K163TRH fiesta xr2i 16v, my first love, engine update all built up

[jon_ross]

hello everyone introducing my daily runner and first ford. As with all cars she comes with a little story, hear goes about 2 and a half years ago i bought her in a fair but sorry state for 500 quid as buy it now on ebay, the previous owner owned it for not long but in the time he owned it he spent alot of money have servicing and maintence and also recent clutch, but it was slipping as stated when advertised. it was a good car but needed tidying up, the front bumper had loads of chips but on closer inspection found it to be a white bumper underneath and it also had damage to the front panel and the offside door used to be white. I started to tidy her up doing what i could being an apprentice and living in a rented house at the time but got her looking quite good hears a few pics of the early days and after loading these im going to bed coz its 12am ill finish tomorrow after a good cleana nd polish and a bit of paint in the engine bay she came up alright il carry on threat tomorrow nite nite

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[warrenpenalver]

The car did get a lot of stick and abuse by the previous owner!!

[jon_ross]

jesus christ!!! was that a pic of you in the speeding ticket? did you go rallying in it or somthin?? do you know anything about the crash damage??

[warrenpenalver]

yeah thats me in the speeding photo

The muddy photo was after going camping and the field turned into a bog after raining ALL weekend It had been cleaned the day before!!!!

Dont know about the crash damage - I only bought it to thrash round in so didnt care about the damage.

[jon_ross]

right hear goes from day one (all i can remember).

when i drove her home from portsmouth the first time i hit the brakes there was hadly any atal and i went flying around a roundabout, so i bled brakes the next day at work and nearly knocked myself out on the wheel when i braked. i bought it with a slipping clutch and i was told it had a new one (which it did) and it was probly the quadrant so i thought its got to br easyier than do a clutch so i got a quadrant and cable and set to work. how wrong was i?? the quadrant was a horrible job and took about 4 hours (i can do a clutch in 1 1/2 hours) and it still slipped, so i put a clutch in and found the gearbox was input shaft seal was leaking oil all over the clutch. i had to put it back to gether as i was my only car and it lasted a month before it started slipping again. so thinking i want to do it properly i saved up and brought a ebc fast road clutch, rear main oilseal, and a recon stage 2 escort turbo gearbox with modified gears and big bearings and lsd. my mate terry bought a red frst for cheap and broke it down so i had the front bumper to get rid of chips, bonnet and frontseats. time went along and she was very reliable until she got side swipped on a roundabout. so i quick fixed it and thats were i lost interest and it went downhill from there and i got my rst around then and started to restore(not intented) she went on for a very long time until she overheated and blew the head gasket, so time for mini overhaul, due to lack of space and time i only got half the jobs i wanted done but did fit my ported and polished head which i done myself but only smoothed the ports but i didnt get it skimmed so it blew again. i was so pissed off i was going to scrap it coz it even still looked like shit, but after a while to calm down my dam unconditional love came back and decided to do a mini resto on engine and body so heres some pics of the crash damage, wot she looked like after 2nd time head went, and pics of the mini resto (ill tell you about that tomorrow coz its late AGAIN!!!lol





















now the mini resto pics

































































i know it needs to be mopped but not bad for first paint job

[nealo]

awesome for a first paint job if i do say so mate, did you jsut have a go yourself?

[jon_ross]

Originally Posted by nealo

awesome for a first paint job if i do say so mate, did you jsut have a go yourself?

yea i just got a load of tips off my mate at work and just borrowed a gun a bought aload of 2k paint and primer (the pics do make it look better as its quite rough)
cheers for the complment, jon

[danny_boy699]

looks good mate, after a good g3 and polish it should look good

[dingla rs]

nice job so far m8,one question did you weld panel in round filler cap?

[jon_ross]

Originally Posted by dingla rs

nice job so far m8,one question did you weld panel in round filler cap?

cheers for comms guys, with the filler cap i got a repair panel and offered it up to the car scored around it then cut out old bit then welded and flushed it in. it looks ok but could have done it better

[tezmanian devil]

dammit, been caught on camera lol
forgot about how bad it looked befour the respray, certainly havn't forgot about how much of a misson it was preping it for paint though lol, does look 100 time's better now though
just need to get on the case with rebuilding that 2ltr engine :P


when you gona do a thread for ya rst??

[jon_ross]

hi peeeps ive got and update but still need to load some pics on photo bucket so ill do that 2muz.

