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500+ BHP Mk3,5 Fiesta Zetec Turbo - Just bought a Cossie.. (01/08/17)

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Old 20-07-2011, 08:59 PM
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GenSC
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Default Gensc's Mk3.5 Fiesta Zetec Turbo
Hi Guys,
I bought my Fiesta Xr2i 4 years ago.. It worked with no problem... I loved it, but wanted more powaaaaaah' ...












So I've decided that it is time to rebuild it...




















Once we finished with stripping it down, we realized this car has some nasty surprises under the paint..

































We had to get a donor car at the end...
















Let the game begin....






























































































Something's gonna happen...At long last......
































Here we are now...



























Lots of goodies inside...

































































I think some of you know who's car is in the background.. He is basically the one who builds the car..
https://passionford.com/forum/restor...wd-escort.html
https://passionford.com/forum/restor...-fwd-ford.html

The Specs are; (before I bought Szabyk's engine)

2.1 Zetec turbo

86mm Custom made Forged Pistons 9:1 CR
Lightened and polished Rods, Cranckshaft...
ARP everywhere...
Polished and ported cylinder head with DBilas valve spring set...
Cometic gasket...
Vems EMS full-full...
Quaife MTX...
AP Racing Clutch...

....To be continued....
Last edited by GenSC; 27-04-2020 at 09:46 PM.
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Old 20-07-2011, 09:03 PM
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Dan F
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Progress looks good so far and hopefully you'll bin the chrome horse
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Old 21-07-2011, 07:06 PM
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to get the panels to line up so well, have you 'joggled them' so they over lap before being welded??

looks awsome
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Old 21-07-2011, 08:04 PM
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GenSC
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Originally Posted by zippyobrien
to get the panels to line up so well, have you 'joggled them' so they over lap before being welded??

looks awsome
That's exactly what we have done...

Thx Mate!
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Old 21-07-2011, 10:12 PM
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think i need to get a joggler then, got inner and outer arches to pop on my escort,
not looking forward to getting the grinder out
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Old 24-07-2011, 02:32 PM
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GenSC
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Originally Posted by zippyobrien
think i need to get a joggler then, got inner and outer arches to pop on my escort,
not looking forward to getting the grinder out
... And you'll need a bit of patience.
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Old 15-08-2011, 06:36 PM
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GenSC
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Default Bit of update:)
A bit of update...

Szabyk is unstoppable.... Cracking on well...




























I have just ordered a set of Compo's... Was not cheap, but goes with the car well imo...
Last edited by GenSC; 26-04-2020 at 07:17 PM.
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Old 15-08-2011, 07:17 PM
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Very nice
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Old 15-08-2011, 08:52 PM
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Nice work
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Old 12-09-2011, 06:40 PM
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GenSC
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New parts just arrived...






Compomotive....







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Old 24-09-2011, 07:08 PM
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GenSC
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Default ...
The intercooler has been fitted... Just a few things left to do and it's ready for mapping..

























Will be back...
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Old 24-09-2011, 07:20 PM
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I like that a lot.Im loving the engine.Just do one thing for me...Leave the horsey badge off the bonnet.
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Old 24-09-2011, 07:35 PM
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GenSC
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Originally Posted by Glenn.
I like that a lot.Im loving the engine.Just do one thing for me...Leave the horsey badge off the bonnet.

Thx Mate... I promise I won't pit it back on...
Last edited by GenSC; 26-04-2020 at 07:17 PM.
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Old 15-10-2011, 07:09 PM
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Default .
The chaps worked hard on the Fiesta recently..

Here is the result...

http://www.youtube.com/watch?v=n4ymHr4C484

More work in progress...
Last edited by GenSC; 15-10-2011 at 07:10 PM.
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Old 20-10-2011, 07:16 PM
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A few pictures... Nearly there..











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Old 21-10-2011, 06:08 PM
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...



















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Old 21-10-2011, 06:31 PM
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Very nice


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Old 05-12-2011, 02:49 AM
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love it mint mate top work
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Old 05-12-2011, 09:33 PM
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any updates? how is it running
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Old 08-12-2011, 07:39 PM
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GenSC
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Originally Posted by nevsrevs
any updates? how is it running
It runs really nice... Produces around 300bhp at 1 bar..

We had some teething issues with the cooling.. We also had to replace the turbo.

