View Single Post
Old Jul 7, 2011 | 07:01 PM
  #1  
robp-tt's Avatar
robp-tt
ZETEC TURBO
iTrader: (1)
 
Joined: Oct 2005
Posts: 1,527
Likes: 3
From: southampton
Default mk3.5 zetec turbo fiesta UPDATE

hi thought i would start a new build thread for my new project and tell the story of how it has got to the stage
its at now.
most of you will recognise my old fiesta as it was the cover car for the sleeper issue of fast ford last year,after
the feature i used the car loads for about a year then decided that i have gone as far as i wanted to with the mk2
so i found a mk3 shell that was for sale from a member on here(zetaboostboy522bhp)here are some photos of my old
mk2 and the shell before i got it
Name:  9309.jpg
Views: 466
Size:  58.5 KB
Name:  9160.jpg
Views: 1020
Size:  105.2 KB
Name:  FAF288cover1.jpg
Views: 426
Size:  50.6 KB
Name:  paulpics0782.jpg
Views: 1017
Size:  96.1 KB
Name:  paulpics1421.jpg
Views: 437
Size:  103.9 KB
after sorting out a colection date i made the trip up to pick the car up,when i got there we loaded the shell up on
to the traler( a very bad and small one at that)and 2 big bars and 4 people later we then made the trip home that
took about 6hours because the trailer didnt like going over 50mph but once home we unloaded it off the trailer
(very hard to do with only two people and no wheels on the car lol, here are a few of the shell when i got it home
Name:  DSC00029.jpg
Views: 417
Size:  117.8 KB
Name:  DSC00030.jpg
Views: 410
Size:  86.5 KB
Name:  paulpics1371.jpg
Views: 427
Size:  102.7 KB
once home i made a start on chatting up my mate dean to sort the body work out(in needed two sills and two plates
sorting out) so he made a start on getting it to his mates pete's garage and they made a start on sorting the body
work out ready for paint and i would like to say a big thanks to both of them for all the hard work they put in to
it,here are some pics of it during the pannel and prep stage
Name:  pot019.jpg
Views: 387
Size:  71.5 KB
Name:  pot020.jpg
Views: 440
Size:  75.8 KB
Name:  pot029.jpg
Views: 413
Size:  81.8 KB
Name:  pot030.jpg
Views: 434
Size:  63.5 KB
Name:  pot032.jpg
Views: 394
Size:  49.8 KB
Name:  pot033.jpg
Views: 407
Size:  56.8 KB
Name:  pot034.jpg
Views: 434
Size:  46.3 KB
once the body work was sorted out i then had to decide on what colour i wnated it to be painted, after having loads
of spray out cards done in diffrent colours i decided to keep it stelth looking and chose panther black,so then the
car was taken to work on a saturday morning and painted
Name:  pot040.jpg
Views: 388
Size:  82.2 KB
Name:  pot044.jpg
Views: 417
Size:  86.1 KB
Name:  pot045.jpg
Views: 391
Size:  72.5 KB
Name:  pot046.jpg
Views: 388
Size:  57.9 KB
Name:  pot047.jpg
Views: 381
Size:  71.4 KB
Name:  pot048.jpg
Views: 403
Size:  71.3 KB
Name:  pot050.jpg
Views: 375
Size:  95.5 KB
Name:  pot054.jpg
Views: 419
Size:  90.7 KB
Name:  pot059.jpg
Views: 411
Size:  99.3 KB
Name:  pot062.jpg
Views: 391
Size:  55.8 KB
Name:  pot066.jpg
Views: 403
Size:  67.5 KB
Name:  pot069.jpg
Views: 422
Size:  64.5 KB
Name:  pot070.jpg
Views: 414
Size:  27.1 KB

once it was painted i then made a start on sorting out all the suspension parts for it,i started by having the
subframes painted lambo orange and a zetec s rear axle done the same
Name:  DSC00605.jpg
Views: 417
Size:  151.9 KB
Name:  DSC00607.jpg
Views: 375
Size:  152.7 KB
Name:  DSC00608.jpg
Views: 401
Size:  168.5 KB
once that was done i had the avo coilovers painted the same colour
Name:  DSC00618.jpg
Views: 401
Size:  156.7 KB
Name:  DSC00587.jpg
Views: 400
Size:  120.5 KB
after i had those bits done i got a set of lower arms form ian howell and had them painted panther black with the
antiroll bar and strut top caps
Name:  DSC00589.jpg
Views: 381
Size:  149.1 KB
Name:  DSC00612.jpg
Views: 383
Size:  142.4 KB
all the bits together before they where fitted and once fitted to the car
Name:  DSC00629.jpg
Views: 406
Size:  151.1 KB
Name:  DSC00632.jpg
Views: 418
Size:  139.9 KB
Name:  DSC00630.jpg
Views: 451
Size:  235.2 KB
Name:  DSC00633.jpg
Views: 385
Size:  214.0 KB
Name:  DSC00641.jpg
Views: 390
Size:  151.1 KB
Name:  DSC00676.jpg
Views: 456
Size:  166.4 KB
once it was all fitted i decided to fit the focus st170 rear brakes with the racing puma hand brake cables
Name:  DSC00625.jpg
Views: 552
Size:  156.1 KB
Name:  DSC00674.jpg
Views: 409
Size:  110.1 KB
Name:  DSC00639.jpg
Views: 395
Size:  165.3 KB
Name:  DSC00648.jpg
Views: 498
Size:  167.9 KB
once i had it rolling how i wanted it to be i set about with sorting the engine bay and getting the rads in and
fitted and to make sure the rs500 pro intercooler fitted and relised that the standard headlights would fit so had
to fit a set of quads and had to have the lower lip on the bonnet choped off so it would close
Name:  DSC00654.jpg
Views: 437
Size:  181.1 KB
Name:  DSC00657.jpg
Views: 409
Size:  143.7 KB
Name:  DSC00658.jpg
Views: 376
Size:  107.4 KB
Name:  DSC00619.jpg
Views: 402
Size:  189.8 KB
Name:  DSC00620.jpg
Views: 410
Size:  178.8 KB