all was going really well and i was enjoying the car, i had it dyno'd at my mates mark and pete's garage (south coast performance) and it run 130hp at the flywheel and 140ftlb of touque which is quite good for the 105 ecu, then i was driving down the road and as i come on the bypass i had the typical bmw right up ur ass syndrome so booted it on to the bypass, as i hit redline in 3rd went to hit 4th and hit 2nd intstead gearbox fuked!!, to keep the car on the road i just got a standard new clutch and the stage 2 geartorqe gear box with quaife diff and fitted that. All was great but times got hard and i had a mate keep asking if i would sell my gearbox and kept saying no but he asked again at the right time so a deal was done for Ł350 and a good lsd box, we swaped over and straight away gear box sounded awfull. CHEERS MATE. i know i should of taken it off the road but i had no other car and seeing how id be waiting an age for my mate to sort a good box i thought id limp about till the end of the month. one morning going to work down the bypass doing 55-60mph gear box shit itself, locked up and before i could dump the clutch it smashed my engine to shit, and hauled me up so quick i nearly went through the screen. so over haul number 3 on the cards. we got the driveshafts out of te box and towed it to my work and during being moved in and out everday it picked up some nice scratches and dents, but im not too worried as my mate arron is going to redo my crap paint job while i build a 2 litre lump and rebuild the first box i blew up, im also going to sort a load of little jobs aswel, i get a few pics up 2muz

[andy130]

shit news matekeep at it tho

[G950KDT]

sounds like your sticking to your guns mate! love seeing these xr2i's restored, i miss my old 8v one would have a 16v anyday!

cracking stuff!

[cossiejsy]

good project mate

[tezmanian devil]

told ya you shouldn't deal with that nob end after he tried muggin me off
still think you should paint up the engine bay while the engine's out!! will look much better with nice fresh paint in there

[XRdodgybird]

Good cars them.... had mine over eight years now and never have much bother.....

[Fiesta_ie]

love them i got one too. what brand of the st170 style mainfold?

[jon_ross]

Originally Posted by andy130

shit news matekeep at it tho

will do as always cheers mate

[jon_ross]

Originally Posted by G950KDT

sounds like your sticking to your guns mate! love seeing these xr2i's restored, i miss my old 8v one would have a 16v anyday!

cracking stuff!

always guna stick with it mate i love it too much. those 8v's are realy good cars and i had a with one when mine was standard aswell and there wasnt that much difference atall, it will be my track car wen the cossies done

[jon_ross]

Originally Posted by XRdodgybird

Good cars them.... had mine over eight years now and never have much bother.....

yea i agree i had no probs with engine for ages and the only reason it started going wrong is wen i stoped spending money and let it deterioate, but my xr was a dog when i bought it with not that much history and 14 owners! so christ knows whats been done to it. Yours looks realy nice in your sig i'd love a silver one but anytime one came up it was far to far away to get it.

[jon_ross]

Originally Posted by cossiejsy

good project mate

cheers mateits appreciated

[jon_ross]

Originally Posted by tezmanian devil

told ya you shouldn't deal with that nob end after he tried muggin me off
still think you should paint up the engine bay while the engine's out!! will look much better with nice fresh paint in there

i know but u no me always learnt the hard way u should no that being school buddys
i keep changing my mind about the engine bay so it will probly end up being painted as this is after all a no expense spared car (kinda hard to keep going wen u got no money tho)

[jon_ross]

sorry no pics ill doit sunday as ill be able to get a few more wen i get the crimbo events on the pc.. MERRY CHRISTMAS ALL!!!!!!

[tezmanian devil]

Originally Posted by jon_ross

i know but u no me always learnt the hard way u should no that being school buddys
i keep changing my mind about the engine bay so it will probly end up being painted as this is after all a no expense spared car (kinda hard to keep going wen u got no money tho)

you still got paint left from spraying the car though aint ya, just turf abit of that in there, job done

[XRdodgybird]

Originally Posted by jon_ross

yea i agree i had no probs with engine for ages and the only reason it started going wrong is wen i stoped spending money and let it deterioate, but my xr was a dog when i bought it with not that much history and 14 owners! so christ knows whats been done to it. Yours looks realy nice in your sig i'd love a silver one but anytime one came up it was far to far away to get it.

I live near Leeds and actually got this one from South Woodham Ferrers in Essex. The original intention was going to look at and buy an RS1800 but it turned out to be a dog, so having bought an autotrader down there, spotted this one and fetched it home. I've always found you need to travel to get a good one and have been as far as Bracknell in Berkshire and Invergordon go buy cars...

Mine doesn't have the turbo bonnet anymore after a little accident I had in October but she doesn't do bad for her age...

[jon_ross]

Originally Posted by XRdodgybird

I live near Leeds and actually got this one from South Woodham Ferrers in Essex. The original intention was going to look at and buy an RS1800 but it turned out to be a dog, so having bought an autotrader down there, spotted this one and fetched it home. I've always found you need to travel to get a good one and have been as far as Bracknell in Berkshire and Invergordon go buy cars...

Mine doesn't have the turbo bonnet anymore after a little accident I had in October but she doesn't do bad for her age...

yea this one was a rite dog as well but there worth it in the end i think. theyve got so much character!! i have to admit i didnt look long or travel very far as i just bought it buy it now on ebay after a couple of weeks looking and it was only in portsmouth which is not far from eastbourne. yours still looks mint though.

