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Mk2 Fiesta Cossie Managed CVH Turbo Project

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Old Nov 11, 2012 | 01:44 PM
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Default Mk2 Fiesta Cossie Managed CVH Turbo Project

Thought I would start a thread on here for this, first post is copied from xrtwo.com so a lot of it mite seem strange and irrelevant untill I edit it, if I edit it lol



Hello everyone I'm new here and this is my first mk2!

I've owned many Fords in the time I've been driving including 2 mk3 fiestas, a mk5 ZS, a swa kitted mk6, escort rs2000, 4x4 saph cossie to name a few!

I wasn't actually in the market for a fiesta at all and in fact I was looking at jap drifty cars but my mate had aquired this 50k 1.1L mk2 and I just couldn't resist!

Here's a pic a few days before I bought it with massive hub caps they cable tied on for a joke lol



This is when I got it home parked behind my pajero which I now need to sell



I bought some pepperpots from the for sale secion on this forum




Unfortunatly at this ride height there was a lot of rubbage so my mate trimmed the arches




The trim helped but didn't toally cure the rubbing so I have ordered some 175/50's, once they are here the pots will be coming off to be painted.

I have only had the car a few days but I've already got a good idea what I want from it!

The plan is RS Turbo power and small tweaks on the outside but no xr kit, I've got some rainbow cloth cossie recaros which I fitted to my pajero which will be going in if they aren't to big for the little fiesta!

I haven't taken many pics yet and I'm new to mk2's so I've got a lot to learn about the Modding tricks on them!




175/50's are here!




Now the pots are coming back off for paint but im unsure on colour, gloss black is what I usually do lol




Few pics of the car taken today, back on steels as the pots are at the powder coaters.











Bought some clears for it off a member on here, most people are saying keep the ambers but I prefer the clears!




Last edited by lozi; Apr 16, 2013 at 02:58 PM.
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Old Nov 11, 2012 | 02:20 PM
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My first car was a 1.1 ghia, I loved it always will have a soft spot for the mk2
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Old Nov 11, 2012 | 03:43 PM
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Abit of an update

I got an escort rs turbo t3, manifold and downpipe for peanuts last week off a mate. I got them mainly for the manifold and downpipe as the turbo isn't great but I have stripped the turbo down anyway to see if I can restore it and get turbo technics to freshen up the internals.






I also now have an engine for it! I picked it up yesterday its a fiesta rs turbo cvh, unknown history and spec or even if it works so I will be part stripping it for a freshen up and hopefully it will be in good shape internally.

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Old Nov 11, 2012 | 03:47 PM
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Cool project mate.Its a bit low lol.
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Old Nov 11, 2012 | 04:11 PM
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Originally Posted by Glenn_
Cool project mate.Its a bit low lol.
Haha thanks I get that alot its on the floor lol
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Old Nov 11, 2012 | 04:15 PM
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Nice project, can't believe how much it changed just by lowering it, it looks awsome for it.
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Old Nov 11, 2012 | 04:21 PM
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Nice project, deffo looks too low though and it needs the ambers lol
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Old Nov 11, 2012 | 05:07 PM
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Great project!
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Old Nov 11, 2012 | 05:13 PM
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Awesome looking project so far
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Old Nov 11, 2012 | 08:38 PM
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Thanks for the comments, a few people have said its to low but at the moment I like it that was its hilarious lol
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Old Nov 22, 2012 | 07:39 PM
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Ive got a few updates on this!

Firstly the turbo, after stripping it i went to work cleaning it up and getting some bits of it ready for paint etc

I grit blasted and water bead blasted the compressor housing and back plate













And grit blasted and coated the brackets using kephos as a primer followed by a couple coats of xylan 1088





I had also cleaned up all the other bits ready for re working when i visited turbo technics who told me they wouldnt fix this turbo they will just do an exhange on a new turbo so i have wasted my time lol


I have also gone to work on the downpipe

Before




Grit Blast




Dry Glass




1200 then 800 paper followed by a going over with the buffer and lots of autosol





I will be blasting and painting the clamp with some high temp stuff we do.



ALSO


The pepperpots are back from the powdercoaters!







And i have got an inlet which i promptly stripped down as soon as it arrived ready for paint etc lol





I have decided to go cossie management and it turns out the type of top half my efi inlet isnt ideal for that conversion so im trying to sort the other type top half with remote iscv.


My engine stand arrived this week so i should hopefully start pulling the engine apart next week!
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Old Nov 22, 2012 | 07:54 PM
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My first car was a mk2 1.1 L,

Allways keep my eye on eBay, will have another one day!



