RS1600i Turbo Rebuild. Start to Finish

RS500 Steve · 13-01-2010, 07:00 PM

Im Steve, Liam's Dad, Im home because of the bad weather so I thought I would start this thread for Liam

Here we go gang...............

Im sure you diehard boys & girls know this car. I brought the car from Keegan in Essex as a rolling shell over 12 months ago. The car was transported home including a BIG box of nuts, bolts, chrome, you name it i "THOUGHT I HAD IT" to finish the rebuild, well.....
NO !! many many parts were missing or fitted incorrectly or didnt work.
The original advert said "engine checked" oh NO the engine was knackered, so I bit the bullit and had a FULL engine rebuild including forged pistons, new cams, new metering head etc etc........
I will let the pictures tell the story.
The 1st few pictures were taken by Keegan, his style of a rebuild was sadly not to my liking , the coloured bolts, nuts etc etc.
You will see MY idea of a rebuild towards the end of the pictures.......
Hope you enjoy the show

Liam

1st picture shows the car BEFORE the rebuild started......

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RS500 Steve · 13-01-2010, 07:01 PM

Im sure you can see now, that lots of work was done before I became the new owner BUT........

I just had to change the position of dials and that footplate had to go LOL
Slowly but surely working around the car I replaced the coloured nuts & bolts with polished Stainless or chrome

Liam

RS500 Steve · 13-01-2010, 07:02 PM

Liam

RS500 Steve · 13-01-2010, 07:03 PM

Liam

RS500 Steve · 13-01-2010, 07:04 PM

The pictures above are is how I brought the car, engine fitted, gearbox fitted.
Its a bloody shame the engine was fooked, more money LOL

The following pictures show what ive done to the car.
To get to this standard was a money pit, far more than I expected to spend.

Liam

RS500 Steve · 13-01-2010, 07:04 PM

Some shiney bits LOL

WELL !!!!! I am a bufty

Liam

RS500 Steve · 13-01-2010, 07:05 PM

Just a few of the nuts and bolts LOL

YEP !!!! sorting throught them looking for the correct one was a real pain.....

Liam

RS500 Steve · 13-01-2010, 07:06 PM

Sorry son LOL...........

Liam busy at work hehe

RS500 Steve · 13-01-2010, 07:07 PM

My garage is just wide enough to get the car in, this car has been built on the drive and in the rain (sometimes) LOL

Liam

RS500 Steve · 13-01-2010, 07:08 PM

Interior............

I know what your all going to ask LOL
The steering wheel and the seats were done by Keegan, I dont know who, or how much or where LOL
Great job though whoever recovered them.......

Boost gauge moved
Back seat fitted
Puma gear knob
Stainless dials
Vent replaced, with alarm LED
Harnesses fitted etc etc

RS500 Steve · 13-01-2010, 07:09 PM

THEN !!!!!!!

A change of mind meant this had to happen.......

RS500 Steve · 13-01-2010, 07:10 PM

E-Bay bargain.............

Marmite moment !!!!!!!!

Alcanterra covered dash, I know it wont be to everybodies taste and its slightly a different colour BUT just had to have it LOL

Liam

RS500 Steve · 13-01-2010, 07:11 PM

RS500 Steve · 13-01-2010, 07:12 PM

Engine............

Rebored, new forged pistons, new cams, new followers, new valves, seals gaskets etc etc......All we know is, lots of money has been spent to make this engine A1 1st class reliable 160BHP

Liam

RS500 Steve · 13-01-2010, 07:16 PM

E-Bay again lol........

Stainless fuel lines

Liam

RS500 Steve · 13-01-2010, 07:17 PM

Brand new metering head.... OUCH !!!!

Liam

RS500 Steve · 13-01-2010, 07:18 PM

Final few pictures..........

Liam

RS500 Steve · 13-01-2010, 07:20 PM

The cars is now running very sweetly BUT sounds like a RST lol
Oh well cant have everything.....

All we need to do now is a few bits and bobs to finish, MOT and look out concours hehe

Steve & Liam

FORD RS MAD · 13-01-2010, 07:20 PM

One word,awsome work

lovely colour Rs

RS500 Steve · 13-01-2010, 07:20 PM

Liam !!!!!

I think you can take over from here LOL
WOW that was a marathon

Dad

hatton89 · 13-01-2010, 07:27 PM

that is truely amazing!!!

fair play to you is beautiful!!!

cossiejsy · 13-01-2010, 07:35 PM

Well done Steve and Liam thats amazing mate and i am very impressed and also where did you get the ford wing covers from please

Munch · 13-01-2010, 07:48 PM

Stunning.....Does Liam still drive around in that dodgy Escort Si?

rs2000 Liam · 13-01-2010, 08:19 PM

Quote:

Originally Posted by Munch

Stunning.....Does Liam still drive around in that dodgy Escort Si?

Witch dodgy escort you on about lol.....
-The white one
-The blue one
-The cabriolet......

