MK3 fiesta project - 2.1 zetec turbo - 358bhp-365ftlb for now

[Twins]

Wow fantastic work

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[cosmo V6]

Originally Posted by bridgend boy

you've put a doubt in my mind gary,
so after speaking to ian H
i've got some new idea's will post up more soon after a few phone calls

Go for the T2 Rob, and you know the man to supply and map it

[Ken_ZS]

wow what a nice looking car, i love mk3s, well i love fiestas fulse stop having had 4 (stil got 2) but this one is very nice, wish i could afford all the new shiny bits, top effort mate, keeping it clean and going for the power as well, very nice

[RS_Rob]

thanks for the compliments
should have some good updates this week

[RS_Rob]

in the engine bay i've decided to move the ecu and its wiring
so the factory hole is useless




so it was welded up, grinded back, then a some filler over the top
also had the last few holes welded up which hold the factory fuel filter and abs on other models of this car aswell




after being sanded back




and in primer




inside of the arch was smoothed aswell




to reseal the car back up i've been using a fords sealant,





from inside the shell, under the bulkhead you can see the plate welded over the location for the factory ecu
aswell as the sealant i've been putting in the panel gaps





i've sealed up the same places as done originally, except i've not putting it on so thickly
just making sure it's pushed into the gap and looks neat

[Brian]

Looking good mate

Thats what i need to do in a few weeks on my Mk2 Fiesta got a few bits to sort out first.


Brian

[RS_Rob]

well next up was more sealant,
just applied a different way,

the mk3 fiesta was known for water leaks mainly on the front bulkhead,
so with this in mind i'm making sure cover all the seams well as i dont want a leak when its all built up



the choice of sealant,





how i'm going to apply it with an airline





a test section on some cardboard using masking tape for edges





test section with the masking tape removed, happy days!!





the important bits were masked around the bulkhead and sprayed with sealant






a close up after the masking tape was taken off






how it looks now, much better coverage of sealant without looking messy

[fezzajsy]

awesome stuff mate

[RS_Rob]

well the sideskirts that were fitted previously catched the bottom of the doors and rubbed the paint off
so that being done 3/4 years ago i have a little surface rust starting
so that needed to be sorted


stripped both doors down completely





while i was there, i had to see the how bad the rust was,
thankfully with a small d/a it showed clean metal behind, so that was a big relief ! !





next was a test fit of the panels, any adjustments made before the car is ready for paint
so doors were fitted first to line up from the quarters,

while i'm catching up i'll show a picture from weeks ago, i did'nt post up because it would show my newest idea,
but while the front chassis was bare, it was the perfect time to get some paint on before the wings go on
as you dont get much access when the wings are on





it seems the last it was at the other bodyshop washers were used and parts of the hinge grinded away to allow the door to sit higher
so rather than replacing the hinges which seemed fine apart from the washers,
we used new washers and welded them on, so would look a better job





then with the belt sander the welding was tidied up





so with the doors on properly, the wings and bonnet were test fitted






so with the wings in the perfect place, the metal was prepped for spot welding

[RS_Rob]

then spot welded on by a pro, its a lump of a machine





heres the wing after spot welding





then where the front valance meets the wing was welded





while we were test fitting, the skirts and arches were trimmed to fit nicely
aswell as being trimmed for my big wheels




also the wings were trimmed back to make more room for the 8"wide cossie wheels aswell

[Twins]

[RS_Rob]

had some more parts back from the powder coaters
front hubs, another front engine mount and the back plates for the rs2000 rear disc/drum setup





recently tried cleaning up the brake bar which runs along the rear of the engine bay,
after lots of scrubbing it was'nt getting any better, so it was a choice of having it recoated, or a new one

so bought a new one along with new bushes and springs





some bump stops for the bonnet, screws for the bonnet hinges and bonnet
also nuts for the front and rear bumpers





new upper and lower steering cowl's





new plugs for the floor





new seal which holds the rear glass in the tailgate





new washer bottle





two new door seals and tailgate seal

[zetaboostboy522bhp]

nice matey , are you planning on using this as a track car , if you are then i would fit top mounts and plates to the turret towers before you decide to paint it. i think it maybe a worth while mod.

looking really good

[RS_Rob]

new door hinge bolts and clips
one of the new door strikers aswell





got hold of an RS accessory part i've not seen before,
its a light dimmer relay basically rather than the on/off switch





also another accessory, the credit card style spare key





the panels under the rear lights which were lead filled,
have been finished off with a skim of filler
before





after sanding

[RS_Rob]

