My MK3 Fiesta Zetec turbo build....

[Adam31]

Ok after a long time in the making(nearly 3 years!) of not doing very much with my project other than removing parts and getting it painted, its finally time to get myself into gear and get it on the road. The car was originally a 1.1 HCS engined MK3.5 Fiesta, 1995 N registered. Its covered, 54K from new and was in very good condtion when I bought it from my neighbour for £80!....the original plan was to replace the engine with a N/A 2.0 silvertop zetec and have it fairly standard looking, however after a while I knew this wasn't really what I wanted. I really wanted turbo power so thats where we are at the moment...an empty shell awaiting a new engine and everything that goes with it. Here are some pics of what the car is like at the moment Pic showing the mk5 Zetec-s rear beam with focus rear disk setup The 300mm front brakes, without calipers fitted, just squeezed behind the 15" wheels. These will have to be upgraded when the engine is completed. Empty bay, just showing my newly finished front subframes and anti-roll bar. Battery tray removed also. The inside has been fully stripped and the dash cut down but not finished. Carbon door cards will be fitted however the rest of the inside hasn't been decided on yet. I have been contact wih Simon Smail from Sitech Raing, Perth with regards to getting the project finished to a high standard. Hopefully this will be on the cards when I return from holiday next month. The engine will be based around an ST170 engine and gearbox with all the necessary changes reuquired for a turbo engine. Final output I am looking for will be in the region of 280-320BHP. Any comments and ideas welcome, Thanks, Adam.

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[Brian]

Looking good mate

How hard was the Mk5 rear axle to fit?


Brian

[Adam31]

Cheers, it was literally a staright swap using the same mounts and mk3 shocks. I removed the drum brakes and fitted the focus hubs staright on after removing the abs sensor. Its a lot stronger and stiffer.

[Alan2525]

car looks nice mate

[frst-pete]

very nice.
i'm gonna keep my eye out on this one mate.
be prepared for a few questions fired your way Adam31 cos i've just started a stripdown and rebuild on my own fiesta.

[robp-tt]

looks good, dose the zetec s rear axle use a antiroll bar?, also dose any of the zetec s axles fit?

[Adam31]

Cheers guys, its a long way from being finished but I will get there one day. I'll do my best to answer any questions but I am no expert so be warned! Regards the rear axle, it doesn't have an anti-roll bar as its stiffer than the RS mk3 one without one. However you can fit one from the RS, I haven't tried it so I don't know how it affects it. The best one has to be from the 1.6 Zetec-s or later model Puma 2000 onwards, mine is from a 1.6 fiesta zetec-s.

[Adam31]

I'm heading up to Sitech on Sunday for a rolling road day, so hopefully I'll sort out a date with Simon that I can take the fiesta up to start the work. I haven't forgotten about this yet....

[rst in breaking]

cool project mate

[DHMC]

mate im looking to do the rear beam that you've done... can you talk me through how you did it and what parts i'll need???

[Adam31]

You need to find a mk5 fiesta(00-02) zetec-s, 1.6 engine. You need the axle from this car, it has a few extra bits on it that make it stronger than the mk3 one, even the turbo with the anti-rollbars. Its a straight swap if you want to keep the drum brakes. If not, and you want disks like mine you need the hubs, calipers etc from a mk1 focus. They only came on the 2.0 models and a few later 1.8's. You can fit the ST170 or focus RS ones but they are a bit pricey and won't make much difference on such a small car anyway.

Including the rear brakes I paid £140 for the whole axle, a bargain really.

[Twins]

Looks very nice already

[Adam31]

Cheers for the replies everyone, one day it will be finished and worth looking at and you never know it might be quite a good drive aswell!

[Matt_fez]

Looks like a good shell to start your project with mate. Best of luck with it

[dingla rs]

looks like a nice shell ,get the under side done while your waiting before that rust gets any worse nice work so far tho

[Adam31]

Originally Posted by dingla rs

looks like a nice shell ,get the under side done while your waiting before that rust gets any worse nice work so far tho

Started that today, its hard work though. I am just rubbing all the spots of rust down as its just surface rust, then painting it with back stone chip paint.