after getting it to fit i made a start on sorting out a bumper and had a few to choose from but ended up choosing
the frst one
Name:  DSC00660.jpg
Views: 397
Size:  152.7 KB
Name:  DSC00663.jpg
Views: 389
Size:  186.0 KB
Name:  DSC00703.jpg
Views: 377
Size:  170.0 KB
once that was sorted i made a start on the inside of the car and fitted the doors up and the carbon door cards and
test fitted the mk4 dash that i choped about
Name:  09012011207.jpg
Views: 537
Size:  107.7 KB
Name:  09012011208.jpg
Views: 388
Size:  111.9 KB
Name:  09012011209.jpg
Views: 634
Size:  105.0 KB

after all that was done i made a start on getting the engine in the bay and gearbox mounts sorted for the mtx
conversion,(i decided to go for the mount that crazy cage makes for the box)but now need to have the engine bay
painted in places again because of the mounts that i welded in
Name:  09012011216.jpg
Views: 505
Size:  121.5 KB
Name:  DSC00848.jpg
Views: 449
Size:  92.1 KB
once that was done i started to think about manifolds and what ones i wanted to get,after some looking around i
decided to go for a area 6 inlet and found ians old 321 stainles duratec turbo manifold that he had on his focus for sale so i had to buy that lol i knew it would need to be modiafied a litte so had a word with paul(zetaboostboy522bhp)about him doing the work on the manifold and he said he would after loads of photos and talking of how i needed it to be he made a start on doing it for me,here are some photos of it in the test fitting
Name:  DSC00856.jpg
Views: 390
Size:  121.1 KB
Name:  DSC00853.jpg
Views: 424
Size:  134.5 KB
Name:  DSC00851.jpg
Views: 380
Size:  120.9 KB
Name:  DSC00850.jpg
Views: 398
Size:  121.7 KB
after loads of work paul had the manifold finished thanks again paul for all your hard work and for the food
when i picked it up
Name:  DSC00941.jpg
Views: 402
Size:  222.3 KB
Name:  DSC00940.jpg
Views: 405
Size:  241.2 KB
Name:  DSC00939.jpg
Views: 405
Size:  230.2 KB
Name:  DSC00938.jpg
Views: 403
Size:  215.0 KB
on the way to colect the manifold from paul i made a trip up to ians to pick up the inlet and my new head for the
zetec
Name:  DSC00937.jpg
Views: 420
Size:  141.7 KB
Name:  DSC00936.jpg
Views: 416
Size:  126.1 KB
Name:  DSC00935.jpg
Views: 421
Size:  132.6 KB
here are some of the manifolds in the engine bay, the only issue i have found so far is that i need to have the
intercooler pipe moved because the wastegate pipe goes straight to it
Name:  DSC00947.jpg
Views: 409
Size:  180.2 KB
Name:  DSC00946.jpg
Views: 414
Size:  163.3 KB
Name:  DSC00948.jpg
Views: 434
Size:  121.5 KB
Name:  DSC00949.jpg
Views: 418
Size:  150.6 KB
Name:  DSC00950.jpg
Views: 398
Size:  78.7 KB
Name:  DSC00951.jpg
Views: 378
Size:  76.9 KB
Name:  DSC00953.jpg
Views: 400
Size:  90.3 KB

so that brings me up to where i am now, next on the list is to sort the fuel system out and to fit the front brakes
adn fit all the braded brake lines on the car,at the weekend i decided to give it a quick wash as it was covered in
dust after sitting for ages,here are some pics of it with my old mk2
Name:  DSC00934.jpg
Views: 414
Size:  130.9 KB
Name:  DSC00933.jpg
Views: 418
Size:  179.3 KB
Name:  DSC00932.jpg
Views: 417
Size:  152.4 KB
Name:  DSC00930.jpg
Views: 423
Size:  164.6 KB

thanks for looking and i will update as when all the fuel system is fitted

Last edited by robp-tt; Jan 22, 2012 at 04:40 PM.
Reply