Cossiejsy.
Make me a silly offer for the wing covers as i know longer require them

marky_g · 13-01-2010, 09:42 PM

thats the bollocks

T3ORA · 14-01-2010, 07:21 PM

love it

10th_racer · 14-01-2010, 08:21 PM

that looks amazing!

kidsRS · 14-01-2010, 08:40 PM

Unbelievable !

adam151082 · 14-01-2010, 08:47 PM

lush!!

jaiscossie · 14-01-2010, 08:51 PM

Very very nice, and great attention to detail.

mk3stevie · 14-01-2010, 08:58 PM

nice work

orionmojo · 14-01-2010, 09:56 PM

Jesus fair play to you polishing a gearbox!

mine got hammerited and that was it!

COLEYST200 · 14-01-2010, 11:26 PM

very nice mate hat off to you well done

fiend · 14-01-2010, 11:57 PM

Quote:

Originally Posted by cossiejsy

Well done Steve and Liam thats amazing mate and i am very impressed and also where did you get the ford wing covers from please

Would also like to know this!

Drizz · 15-01-2010, 10:16 AM

Beautiful!

fiestaturbo1984 · 15-01-2010, 11:50 AM

lovely car, can see that winning many trophies

mulla · 15-01-2010, 12:06 PM

stunning car you got there

1223456 · 15-01-2010, 12:15 PM

I thought I hated Chrome Bling,,,,,, i was wrong

amazing build!!!

The

Bomber · 15-01-2010, 01:18 PM

Very tidy.

But a word of warning, don't use Anodised Aluminium bolts for high stressed areas - Strut brace (front and rear), Turbo housing, Throttle bracket, Throttle body etc. They will shear.

xrmalin · 15-01-2010, 04:08 PM

Thats mint a credit to you both and that re-trim looks amazing

mark.

13-01-2010, 07:01 PM	#2
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Im sure you can see now, that lots of work was done before I became the new owner BUT........ I just had to change the position of dials and that footplate had to go LOL Slowly but surely working around the car I replaced the coloured nuts & bolts with polished Stainless or chrome Liam __________________

13-01-2010, 07:02 PM	#3
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Liam __________________

13-01-2010, 07:03 PM	#4
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Liam __________________

13-01-2010, 07:04 PM	#5
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	The pictures above are is how I brought the car, engine fitted, gearbox fitted. Its a bloody shame the engine was fooked, more money LOL The following pictures show what ive done to the car. To get to this standard was a money pit, far more than I expected to spend. Liam __________________

13-01-2010, 07:04 PM	#6
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Some shiney bits LOL WELL !!!!! I am a bufty Liam __________________

13-01-2010, 07:05 PM	#7
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Just a few of the nuts and bolts LOL YEP !!!! sorting throught them looking for the correct one was a real pain..... Liam __________________

13-01-2010, 07:06 PM	#8
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Sorry son LOL........... Liam busy at work hehe __________________

13-01-2010, 07:07 PM	#9
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	My garage is just wide enough to get the car in, this car has been built on the drive and in the rain (sometimes) LOL Liam __________________

13-01-2010, 07:08 PM	#10
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Interior............ I know what your all going to ask LOL The steering wheel and the seats were done by Keegan, I dont know who, or how much or where LOL Great job though whoever recovered them....... Boost gauge moved Back seat fitted Puma gear knob Stainless dials Vent replaced, with alarm LED Harnesses fitted etc etc __________________

13-01-2010, 07:09 PM	#11
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	THEN !!!!!!! A change of mind meant this had to happen....... __________________

13-01-2010, 07:10 PM	#12
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	E-Bay bargain............. Marmite moment !!!!!!!! Alcanterra covered dash, I know it wont be to everybodies taste and its slightly a different colour BUT just had to have it LOL Liam __________________

13-01-2010, 07:11 PM	#13
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	__________________

13-01-2010, 07:12 PM	#14
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Engine............ Rebored, new forged pistons, new cams, new followers, new valves, seals gaskets etc etc......All we know is, lots of money has been spent to make this engine A1 1st class reliable 160BHP Liam __________________

13-01-2010, 07:16 PM	#15
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	E-Bay again lol........ Stainless fuel lines Liam __________________

13-01-2010, 07:17 PM	#16
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Brand new metering head.... OUCH !!!! Liam __________________

13-01-2010, 07:18 PM	#17
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	Final few pictures.......... Liam __________________

13-01-2010, 07:20 PM	#18
RS500 Steve Part of the Furniture Garage is empty, add now Trader Score: (0) Join Date: Sep 2004 Location: Swindon Wiltshire Posts: 172 Rep Power: 9	The cars is now running very sweetly BUT sounds like a RST lol Oh well cant have everything..... All we need to do now is a few bits and bobs to finish, MOT and look out concours hehe Steve & Liam __________________

13-01-2010, 07:20 PM	#19
FORD RS MAD Ford model mad Garage is empty, add now Trader Score: (1) Join Date: Oct 2008 Location: In the land of models Posts: 1,319 Rep Power: 6	One word,awsome work lovely colour Rs __________________ 1982 Mk1 Fiesta GL 1989 Mk4 Escort L