[jon_ross]

going down unit in a min to strip bottom end and get some more pics but thats it coz i feel like shit

[tezmanian devil]

where's these pic's then, lying blagard
i take it im not in your good book's after earlier pointing out your little wireing problem lol bet you always look foward to me poping in and pointing out more work for you to do

[jon_ross]

hi peeps little update for you, the plan was to tow it to another garage i work at sometimes called auto upgrades (jap specailist) but wen we got there the main gate was closed so we towed it too our unit (not far from a.u). heres some pics of it at work looking very sorry for itself











here some pics of the damage it picked up at work









a little bit of rust bubbling again



the next weekend in moved the 2 litre silver top lump out of storage and took that down the unit and also i pulled the lump out out the car





















with that done i got it rolling again and waited for the next weekend. wen that came around the next plan was to remove the parts i need from the 1800 engine for cleaning and painting



and then strip the 2 litre lump and fit on the engine stand, strip the bottom end for measuring for the new parts and cleaning, clean up block and paint red















while having quite patches at work and during lunch breaks ive been busy with the parts washer and wire wheels and black paint and got this lot done







i did the gearbox cradle aswel but no pic.
today ive been striping the engine bay ready for cleaning and painting. I didnt get any pics because wen i left this evening i was going to break it up, but after along think ive decided to keep it as it only needs to be on the road till the saph is done, the reasons i felt like this was,

i found my offside subframe mount has rot and snaped again (i happen ages ago and i rewelded it)

some wiring in the main loom has burnt through the insulation (everything works though??)

front engine mount has been welded to the chassis leg

rear engine mount stud fitted so that the mount is under the braket and the stud put through the hole in the braket with a large washer and then bolted down (baisicly the bottom part of the stud has a tapered collar larger than the hole in the bracket and it was siezed so i had to cut though the stud (ill get pics as that probly makes no sense)

fucking cowboys get back on your horse and fuck off, you know who you are!!! sorry to all the other people that do things properly.

the carpets are soaked were its been outside. It comes in through the door seal but the car has been crashed and you can see that the hings have been welded back on, but not badly just slightly off i think

its not much but wen ur borrowing your sisters car and have hardly any money and you find bits that add to the final bill it dont take much to think fuck it, break it, but ive calmed down and decided to carry on

more pics next weekend

[tezmanian devil]

stop being a big girl you tart
you have to much love for your car's, wish i did, would proberly have my old escort if i did (real tear's) lol

[jon_ross]

Originally Posted by tezmanian devil

stop being a big girl you tart
you have to much love for your car's, wish i did, would proberly have my old escort if i did (real tear's) lol

fuk u funny man i dont know why im so attached to em, u saw wot i was like the other day i was for breaking and then thought about it for 2 mins and made my excuses to keep it

[tezmanian devil]

you know my opinion mate, least you'd have abit of dolla to spend on te other's if you let go of this one... make's sense to really..... to a normal person lol

[jon_ross]

Originally Posted by tezmanian devil

you know my opinion mate, least you'd have abit of dolla to spend on te other's if you let go of this one... make's sense to really..... to a normal person lol

i no your opinion nobend and im not lisening, it will be awsome wen its done

[tezmanian devil]

yeh... WHEN lol

parked in the most awkward place possible havn't ya, night mare trying to get in teh unit earlier you working tomorrow?

[jon_ross]

right peeps ive been at the unit today for abit so firstly heres some pics of the bodged engine mounts and the striped bay ready for cleaning and touching up











in the pic below were the engine mount was bodge fitted as i explained in previous update it needed cutting out, but i couldnt get in there even with my little 3" cut off tool, so i had to cut out a smal piece of the mount bracket off so i could get the cutting disc low enough to cut the base of the stud. i have kept the piece i choped out so it will be welded back in wen ive got my welder sorted



i didnt get a pic of the subframe mount but i wil wen i sort it out

as i couldnt be down the unit for long today i thought id drop the fuel tank and clean and paint it, remove all fuel lines and the rotten fuel breather pipe, and replace the brake pipes. heres some pics







below this is why i'm replacing the brake pipes!!! people that do brake pipes this bad should be shot!!!!




firstly i droped the tank out and cleaned it right up. the bottom of the tank was platered in undersealer and took an age to remove but got it clean in the end with about 15quids worth od brake cleaner.
i then painted the tank and left hanging to dry. by the way the tank is mainly being removed due to the fuel sender not working so im replacing the whole unit with an rsturbo one as its laying around, i then went on to replace the brake pipes and first problem.....no lock wheel nut, i realised ive left it at work in the bolt box for my car as i was cleaning all the bolts in the parts washer!!!! so i tryed with out it but the brakets that hold the rear hoses to the inner arch have been welded back on in totally the wrong place and that means my at work made brake pipes (i had some old original pipes from a fiesta that failed mot on them to make copys from) wont fit.
ill take pics of them wen i fit them
heres the tank and thats all folks till next weekend. cheers for looking

[tezmanian devil]

hairy mice.
seem's to be more and more bodge job's on this thing

[jon_ross]

wot u saying sunshineim doin it properly!!lol
i know wot u mean dude its gay but it was a 500quid banger. it will be ok for the next year now

[jon_ross]

oh yea we need to ave a sort out of the unit next weekend, tis a shit hole

[ROADWARS]

looking good