Loving yours tho, and clears on a silver car looks spot on, keep them
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Old Nov 22, 2012 | 07:54 PM
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Looks a cool little project, I've some cossie management parts I don't need anymore

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Old Nov 22, 2012 | 08:02 PM
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Originally Posted by Fil
My first car was a mk2 1.1 L,

Allways keep my eye on eBay, will have another one day!



Loving yours tho, and clears on a silver car looks spot on, keep them

Thanks! i love it makes me feel 17 again lol

For me im so used to ditching ambers in favour of clears over the years as an upgrade that i cant get into this amber disease thats going round lol



Originally Posted by studabear
Looks a cool little project, I've some cossie management parts I don't need anymore




Funnily enough i know that as you replied to my thread on OKC lol
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Old Nov 22, 2012 | 08:35 PM
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Nice project would like a mk2 one day
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Old Nov 22, 2012 | 09:34 PM
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Cool project mate
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Old Nov 23, 2012 | 07:03 AM
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That thing should shift with the turbo engine I had a mk2 xr2 which was fitted with a 240bhp turbo cvh which wouldnt run when i bought it so i fitted a 2.0 zvh turbo on megasquirt and it was a flyer heres the thread if you fancy a nosey! Love mk2's and il have another one day! that one looks really clean btw
https://passionford.com/forum/restor...zvh-turbo.html
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Old Nov 23, 2012 | 11:35 AM
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will be keeping an eye on this one.cool little project
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Old Nov 24, 2012 | 03:33 PM
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cool project fella im keeping my eye on this one
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Old Nov 24, 2012 | 03:46 PM
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Thanks for the comments! It could end up a cool little car when its finished!



Originally Posted by bigryrs
That thing should shift with the turbo engine I had a mk2 xr2 which was fitted with a 240bhp turbo cvh which wouldnt run when i bought it so i fitted a 2.0 zvh turbo on megasquirt and it was a flyer heres the thread if you fancy a nosey! Love mk2's and il have another one day! that one looks really clean btw
https://passionford.com/forum/restor...zvh-turbo.html

You have PM!
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Old Nov 24, 2012 | 03:48 PM
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looks a nice base, i did wonder why you stripped the turbo, far easier to just send it off.
i'm actually in the process of breaking my xr2 zetec turbo, end of an era for me, nice to see others being resurrected and moving forwards.
top marks for effort

p.s. too low man
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Old Nov 24, 2012 | 04:16 PM
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Very nice ,looks great with the ambers on silver
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Old Nov 24, 2012 | 05:29 PM
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Originally Posted by xr2wishy
looks a nice base, i did wonder why you stripped the turbo, far easier to just send it off.
i'm actually in the process of breaking my xr2 zetec turbo, end of an era for me, nice to see others being resurrected and moving forwards.
top marks for effort

p.s. too low man

Turbo was scrap when i got it as far as i was concerned but i cant help but mess with things and with the job i do it would be rude not take it all to work and refurb it lol


p.s it needs to go lower
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Old Nov 24, 2012 | 05:47 PM
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lower, pfft!!!
i spent years driving mine too low, then i changed things and had to raise it to fit bigger things under things
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Old Nov 24, 2012 | 05:59 PM
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Originally Posted by xr2wishy
lower, pfft!!!
i spent years driving mine too low, then i changed things and had to raise it to fit bigger things under things

I can see i will have to do the same at some point as i cant see myself fitting very big brakes under the pepperpots lol
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Old Nov 25, 2012 | 04:33 PM
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UPDATE


Got the tires put on the wheels yesterday so today despite have viscious man flu i fitted the wheels lol






a few GoPro pics






And some pics in the petrol station after a drive about to get the springs to pop back in lol






Also my mate gave me a few bits from his old turbo, i will refurb the rocker and charge carrier so even if they turn out to be no use to me i can sell them on

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Old Nov 27, 2012 | 09:28 PM
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Latest arrival

FRST EFi Charge Carrier





also got the engine up on the stand ready for work to start



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Old Nov 29, 2012 | 09:04 PM
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Did a few bits today


Painted the clamp for the downpipe, i decided to give halfords black VHT a go and tbh im not to impressed its not very black at all lol




Grit blast



Painted, looks grey in the first pic its meant to be black im not happy with it at all i may have to find another VHT black to try... one thats actually black lol






I also started stripping the engine, the water ways etc in the block are very rusty and there is some rust in the bores. Having never done this before im unsure what do to and wether its ok, idealy i would like to avoid stripping the bottom end but im unsure how to tell if its ok to use.