I took my dash out again as I have changed my mind(again!)might want a mk5 fiesta dash instead now.

[DHMC]

When you say axle do you mean the beam???

[Adam31]

Originally Posted by DHMC

When you say axle do you mean the beam???

Yes I mean the rear beam.

[Glenn.]

I like this little fezzer.

[1098]

Nice project, something I would be looking to do to mine in a few years. What budget do you have for the engine conversion?

[leader]

nice project mate

[Adam31]

Originally Posted by 1098

Nice project, something I would be looking to do to mine in a few years. What budget do you have for the engine conversion?

Thanks mate. I am expecting to pay near to £4000 including the turbo, which will probably be a GT28.

[crazycage]

Originally Posted by Adam31

Thanks mate. I am expecting to pay near to £4000 including the turbo, which will probably be a GT28.

what spec gt28 are you going for.

[Adam31]

I am not sure of the turbo spec yet. I am taking the car up to Sitech on the 14th to start the work, I'll have a chat with Simon then and decide, but I'm sure as with most projects the spec will cange during the build.

[Adam31]

Dropped the car off with Simon yesterday and had a chat about the spec etc. We are going with a blacktop 2.0 zetec with the 6 speed getrac box, GT28 turbo, ERST exhaust manifold and custom inlet.....and a few other bits and bobs, once I go up again I'll get a full spec list made up.

[Adam31]

Ok Simon e-mailed me the full engine spec this morning....

Zetec 2.0l block
Wossner pistons
Eagle rods
Fresh crank and bearings
MLS head gasket
Uprated head bolts
New oil and water pump
Black top head
Slightly ported (cleaned up)
Uprated valve springs
Mountune turbo cams

GT28/63 on RST manifold

Gotech pro-x and loom

FRS injectors

Sitech Racing inlet

Cossie throttle bodyThis will take up most of the budget with a pro-alloy radiator and airtec intercooler sitting up front.

With this spec I am sure I'll see over 300bhp.

[clarke5700]

sounds good be sure to get pics up tho

[sas]

Hi Adam, Nik said you called, and passed on the info.

Looking forward to getting the engine put together on this. Also the 6 speed conversion which is well worth it.

Simon.

[tezmanian devil]

look's like this could be a good project.
gone for the same colour's as me with regard's to the subframe/roll bar and rear beam. look's much better than black i think, just gotta keep it clean

[Adam31]

Aye it'l be hard to keep clean,but its worth it. Having some trouble sourcing a gearbox which still has the driveshafts and selector rods etc, I'll keep looking though.

[Adam31]

Very small update, I managed to source an FRP handbrake cable as its a straight fit for the rear disk brake conversion. Simon was quite busy when I dropped the car off but should have some updates soon.

[sas]

Hi Adam, I have managed to get a 6 speed box, drive shafts and gear selector, will be sorting out delivary today.

S.

[Adam31]

Bit of an update but no pics. Spoke to Simon yesterday and we got most of the parts ordered for the chassis prep, cage, pedal bx, brake lines, fuel lines, fuel pump, new fuel tank, seat mounts and the dash is off to get flocked.

After a chat I decided to go with an OMP bolt in cage, however we will add in quite a few extra bars. I can use the money saved for other things.

I'll get some pics after christmas and new year is out the way.

[Alan2525]

sounds as if its all coming together are u going to be fitting a diff to the 6speed box

[marky_g]

gonna be a cool fiesta

[Adam31]

Alan, I will decide after I get the shafts, flywheel and clutch out the way as that is going to cost a fair bit. How is yours coming on?

[Alan2525]

getting there car is in primer also got my subframes anti rollbars and axle back from the powdercoaters today need to collect the st170 box tomorrow

[Adam31]

What colour did you decide? I bet it wasn't my idea of renault liquid yellow......

[Alan2525]

toss up between white and kawasaki green for the car the axle and subframes are kawasaki green the anti roll bars are white what a job the guy done

[Adam31]

Mine is going anthraite inside, cage and engine bay. Will get cage fitted, extra bars welded in then its in with the fuel tank, fuel lines and brake lines.