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

[RS_Rob]

thanks mate, i had my doubts with the red at first but i think i made the right choice now

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[RS_Rob]

something i done a week or two ago,

basically as my car originally had power steering and i've chosen to take it off for many reasons
i've come accross the following differences
- steering rack (obviously)
- steering column
- lower arms (but wont apply to me as mine are adjustable)
- the bulkhead grommet
- the bulkhead hole is different aswell



heres a picture of the manual steering rack, with manual steering column
but with the power steering bulkhead grommet, so you can see the problem i had





so using the power steering grommet i made a template of the hole and cut some steel to shape,
then made a hole to the size of the new non power steering grommet ordered from work,
used this hole punch for a neat edge





the result





with the new grommet in






the only problem was that the grommet did'nt fit to good around the steering column
as the grommet ment for the steering rack was'nt available anymore from fords
so ordered the newer version thinking / hoping there would'nt be much difference

so the old man machined a piece of delrin to fit snuggly around the column and to fit inside the grommet





job done

[RS_Rob]

when test fitted the plate to the car i put the steering wheel back on aswell,
which caused another problem
the steering wheel pulled the column further towards the wheel than i'd thought which changed the angle
that the steering column goes through the bulkhead



so made another bulkhead plate, knowing the angle was right this time
i gave it a few coats of satin black aswell




i'll get some pics of it fitted later


bought these bits a while ago
to stop the clicky clutch pedal by converting it from the self adjusting to manual
hopefully should be more up to the job of the 4 paddle clutch





all fitted





except when the outer bracket goes on, it fouls the self adjust bar and does'nt let the pedal go down





after going over the old ford tsb for this upgrade i realised there was a different bracket for the job,
no longer available, but after a few phone calls i got hold of one

a comparison shot, new bracket on the left





all fitted and much better





was an extra spring i got hold of aswell, so thats the pedal box all ready to go
as it has the manual clutch rachet, new bushes etc

[fezzajsy]

looking good mate

[RS_Rob]

heres how the steering grommet turned out





if you look lower to the floor you can see the white delrin i had machined,
but not too bothered, it serves a purpose and the engine will be in the way of that view





centre vent all blocked up to make way for the gauges in the dash





put the front wheels on, first time on all fours for some time

[RS_Rob]

more new parts





as most people in work know about this project,
one mate had this from years ago and offered it to the cause haha
cigarette lighter kit,
(thought its one more brand new thing)





new arch liners





got a set of fiesta turbo dials, as they show 150mph rather than 140mph
also my original dials has a dodgy tripometer





and off with the white dials within five mins

[xr2john]

That is going to be absolutely stunning mate. Keep up the excellent work

[RS_Rob]

thanks mate,
comments like that keep you going, when enthusiasm is running low!!

[Brian]

Looking good mate can't wait to see it finished


Brian

[jamie rst]

stunning mate just stunning

[WongRS]

Originally Posted by RS_Rob

thanks mate,
comments like that keep you going, when enthusiasm is running low!!

No, find some more, i cant wait to see this car finnished, its going to be something else!

[RS_Rob]

Originally Posted by Brian

Looking good mate can't wait to see it finished


Brian

Originally Posted by jamie rst

stunning mate just stunning

Originally Posted by WongRS

No, find some more, i cant wait to see this car finnished, its going to be something else!

thanks very much, hope to have a good day on it tomorrow (sunday)

[cosmo V6]

Looking well sexy Roberta

[RS_Rob]

well some small news,

the engine was been taken to harvey gibb's yesterday,
so when they can fit it in, it will be connected to his engine dyno to be 'run in'
then map it the on the pectel T2 management,


also i've got another gearbox but will explain more on that with another update later
but did a little research on the ratio's which will be in the gearbox,
came up with the following

should be interesting





bought a brand new fuel filler neck pipe as mine just would'nt clean up
and would of stood out like a sore thumb with everything else on the shell being to a good standard

quick iphone picture for now

[12_Second_rst]

looking good cant wait to see the next update

[RS_Rob]

well this week my engine was with well known Harvey Gibbs @ scs on the engine dyno
with all connections made such as exhaust, air, water etc etc
then they built the oil pressure up before starting for the first time since the full rebuild
and was run in properly

also i've gone for air injectors for boost control supplied by harvey

today was mapping time
had some figures at different times of the day during the mapping
220bhp @ 3k revs
310bhp @ 4.5k

the escort series 2 exhaust manifold was the first restriction which got the temps up
when it made 365-370
so it was turned down, and map was trimmed for smoothness

so an upgrade exhaust manifold may be sourced at a later date if the power is'nt enough
but i'll deal with what i've got first


final peak power result was
358bhp and 357ft lb of torque boosting at 26psi at the crank





a massive thanks to ian howell who spec'd and built the engine
and harvey gibbs that run the engine in and mapped the pectel t2 ecu

the results show ian is a superb engineer and knows what works, flow rates, cam profiles etc
still shocked how early the t38 made power


will have a power graph soon when i collect the engine

[12_Second_rst]

whats the full engine spec mate

[frsjon]

well done to all involved rob,cant wait to see this one finished

[RS_Rob]

well the results i given for the engine over the phone were only slightly out,
358bhp and 365ftlb torque


thought i'd show some images of my lump on the engine dyno @ scs
big thanks to jimbo for taking pictures for me








some pictures of the vehicles there when i went to collect the engine

[frsjon]

looks lovely rob,i know the moonstone 3dr in the pick at harvey's,good friend of mines

[Mike Kerbey]

Thats impressive, congrats mate!