RS2000 brake setup needs to be upgraded too..
Last edited by GenSC; 26-04-2020 at 07:19 PM.
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Old 08-12-2011, 10:04 PM
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charge cooling or water temp?, wat turbo now?
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Old 09-12-2011, 09:40 AM
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nice love a zetec turbo one thing tho please tell me you fully welded them patchs before painting? its an mot failure in this country to repair the floor to sill without fully welding not sure how it is in your country tho
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Old 10-12-2011, 06:15 PM
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GenSC
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Originally Posted by nevsrevs
charge cooling or water temp?, wat turbo now?
We issues with the hoses... So silicon hose set is the way to go... The turbo is gonna be bigger mate...

Originally Posted by 12_Second_rst
nice love a zetec turbo one thing tho please tell me you fully welded them patchs before painting? its an mot failure in this country to repair the floor to sill without fully welding not sure how it is in your country tho
Hah, yes, patches are fully welded ofc.
Last edited by GenSC; 26-04-2020 at 07:21 PM.
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Old 30-01-2012, 11:41 AM
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verry nice build Gen!

i have a mk2 fiesta with a zetec turbo build in progress, i'm also going to use VEMS, who mapped yours? i'd like to go to hungary to have it mapped properly as no one has any expirience on turboed zetecs here in romania.

cheers!
Last edited by tekno; 30-01-2012 at 11:45 AM.
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Old 30-01-2012, 05:24 PM
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GenSC
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Originally Posted by tekno
verry nice build Gen!

i have a mk2 fiesta with a zetec turbo build in progress, i'm also going to use VEMS, who mapped yours? i'd like to go to hungary to have it mapped properly as no one has any expirience on turboed zetecs here in romania.

cheers!
Hi mate,

I'll send you the details on PM.
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Old 29-05-2012, 09:44 PM
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A few new pictures... I've just bought a new camera, so here we are now...






























I got a race to go on saturday... We will see how it is gonna be...
Last edited by GenSC; 17-06-2012 at 07:38 PM.
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Old 17-06-2012, 03:00 PM
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news from the races? how did you do?
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Old 17-06-2012, 07:54 PM
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Originally Posted by tekno
news from the races? how did you do?
Nothing proper yet, just wanted to see it moving really (car was on road tires, low boost, etc)... And to be safe, we also reduced the limiter to 6200...

This was enough to realise that we need to change the clutch and that there is something going on with the current map... Will be fine, but need to look into these issues..

Hope we can get it ready by September...







Cheers
Last edited by GenSC; 26-04-2020 at 07:25 PM.
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Old 17-06-2012, 08:15 PM
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awesome zetec turbo mate
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Old 14-08-2012, 08:35 PM
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Guess what happened...

So the car had a reinforced BC..

Next step is an IB5 (reinforced)... If this one brakes as well, then there is no way around i am afraid - only the mtx route... (this is what we should replace the bc with but have not got enough time until the next event so IB5 it is.. for now)

Poor Dad was not too happy either : - )
http://www.flickr.com/photos/77784548@N03/7783643810/
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Old 14-08-2012, 09:52 PM
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Only 1 cure there mate! And you said it.
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Old 14-08-2012, 11:58 PM
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Beautiful Fiesta!! Very good build!!!

Would love my fiesta to have a 300bhp zetec turbo
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Old 19-09-2012, 10:53 AM
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So..

We got a new gearbox. Reinforced IB5... Not sure how long it is going to last..

Gotta go to Kiskunlacháza on Saturday.. I hope I can run a good one... We will see...
Last edited by GenSC; 26-04-2020 at 07:28 PM.
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Old 19-09-2012, 04:37 PM
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Its looking well.
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Old 16-10-2012, 08:46 PM
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So....

I went home to hungary for 2 weeks, and enjoyed the car for a while... Until...

http://www.flickr.com/photos/77784548@N03/8094865847/
I am not happy at all... Driver of the transporter thought he can get through the red while i am front of him. Car is a write off, there is no way we can salvage this shell.

We had to source a new shell..

Meanwhile Szabyk put his fiesta on the market https://passionford.com/forum/restor...-fwd-ford.html. - "This can not be a coincidence i thought to myself ... So I just bought the whole "drive train" off his car... It should handle 400bhp+ easily..
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Old 11-11-2012, 11:19 AM
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Work has started...








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Old 04-12-2012, 05:52 PM
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As I mentioned before, I bought Szabyk's complete drive train... I thought this will be end of the story.. We rebuild the car and that is it. I did not want put more money in this project...

Everything is Szabyk's fault, He made an undeniable offer on his 2.0 Zetec Turbo engine. (550bhp - 9,3@243)

Obviously i had to buy it...








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Old 04-12-2012, 06:16 PM
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Very nice mate
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Old 04-12-2012, 06:40 PM
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cool stuff! Still loving these rims, too!

kind regards, Flo
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Old 04-12-2012, 09:21 PM
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Thanks for the read, one mighty nice car
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