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Old Nov 30, 2012 | 11:50 AM
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Would say the head gaskets been leaking.

Would deck the block and hone the bores as a minimum. Does it turn over freely ?
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Old Nov 30, 2012 | 12:30 PM
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In focus pics would be nice, but looks ok. whats the bore step like? do the pistons rock? does it turn over with very little effort and no tight spots? ie is the turning force the same for the full 360 degrees?
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Old Nov 30, 2012 | 02:04 PM
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looks ok, i'd hone it and fit new rings, check for a lip on the top of the bores to indicate excessive wear.

Originally Posted by lozi
I can see i will have to do the same at some point as i cant see myself fitting very big brakes under the pepperpots lol
very big brakes need 16" rims, i have just the things for you
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Old Nov 30, 2012 | 04:09 PM
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Originally Posted by zippyobrien
Would say the head gaskets been leaking.

Would deck the block and hone the bores as a minimum. Does it turn over freely ?

It turns over fine but it definatly needs alot of work i think its been sat for a while.


Originally Posted by the_frozen_one
In focus pics would be nice, but looks ok. whats the bore step like? do the pistons rock? does it turn over with very little effort and no tight spots? ie is the turning force the same for the full 360 degrees?

My phone camera is fucked it wont take close up pics lol no real step tbh, the pistons dont rock and it turns over ok.


Originally Posted by xr2wishy
looks ok, i'd hone it and fit new rings, check for a lip on the top of the bores to indicate excessive wear.



very big brakes need 16" rims, i have just the things for you

lol i would never get 16's on without xr2 kit unless i got all sensible with the ride height lol
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Old Nov 30, 2012 | 04:24 PM
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Originally Posted by lozi
It turns over fine but it definatly needs alot of work i think its been sat for a while.





My phone camera is fucked it wont take close up pics lol no real step tbh, the pistons dont rock and it turns over ok.





lol i would never get 16's on without xr2 kit unless i got all sensible with the ride height lol

Then leave the bottom end how it is. Clean the deck with a nylon or brass brush (no steel brush or emery cloth or polish) fit a new ford or payen head gasket and way you ago. Engine looks reasonably fresh and well maintained, no burnt oil deposits or sludge anywhere. You'll do more harm than good opening it up for a yee haw hone and rings
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Old Nov 30, 2012 | 06:01 PM
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Coming on nicely, will be a missile with a CVH turbo.
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Old Nov 30, 2012 | 09:34 PM
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Cool progress matey.
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Old Nov 30, 2012 | 10:33 PM
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Cracking project
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Old Dec 1, 2012 | 04:19 PM
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Originally Posted by the_frozen_one
Then leave the bottom end how it is. Clean the deck with a nylon or brass brush (no steel brush or emery cloth or polish) fit a new ford or payen head gasket and way you ago. Engine looks reasonably fresh and well maintained, no burnt oil deposits or sludge anywhere. You'll do more harm than good opening it up for a yee haw hone and rings


Thanks for the advice, ive decided to go overbore and forged pistons as i will never trust this bottom end even if it is ok so im going to start stripping it today.


Originally Posted by gjh
Coming on nicely, will be a missile with a CVH turbo.

I hope so!

Originally Posted by Glenn_
Cool progress matey.

Its getting there im just spending my time refurbing bits atm



Originally Posted by QplateRST!
Cracking project

Thanks, nothing compared to your of course lol
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Old Dec 1, 2012 | 04:55 PM
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Originally Posted by lozi
Thanks for the advice, ive decided to go overbore and forged pistons as i will never trust this bottom end even if it is ok so im going to start stripping it today.





I hope so!




Its getting there im just spending my time refurbing bits atm






Thanks, nothing compared to your of course lol
Pm me have everything you need, brand new going cheap pistons, rods, bearings, crank, block head.
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Old Dec 3, 2012 | 05:44 PM
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Done abit more work on some bits, i have refurbed the main parts of my EFi inlet, which now im going cossie managment i wont even use but i suppose it will sell easier all minted up!

So i grit blasted and black 1488 Xylan coated the main body of the inlet plus a bracket and the fuel rail, i cooked the two halves of the inlet before i coated them to get any contaminants out of the inside/surface before i started to prevent it ruining the coating as that was cooked.


Grit Blasted








Xylan Coated










Last edited by lozi; Dec 3, 2012 at 05:47 PM.
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Old Dec 3, 2012 | 05:52 PM
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Good work. Cool fiesta
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