Right, after reading some of the threads on here I though it would be a good idea to stick a project thread of my own up. I can't promise to keep it bang up to date (as I'm a rather forgetful soul ), or that it will be anywhere near as detailed (fabrication wise) as some on here, but here goes anyway!

On one of my weekly cruses of the classifieds (which I like to think of as the blokes alternative to window shopping), I came across this little beast...





...my head immediately filled with all sorts of ideas for modifications and how good it would be on the track. Which led to me ringing the bloke and buying it the following day

So after a trip to Doncaster to collect the car and then suffering the tiring and slightly embarrassing 3hr journey back. Well a car with beefy looks should really have a beefy engine to go with it, not an asthmatic 1.3 causing me to drop a cog at every incline Plus there was no interior, stereo or even window winders for a fag. Good job there was no carpet

After arriving home, on went the kettle and the laptop. The search was on for the biggest engine I could squeeze in to the tiny engine bay, for the least amount of effort and cash outlay (that was the plan anyway!!).

And this is what I came up with...



...a standard MK1 Focus RS engine, complete with standard turbo, manifold, loom and keys.

Now I had heard this had been done before, it was just a case of tracking down the fella that did it! After a quick search on the net I found him...Joe at http://www.trackdesigns.co.uk/index.htm and what a helpful chap he was/is. He helped me out no end and even supplied me with same handy little kits he'd made up to make the conversion easier. If you happen to read this Joe, thanks

By this time I was getting a nice pile of bits mounting up in the dinning room, you can imagine what my wife thought about that
So I had to get cracking with the conversion, now I'm what you'd call a mong when it comes to spannering! So I enlist the help of someone who knew what they were doing and wouldn't set fire to themself when the welder was in use! Enter my mate Dan Owen at http://www.oweneng.co.uk without who the car would still be in my garage in the same state as when I bought it

Anyway enough of the waffle (don't worry there'll be plenty more), if your still with me, i'll get to the pictures now. Well the pictures I have, as i didn't intend to do a project thread and didn't take any pics of the first stage of the build, so it kinda jumps a bit

After the old engine was out, the FRS engine was tried out for size



It went in from the bottom, which actually went easier than expected! Don't quote me on this, but I think with the kit from Track Designs (to relocate the alternator) the original engine mounts work...I'm sure I will be corrected on that one though!

Dan modified the front crossmember to give us as much room as possible, so the rad and intercooler could mounted up front without modifying the front bumper



Nice bit of handy work I think!

I then got to thinking about a gearbox to mount to the engine (should have thought of this before I know!). Joe at Track Designs to the rescue again! He told me that he'd used the original IB5 box on his conversion, which was running over 300bhp no problems. After a bit of shot peening and a lengthened final drive ratio plus a Quaife diff, I was ready to go, oh and a lightened wallet

S2 RST 4 paddle clutch and a lightened flywheel should see the power down pretty well





With my intention being to use this mainly for a track car, I turned my attention to a cage. For those that know me will know that it's a very good investment

I had a look at some off the shelf setups, but didn't really like any that were available. So I asked Dan @ OwenEng if he could fabricate me one. To which he said "of course I can, got a metal bender ain't I!"

Here's the result, not very good pics i'm afraid





It's a fairly substantial cage, if you look back at the engine bay pics you'll see where it comes through the baulk head and meets the strut tops. A bit OTT for what I want, better to be safe than sorry though

I will get some better pictures of it when I get back down his workshop.

Stopping power will come from the standard FRS setup...

Brembo fronts



Standard rear hubs and stoppers



And a few other bits I've got







And my favourite bit, I bought this before anything else







If you've made it this far, thanks for sticking with me

The build has kinda been at a standstill for the last couple of months. Waiting for my MK1 FRS to sell, it's gone now though, so once Dan's schedule has a gap it's full steam ahead again, with Central Day 2011 my deadline!

All comments welcome, even if it's only to tell me to STFU

 

cracking that mate good luck with it keep it updated with picccys!

 

that looks hard as nails going to be a great little car when done

 

Cheers guys

Work will commence again start of next month hopefully. Pictures will be more detailed!

 

love the look of that kit on a KA, i'm pretty sure there use to be a grey
cossie powered KA around with that kit on.

 

coming on nicely

 

Looks like its gonna be a beast mate! keep up the good work!

 

What bodykit is that? ithink its the only one ive ever seen on a KA i actually like..

Top project!

 

You must be thinking of this one
http://www.djm-motorsport.co.uk/Ford_KA_Project.html

It was made by DJM Motorsport for their 4x4 cossie project (see link above).

After speaking to Dave who runs the company, he told me that mine was the first one they built and his mrs used to use it as a shopping car, typical Ka then

I think there have been a total of 4-5 made, not 100% on that though

 

You must be thinking of this one
http://www.djm-motorsport.co.uk/Ford_KA_Project.html

It was made by DJM Motorsport for their 4x4 cossie project (see link above).

After speaking to Dave who runs the company, he told me that mine was the first one they built and his mrs used to use it as a shopping car, typical Ka then

I think there have been a total of 4-5 made, not 100% on that though

 

Good to see someone else having a go.. but get shot of that clutch straight away! It's absolutely crap and I wouldn't want someone else having the same ball-ache as me. It'll last 5 mins and it'll slip in 5th gear under full load, if not every gear! Can you tell I'm pissed off with mine!

You want the helix 4 paddle with the heaviest cover plate possible.

 

if you do get rid of clutch i am interested in it, for my ka, running less power lol

 

This thing will be stupid fun.

 

Interesting Project.

Is it going green though as per the sig.....?

 

Yeah sounds like someone's bought himself a duffa

I was recommended this clutch by someone who was running it with much higher bhp than i'll be running! No problems reported, you watch me eat my words no

Is this the one you have?
http://cgi.ebay.co.uk/FORD-ESCORT-S1...ht_1270wt_1102

Link above is where I bought mine from

My thoughts exactly

Not 100% decided on the colour yet, just photoshopped it that colour to get it noticed. THB it's actually growing on me, it's the Porsche green they put on the 911

 

You mean joey told you it was ok.. I can tell you it's not ok haha

Joe said to me it slipped if he gave it full beans sometimes. It is a crap clutch mate, trust me. Dan, my brother is having the same issues. The clutch has done 1000 miles and it's started slipping. His was brand new on a skimmed and balanced flywheel.

However, it'll be ok with about 250 lbs torque I reckon. The limit of the clutch is 236 anyway. It's all its rated to.

Just trying to help mate, cos there's nothing more irritating than having a clutch that doesn't work properly. It's such a hassle to do too.

And yes, it is stupid fun You will love it.

 

looks like lots of fun, wanted to put a cvh into mine but far too busy for that LOL, cant wait to see the updates, good luck