terribletaj

Hi

Brought this car nearly a year ago now, brought as a non-runner apparently only needing a turbo, but after getting it home there was alot more it needed to have done,so the decision was made to rebuild it fully:






Advertised as having a 2.1ZVH forged engine, LSD box etc etc, however after closer inspection it appeared to have a completly standard bottom end that had broken piston lands on 3 of the pistons, standard non-LSD box, no RS1600i front anti-roll bar.

So gave it a quick clean and started to strip it back to a bare shell, found a little rust on the drivers sill, but other than that no rust what so ever. After 4 rusty RSTs this shell was a god send

Cleaned all underneath and applied 6L of anti-stone chip and 4L of white hammerite leaving it looking like this:




Refurbished the Koni adjustables, new Apex springs, Full polybushes, Sandblasted and powdercoated the tie bars and wishbones, rear disc conversion and stud and nut conversion too:



All fitted up:



Taking inspiration from twins engine bay, gave it a full seam weld and smoothed alot of it off:




New steering rack, new TCAs, Brake bars blasted and powdercoated:



Painted the floor:



Resprayed the shell in the whitest of the diamond white shades:




Gas strut conversion for bonnet:



Started to refit the bodykit:



Rear disc set-up:



Refurbished tank from an XR3i EFi:



Brought a rebuilt IB5 box and had a RST LSD fitted to it:



After finding out the ZVH was no good, I bought and rebuilt a 1.6CVH EFi engine:



Fitted into the bay:



Fitted side glass:



Inlet fitted, was orginally going to run OFAB so this was fitted at the time:



Exhaust and rear bumper fitted:



Airtec front mounted intercooler fitted:



New screens fitted:




Turbo and alternator fitted:




Underside shot:



Building up the engine bay:





Fitted a RS1600i grille to keep its origins:



Fitted dash, Full interior is now fitted but can't find the pics:



Then the problems started, was orginally going to run OFAB management, fitted it all in, but could not get it running right, eventually decided to strip it all out and fit weber management, brought a OKC kit of the bay. So pull it all off again:



Will be getting the last bits I need of Jano next week, so hopefully after 10 months of work I will be able drive it!

Full spec is:

RS1600i shell
Full Series 1 kit
1.6 cvh, rebuilt to standard spec with minor headwork, ARP bolts and ACL bearings throughout
Cosworth 2wd T3 turbo and downpipe
Mongoose exhaust system with 3.5" tailpipe
Airtec pro series front mounted intercooler
Cosworth managment with L8 ecu
Bosch 803 dark green injectors
3 Bar map sensor
SFS full silicon hose set
Bailey breather
IB5 gearbox with LSD
Ap racing 4 paddle clutch
Mk5 clutch mod with alloy quadrant
Koni adjustables with Apex 30mm springs
Stud and nut conversion
Full polybush kit
RS1600i front anti-roll bar
Puma gear-linkage
Escort cosworth alloys with 205/40/16 yoko paradas
300mm ST170 discs with mondeo mk3 front calipers
Rear disc conversion
Full refurbished series 1 interior with uncracked dash
Zenon headlight conversion
LED bulbs throughout

Will update as more work gets done.

Zetecfiesta

id just put the series 1 grill in, looks mint though!

cossiejsy

Wow thats is Stunning

terribletaj

thanks, the series 1 grilles never fit right, and I prefer the look of the 5 slat one, although everyone keeps telling me to fit the series 1 grille.

thanks

Ginger Will

Nice

Rab

That is stunning!!!

liam-rst

iTrader: (1)

stunnin

njietro

great car!

rst in breaking

iTrader: (2)

lovely motor mate and job looks great

terribletaj

thanks everyone, makes all the work worthwhile.

jonny s2

iTrader: (12)

awesome work pal!
but put the s1 grill in will look loads better with the style you have gone for,i love it

smitsturbo

lovely mate well done

jonboisescort

lovely motor mate

jay

spot on mate!!

Glenn_

iTrader: (1)

I like that alot.Its well mint.

tosher71

well done pal, looks awsome. get the standard wheels back on.

muz

That looks proper tidy mate. I'd be tempted to leave the S1 decals off. Looks great without them for a change.

terribletaj

Thanks for the nice comments everyone

Yeah the stripes will be staying off, might put the little RS ones on, but I like the clean and uncluttered look.

Got the last bits for the cossie managment off jano yesterday, going to fit it all up this weekend hopefully.

xr2madman

hi there top job mate looks brill where did you hide your wires

Twins

iTrader: (18)

Looks fantastic ,bay looks great smoothed

10th_racer

me too, that looks stunning!

muz

Good lad

andy130

iTrader: (2)

looks mint mate but copper brake lines look dirty?

terribletaj

Most of them have gone through the inner wing into rubber tubing then back into the bay where the wings meet the front panel at the bottom, will get a pic as it will make more sense


Think it might just be my phone, as there brand new copper lines, thinking of painting them black to match everything else.


Yeah, was just having so much problems with the OFAB stuff, plus your limited to what you can with it. Hopefully the cossie managment will be up to the job

muz

It will do everything you need it to do and more mate.

terribletaj

Finished work early today so cracked on with the escort.

Got the inlet, fuel rail and injectors, cosworth throttle body, all sensors, new dizzy, throttle cable, top pulley set-up fitted. Got most of the loom in too, just need to renew the fuel pump wiring and connect up the power to the ECU and fit the bottom pulley, then we're good to go.

Pic of todays progress:

danny_boy699

iTrader: (5)

looks good mate keep the updates coming

cossiejsy

looking very nice

Zetec_mk4_XR3i

work of art mate - well done

terribletaj

Little update, It's done!

Had a few teething problems but with some help from Jano she's now running sweet, just need to get some miles on her then can turn up the boost!


Here's some pics:

muz

That really does look cracking mate! Hats off to you. Love it!

terribletaj

Little update,

Got fedup of the constant rubbing and poor handling with the escort cossie wheels, so decided to changed them for something better sized. Went with some 7x16 compomotive 6 spoke MOs:





Drives so much better now, can put my foot down without it weaving all over the road now. Also the headgasket and pistons rings are dead so brought another CVH, this one will be fully forged with a decent head so should make some decent power! Will update when work starts on it.

smitsturbo

looks nice mate well done

harvcore

iTrader: (8)

ace

oibren85

Love it, really nicely done, not a super fan of the wheels. But then again think they look amazing on RS7! top work.

Twins

iTrader: (18)

Looks great on them wheels ,would be tepmted to get a dmb sticker set down the sides if it were mine

terribletaj

Thanks for the comments

I did actually have a set fitted afew weeks ago, just didn't look right for some reason, so keeping the clean look for now.

jonny s2

iTrader: (12)

awesome craftmanship mate

H7 CYA

iTrader: (3)

That really does look good, loving the new wheels too! Top work mate.

stembo21

iTrader: (1)

nice car mate