Loving the LU5H plate on the 3 door!

[Zetecfiesta]

awsome stuff mate! looking foward to seeing more build up!!

[robp-tt]

Nice work with the grommet didn't ford have any of the proper ones left to convert it from
Pas to non pas? As I bought one a couple of months ago to convert my mk3.5 to non pas,

[RS_Rob]

Originally Posted by robp-tt

Nice work with the grommet didn't ford have any of the proper ones left to convert it from
Pas to non pas? As I bought one a couple of months ago to convert my mk3.5 to non pas,

none available when i looked,
were'nt expensive and would of been alot less hassle but hey ho

[RS_Rob]

my power sheet from the engine dyno

[RS_Rob]

something i've been meaning to do for a while is wax the shell,

so the wax of choice was the 3M stuff used in my fords bodyshop




using this gun on the airline




quick picture of the shell

[harveyrst]

looks well smart so far will be mint when its done

[RS_Rob]

about a year or two ago i bought a CTS stage 2 + gearbox for the car,
which is a BC' box but with larger ib5 bearings, shot+peened gearset and a quaife ATB diff

but after finding out recently that the bc' box suffers with case flex, which could lead to allowing the bearings to move
and basically kill the box,

the ib5 gearbox is a development of the bc' box design
stronger casing, bigger bearings, better syncro's, starter motor at the back of the engine instead of the front etc
also because the gear stick centralising spring is inside the gearbox
this allows me to upgrade to a puma / mk5 fiesta gear stick selector
as the old bc box has the centralising spring in the selector itself,

so with a gearbox package sorted from a good mate on fiestaturbo.com
the plan was to swap the internals and diff over from one box to the other,
so that i'd have a ib5 with shot peened gears and quaife diff with all the advantages of the ib5

but due to lots of bearing size differences, it was decided to simply just swap the diff over to the ib5
which works out better in the end because i've kept the better syncro's


so a roadtrip was needed to collect the gearbox so that i could have the internals swapped over by two good mates in work,
i then borrowed the other halfs car and the company of a good mate mr wolze for the 450mile trip
it got a little dirty on the way with all the salt/grit and snow about





here's a picture of the two gearbox internal swapping legends, without them i'd be buggered
mr Wolze on the left, mr Potter on the right




heres the two box's ready to have their insides swapped




got new ford gaskets, bolts and 5th gear cover plate ready




the two box's mid operation




the quaife atb on the left, the standard ib5 diff on the right




with the swap over complete it was time to clean the ib5 up
with the help of another mate kenny and mr wolze, we got bungs for where the driveshafts go
and gave the whole box a scrub with parafin then blasted it off
heres a pic showing the bungs

[RS_Rob]

now the box was clean from grease etc
it was time to scotch pad the casing box
you can see the difference it made alone with only the top half done




heres the box covered in a nice coat of etch primer on the freshly scotched box,




heres the box after its first coat of satin matt black
i choose black as its easier to keep clean than silver, also goes with the black engine block





then with the 5th gear cover/plate and bolts after it had dried

[tezmanian devil]

awesome build dude, it's only taken me since 10:30 to get through it all lol
keep it up bud, deffinatly going the be a stunner!!

[Twins]

[frsjon]

nice one rob looking good

[packman]

Great build and much time and money has gone into it but i feel you get to a point were its just to nice to use on our shitty pot holed roads. And yes Harvey is the man he mapped my zetec that did 272 hp and 315 ft @ 3k with 18 psi.

[COLEYST200]

some very nice work going on with this car well done mate and keep it up

[wide ka]

great thread, some awesome work going into it!

[RS_Rob]

cheers for the great comments

it'll be used for shows and local drives around the welsh coastal roads
interested in what times i can get down at santapod aswell

[jon_ross]

fooking awsome mate. i only hope i can build mine as good as yours different colour and spec though. but what a car, well done

[RS_Rob]

thanks jon, got a project thread up on here??

[RS_Rob]

bought a new alternator




this is the second one i've ordered, the first one did'nt fitted on my mount
so double checked this one fitted





painted the wiper motor cover satin matt black, new bolts etc
should help keep everything looking fresh in the bay

[GaryHurn]

great work rob as always