mentalasanything

This week I decided its about time I started a build thread on my 1989 XR3i Cabriolet.

It all started in November 2006 when I swapped my 1996 Escort RS2000 16v for a 1989 Escort RS Turbo. I already had a project in the form of a 1988 Fiesta XR2 which was almost complete. I'd wanted an RS Turbo since my early teens so this was an offer I couldn't refuse. The RST had a few months MOT left so the plan was to finish off the XR2, poodle around in the RST then start rebuilding it once the MOT ran out.

Well as with all of these things, the MOT ran out and then my circumstances changed. My wife and I were offered amazing job opportunities 200 miles away in London so we took them and moved. I finished and sold the XR2 to fund the move and put the RST in my parents garage with the intention of tidying it up whenever I was home.

Over the next few years I collected all of the parts I needed to rebuild and upgrade the RST but as I got further in to the build things changed again. Rust and time were against me. I got offered a 1989 MFi XR3i cabriolet by my brother in the summer of 2010 for really low money. It was solid throughout and more importantly an absolute bargain. The new plan: reshell the RST into the cabriolet.

Here's a few pics of how I got it:







A quick wheel change, much better:



So, I stripped the RST shell and sold it on. I fitted the '90 spec front bumper and Recaros from the RST. Then with the proceeds of selling the shell, I had the XR3i re-sprayed to make it minty mint:















I then began the task of cleaning up and painting all of the running gear:









Once it was all freshly painted, I got it transferred in to the cabriolet and got an MOT. I drove it like that for the summer:



















At the end of 2011 she was parked up. Now the RST engine rebuild and transplant coupled with the EFi conversion began. As I already had an MFI RST engine with a few thousand miles since the bottom end was rebuilt I did things slightly diferent. Instead of an EFi bottom end with a CPS hole I opted for a bottom pulley and CPS mount from a CVH Sierra (36:1 trigger wheel). This is a tight fit (impossible with the engine in place) but will work fine :





































And that's where we stand today.

To finish it off for use in the summer I need to sort out a fuel leak, sort any issues starting it, tape the loom, re-fit the dash and tighten the front running gear.

Current spec:

Engine

• 1.6 CVH
• EFi
• Ported and polished head
• Stage 1 T3 turbo & -31 actuator
• Airtec Front Mount Intercooler
• Airtec aluminium radiator
• Black silicone hoses all round
• Group A induction filter
• Mongoose stainless steel exhaust
• Custom EFi loom
• Beige injectors
• Adjustable fuel pressure regulator
• Small turbo EsCos MAP sensor

Running gear:

• Koni adjustable dampers
• AVO -35mm springs
• Flo-Flex polybushes
• RS Turbo hubs, Anti-Roll bars (Front and rear), tie bars and wishbones.

Brakes

• Front: Escort Cossie callipers with Sierra Cossie 2wd disks, Ferodo DS2000 pads and Goodridge braided hoses
• Rear: Sierra XR4x4 callipers with Sierra Cosworth 2wd disks, Ferodo DS2000 pads and Goodridge braided hoses

Lee

Glenn_

iTrader: (1)

Top work matey.Nice project.

mentalasanything

Cheers mate, it's grown on me quite a lot, never used to be a fan of cabby's. Does grate on me though when people call them "RS Turbo convertible"

I forgot to say thanks to my Dad for helping me lift the engine in place and re-fitting the ARB!

Lee

mentalasanything

Well lads I had a very successful weekend. I managed to seal the fuel leak but the car still wouldn't start. Eventually I traced a bad earth to the EDIS module and she fired in to life!

There's still a slight hesitation, but I'm putting that down to the CPS not being long enough (has a 6mm or so gap from the trigger wheel).

All in all very happy. Just need to replace the CPS, tape the loom, refit the dash and tighten the running gear. Basically just need time!

Lee

studabear

How come such a big gap for the cps?

I might have 1 floating about in my box of spares if you need a sierra cvh sensor, cover the post its yours unless your going classic ford.

mentalasanything

I'm not quite sure. I've used what I believe to be a Sierra CVH CPS and it's all the way down the holder but it still has a large gap. The sensor is a bit worn and looks a bit battered so I want to replace it anyway. I'll modify the holder to get it closer.

I'll drop you a PM for your generous offer.

Cheers,

Lee

bigryrs

iTrader: (10)

Cool mate i love cabriolets im wanting to convert mine to efi turbo at some point but its finding time and money as all i do now is spend money on the house lol

Twisterboy

Nice looking XR3i

steve st220

both very nice cars, miss my escort turbo cabby and orion 16i ghia turbo.

mentalasanything

Well, I replaced the CPS last week and she seems much happier now, starts on the button and idles OK. FYI I fitted one labelled for "Fiesta 1.4, 1.6; Granada 2.0;Scorpio 2.0;Sierra 1.6, 2.0" and cut off the screw terminal. Bad new is the gearbox is on its way out so it'll have to come out in favor of the XR3i one until I can get it sorted/upgraded.

