areas like gearbox and diffs etc that i just can not posibly afford what i would like as a first choice,
for the diffs i think for cost and proven capability i will run gripper plated front with thick wall casing and strengthening plate and a gripper plated 7.5" rear diff,

im not sure on the gearbox at present but have looked into the bara boxes via marco as they are not unrealistic with the prices like some others.

the rear wrc set up is made to very high standards with top quality rod ends that imo may be overkill as they are very expensive, but as for the hubs and flanges for the price of the wrc items i really dont think id ever need them for mine being just a serious track car and not seeing the rough terrain your car will encounter on every stage outing, so will be using a custom rear hub to accept a gaz gold front upright and standard cosworth hub flange and bearing, i have ben assured for what i want the car for this will be up to the job and has been proven on past 1 or 2 past cars.

the front tca's, comp struts and adj track rod ends are very heavy duty and custom to my wide track set up and are far from standard quality and strength so no problems there,

i will only compramise on certain things and the suspension/geometry parts are not 1 of them as a failure in this area could be catastrophic for me on track.

i will get some pics etc of parts at a later date once made but as the cost is over 3 times my original budget for the shell and suspension components etc it will be a while yet.

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Old 10-08-2009, 11:01 AM   #36
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looks good mate
what colour will it be?
toying with the idea of anthracite inside and new focus rs electric green on the outside but plain white is also top of my list.
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Old 10-08-2009, 12:35 PM   #37
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Looks to be a well thought out project Mark , cant wait to see it com together.
What size are the front brakes ? I run HiSpec front and rear and im impressed by them.
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Old 10-08-2009, 12:54 PM   #38
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front brakes are 360mm with mega monster 6 pots not sure what il run on the rears yet but prob 330mm with 4 pots.
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Old 10-08-2009, 01:01 PM   #39
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Should stop well then as it will be fairly light, im using Monster 6's front and rear with 380's
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Old 10-08-2009, 02:38 PM   #40
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Quote:
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toying with the idea of anthracite inside and new focus rs electric green on the outside but plain white is also top of my list.
Sounds nice.
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Old 10-08-2009, 02:38 PM
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