Originally Posted by zetaboostboy522bhp

nice matey , are you planning on using this as a track car , if you are then i would fit top mounts and plates to the turret towers before you decide to paint it. i think it maybe a worth while mod.

looking really good

thanks paul,
wont be taking this on track, might do the occasional 1/4 mile tho

[adie_mwell]

wat colour you painting it mate great work so far please dont say red or if it is is there a good reason for it white or imperial blue all the way

[Rs Adz]

just read the lot stunning build keep up the good work

[RS_Rob]

the progress is happening thick and fast
really taking shape now



the car was masked up and taken into the spray booth
where the underneath had a nice layer of 3M stonechip






then the car had the complete outside masked off






the inside had its final prep including wipe down with tack rag's

[RS_Rob]

here she is after some paint in her new colour
ferrari rosso corsa red








as the car is still on the spit, the car was also painted underneath on top of the stone chip






one or two more of the inside, its awesome to finally see it some colour
really makes all the prep work worth it

[RS_Rob]

mr wolz pressed my new bearings and hubs into the freshly powder coated knuckles
big thanks again





i'm proper chuffed with the outcome





also my new coilovers arrived from GAZ
the difference of these compared to the avo's i had before is massive,
the welds are really neat, two adjusters plates to lock the springs in place rather than one with a plastic screw

[GaryHurn]

good work rob, i take it your boss is taking the labour involved out of your weekly wage????

looks excellent mate

[RS_Rob]

Apart from the filler, painting and welding
it's been me gary, so late nights after work and early mornings

so saved loads on labour

[Twins]

Colour looks fantastic

[WongRS]

wow! just flicked through this, awesome work!
This is going to be stunning.

[tonytantrum]

stunning car! cant wit to see the end result!

[Glenn.]

Wow thats looking mint fella,Top work.When it finished you will be scared to use it lol.

[little bram]

looking great mate doing a realy good job

[frsjon]

love your work as usual rob !

[Brian]

Looks stunning mate

Where you buy the plugs for the floor? do Fords still sell them?


Brian

[A16X_TM]

cracking job fella, just hope it doesnt end the same way as the previous two!

[RS_Rob]

yes the plugs are still available from fords mate,

as for this one ending up like the last two,
i really hope not aswell,

[RS_Rob]

well after the shell was painted inside,
the next morning i covered it over with paper, to stop general bodyshop dust getting on top of it






a picture of the underneath all finished





new rear 1/4 glass seals,
so now have all new seals for the car





the engine bay has had a quick prep and all seams which need sealing up have had a guide coat of green spot primer
before the final prep can happen





holes drilled for the front strut brace





to make sure theres plenty of room for the intercooler and rad setup
there was a small lip on the front panel support (highlighted with the red arrow)
so grinded this off and made it smooth to touch

[ram]

Wow havnt seen your thread for ages on ft glad youve moved it onto here too, this is gonna be awsome

[Mint FRST]

Awesome thread. Please dont put the bad boy bonnet back on!

[RS_Rob]

Originally Posted by ram

Wow havnt seen your thread for ages on ft glad youve moved it onto here too, this is gonna be awsome

thanks ram

Originally Posted by Mint FRST

Awesome thread. Please dont put the bad boy bonnet back on!

i know theres alot of photo's lol
but further back in the project
i've got a brand new FRST bonnet to go on

[Portugal]

perfect work!

BHP?

[RS_Rob]

Originally Posted by Portugal

perfect work!

BHP?

a genuine 300bhp ian said, but that will probably change as i change my mind alot

[RS_Rob]

ok been buying more parts

after sourcing a rear bumper only when i got it home
i realised it had been trimmed far too much
so i got hold of a new one


old one on the left, new on the right





i better look of the new one





brand new tailgate





the engine bay sealing is more or less done,
its alot more important to do a good job in the engine bay,
as i'd rather avoid any future waterleaks





even sealed non important bits, with paint over the top
it will all look much better and easier to keep clean






around the hinges all sealed up





under the scuttle panel has been done aswell

[The Loumiester]

cracking work, i remember reading about your fiesta si on fiesta-si.com and that was great work. keep it up

[Brian]

Originally Posted by bridgend boy

yes the plugs are still available from fords mate,

as for this one ending up like the last two,
i really hope not aswell,

Cheers mate

Keep up the good work car is looking really good


Brian