Just need to put a few things back together and then it's off for a setup. I have a week off again next month so it'll get done then.

Lee

Zetec_mk4_XR3i

That looks ace mate, best colour too and love the boot badge, exactly how I would have a mk4 cab!

Top work

mentalasanything

Cheers mate, it has grown on me a lot, probably all the blood, sweat and tears! I had the boot decal made by Sticky, it's exactly what I was after as I hate seeing an RS Turbo badge on a cabby.

Lee

mentalasanything

Well, as is always the case, the car is never without drama...

A month ago I spent a few days on the car. I replaced the gearbox with my old XR3i one and that sorted the whining and crunching for now. During that process I had to fit 2 new track rod ends as they wouldn't come out of the hubs for toffee.

But, after a few moves in and out of the garage and up and down the lane the sump gasket gave up Soooo, last week I replaced the sump gasket which cured that issue. FYI I superglued the gasket to the block before putting the sump in, that made the job quite easy. The rubber rocker cover gasket was leaking ever so slightly too so I replaced that with a cork one.

Finally the car is 99% ready for an MOT. I'm having a nightmare setting base idle at the moment though so I'm looking for a new OFAC MAP sensor. Once I've replaced that she'll be ready!

Cheers,

Lee

Wood5tock

iTrader: (1)

top work there mate, We've added a XR3i cabby to our Mk4 stable going to keep it standard though

0150carmac

looking great theres keep up the good work

mentalasanything

An update on recent developments! I think I found the issue setting base idle. Basically the head was warped and had one bent exhaust valve. I tried everything and couldn't sort it. I noticed that it had developed an oil leak from between the head and block so sent it away to be tested. I'm surprised it ran as well as it did!

I've now got it back after having a skim, new valve and 4 new exhaust valve seats cut. Just need to fit it and test it.

Lee

mentalasanything

I had another day down the garage on the weekend. Managed to get quite a lot done in fairness.

I re-fitted the head and it started first time... With no leaks but the bonnet won't close now and it has a puncture

I think I've sussed the poor idle too, I blanked off the vacuum hoses that come from the inlet manifold directly below the throttle body (The ones that usually go to the oil breather). Apparently these are needed for the idle??!!

Jobs to do:

Fit Turbo Cooler
Sort Bonnet Latch
Sort Puncture
Re-fit oil breather
MOT
Clean and hoover
Drive

Here are a few more recent pics:









Cheers!

Lee

mentalasanything

Had a very productive day on the cabby a few weeks back. I fitted the breather which cured my idle problem (finally!) sorted an issue with the bonnet latch and tidied up a little.

I even plucked up the courage to take her for an MOT. Sadly she failed first time on a split CV boot and 2 corroded brake pipes, easily fixed though!

Finally, well overdue, she has an MOT! As I've been working away a lot recently I set my Dad on the advisories and retest and he sorted it all out.

Rolling road tune booked for Saturday May 3rd then she's all set for the summer.

Can't wait now, it's been a long time coming...

Lee

furry

looking good fella!!!

i remember that feeling well when i finally got my turbo'd SE500 cab on the road

turbo m

iTrader: (2)

As oathers have said boot badge is very neat very oem!!!
Love the cheeky fuel prsesure gauge on the filter.
Nice work...

mentalasanything

Cheers lads. I was let down at the last minute with the rolling road, but she's booked back in for June.

I haven't let that hold me back though, done 150 odd miles this weekend, lots of fun had! The chatter is immense, and she pulls like a train with only 6psi boost.

Lee

mentalasanything

So, it's been a while!

Just a quick catch up. For the remainder of 2014 she looked like this:





In autumn 2014 I drove her 180 miles back to my parents to tuck her up for winter. As my dad was taking her to the garage at my grandparents, this happened:











As some of you know, the catches on a mk4 are dodgy anyway, add an FMIC and they're an accident waiting to happen. Luckily I had fitted a check strap and it was connected. The strap took most of the energy out of the flip so it only hit with half the force. It still ripped the section of body. So we set about correcting the damage:





And installing Aero Catches (Can't have that again!):











She went for paint:







She came back gleaming:



Then I drove her the 180 miles back to me and added the finishing touches:



Time for a spruce up, new valve stem oil seals:



But this happened:





Undeterred I soldiered on:



Done:



Took her for a spin:







On that drive the rear silencer clamp snapped:



Credit where credit is due, 9 and a half years after I purchased it Mongoose honoured the lifetime warranty and replaced it free of charge!

I also fitted a wideband controller, a new alternator and a transit connect starter:









A very quick recap! She has an MOT in a few days so we'll see how that goes...

Lee

dazrsturbo

iTrader: (3)

Real nice project this! Good work!

philg12

Very cool

bigryrs

iTrader: (10)

Top work bud!

mentalasanything

Cheers gents. It's been a lot of work over the years but driving it puts a smile on my face.

Passed the MOT yesterday too!

Lee