13-01-2010, 07:27 PM	#21
hatton89 Shawspeed zs Garage is empty, add now Trader Score: (0) Join Date: May 2009 Location: Blaina Posts: 212 Rep Power: 5	that is truely amazing!!! fair play to you is beautiful!!! __________________ 141.1 BHP ShawSpeed powered MK5 fiesta

13-01-2010, 07:35 PM	#22
cossiejsy PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Feb 2005 Location: St Helier,Jersey Posts: 2,624 Rep Power: 11	Well done Steve and Liam thats amazing mate and i am very impressed and also where did you get the ford wing covers from please __________________ Dont like my drivin then stop watchin me Jersey Rs Owners Club member of the daytime pf talk bollocks and random shite club #65

13-01-2010, 07:48 PM	#23
Munch Mr. Sparkle! Garage is empty, add now Trader Score: (0) Join Date: Nov 2005 Location: Wiltshire - swindon Posts: 12,744 Rep Power: 20	Stunning.....Does Liam still drive around in that dodgy Escort Si? __________________ CHEERS, LEE Onslow Loves COD! Arguing on the internet is like racing in an impreza, even if you win, you're still a twat.

13-01-2010, 09:42 PM	#25
marky_g Fleet Manager Garage is empty, add now Trader Score: (0) Join Date: Aug 2004 Location: Thurrock Essex Posts: 5,382 Rep Power: 14	thats the bollocks __________________ Click to see my RS Turbo project http://passionford.com/forum/showthr..._g#post3406438

14-01-2010, 07:21 PM	#26
T3ORA I've found that life I needed.. It's HERE!! Garage is empty, add now Trader Score: (1) Join Date: Nov 2007 Location: in the midlands Posts: 1,037 Rep Power: 7	love it __________________

14-01-2010, 08:21 PM	#27
10th_racer Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: May 2004 Location: west midlands Posts: 499 Rep Power: 10	that looks amazing! __________________

14-01-2010, 08:40 PM	#28
kidsRS "Ill check the stock" Garage is empty, add now Trader Score: (6) Join Date: Mar 2008 Location: Buxton Posts: 2,256 Rep Power: 8	Unbelievable !

14-01-2010, 08:47 PM	#29
adam151082 Advanced PassionFord User Garage is empty, add now Trader Score: (0) Join Date: Jun 2008 Location: Under the thumb Posts: 2,137 Rep Power: 7	lush!! __________________

14-01-2010, 08:51 PM	#30
jaiscossie PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: May 2004 Location: Essex Posts: 3,729 Rep Power: 12	Very very nice, and great attention to detail. __________________ cheers, Jamie

14-01-2010, 08:58 PM	#31
mk3stevie Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: May 2008 Location: At work probably Posts: 531 Rep Power: 6	nice work

14-01-2010, 09:56 PM	#32
orionmojo PassionFord Post Whore!! Garage is empty, add now Trader Score: (1) Join Date: Nov 2005 Location: Birmingham Posts: 5,211 Rep Power: 13	Jesus fair play to you polishing a gearbox! mine got hammerited and that was it! __________________ "If Sparks dont fly it rides too high!" Member of "The Daytime pf talk bollocks and random shite club #5" - Mojo

14-01-2010, 11:26 PM	#33
COLEYST200 PassionFord Post Whore!! Garage is empty, add now Trader Score: (3) Join Date: Sep 2007 Location: Birmingham Posts: 6,578 Rep Power: 12	very nice mate hat off to you well done __________________ Birmingham group Click here to take a look at my three door project.

15-01-2010, 10:16 AM	#35
Drizz Enthusiast Garage is empty, add now Trader Score: (0) Join Date: Dec 2004 Location: Colchester, Essex Posts: 126 Rep Power: 9	Beautiful!

15-01-2010, 11:50 AM	#36
fiestaturbo1984 aka gareth Garage is empty, add now Trader Score: (2) Join Date: Feb 2005 Location: High Wycombe Posts: 1,492 Rep Power: 10	lovely car, can see that winning many trophies __________________

15-01-2010, 12:06 PM	#37
mulla Too many posts.. I need a life!! Garage is empty, add now Trader Score: (1) Join Date: Mar 2007 Location: stockton on tees Posts: 945 Rep Power: 7	stunning car you got there

15-01-2010, 12:15 PM	#38
1223456 BANNED BANNED Garage is empty, add now Trader Score: (0) Join Date: Dec 2009 Location: North Wales Posts: 1,895 Rep Power: 0	I thought I hated Chrome Bling,,,,,, i was wrong amazing build!!! The

15-01-2010, 01:18 PM	#39
Bomber Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: Jun 2003 Location: West Sussex Posts: 663 Rep Power: 10	Very tidy. But a word of warning, don't use Anodised Aluminium bolts for high stressed areas - Strut brace (front and rear), Turbo housing, Throttle bracket, Throttle body etc. They will shear. __________________