Hi,
I have enjoyed looking at everyone else's project so I thought I should put mine up. It started it a long, long while ago and have just started working on it again. Its a E reg XR2 with the Xr4x4 floor pan, with v6 Cosworth up front waiting for the turbos to be fitted. All the work I am doing myself and looking that some off the working I did before I will properly cut it up and start again. This is the start to my project, hope you enjoy.

 

So as most project start I stripped it down to see what I had.

 

So next I cut off all the bits I didn't need





Just need a new floor?????

 

Donor vehicle number two, this is a great car I found it cheap, it is a 2 litre DOHC 4x4 Ghia. It was the cheapest way to get a floor plan as I'm not cutting up a cosworth for it. Lovely drive home thou.

 

Wow this looks like an awesome project mate will watch with interest

 

This is when it gets interesting, once again I strip the car.
My neighbours love me.



Then I unpicked the car at the seam.

 

Cut 321mm out the middle, jointed it back up, checking square etc. all good, welded up and braced. The length of wheel base is now the same as fiesta.

 

i be keeping a eye on this build looks interesting

 

Wow! Cool project Keep it up!

 

Thanks everyone for your comments

Well I have a floor pan and I have a fiesta so i'll try mating the two together like a bad biology lesson.

First attempt, not bad, tiny bit high in the back for my taste.



Getting there!!



Drop the wings on to get the full effect, nearly finish.

 

ouu! Getting there I think it will be a fun car when finished

 

That looks very interesting.
Are you going to have enough room for the intercooler and radiator when you fit the fiesta front panel?
I'm thinking it will be tight to say the least!
Keep us updated!

 

Looks an interesting build this one

 

I like this build already, well done.

 

Cool project, keep the updates coming

 

Very different I like it fair play

 

hi what V6 engine will you be useing ?

 

Top work and well done for doing all the work yourself.

Do you still have the big fat bulk head seal from the sierra?if so would you sell it??

 

That's Awesome
Work so far mate. There's a guy who drifts at our local banger track on Wednesday nights and he adds all sorts of shells onto e36 floorpans, my fave is the 2.8i Capri shell, drifts perfect and sounds Awesome as it's mainly a 328i

Edited to say he has a Subaru Impreza e36 too lol

 

nice project are you selling any bits from the sierra

 

Thanks for the comments and to answer some questions

155lee - Yes it will be tight but a electric fan will help, if not intercooler in front, radiator in the back.

V6gerry - it's a cosworth v6 24v

Glenn and Ossie Cossie - I started this project about 7 years ago, and had a break and started again so the donor cars went years ago so no parts for sale, sorry

 

Working on tidy up the bulkhead



Front Panel on



Dropped engine in out of xr4x4, bought this as it has all the bit I need to add the v6 cosworth engine to 4x4 system e.g. flywheel, bell housing etc.

 

The rear panel was rusty and I have problems with the two floor levels. At the time this was my solution which I don't like now, I think I will cut this out and make something simpler and maybe make new wheel tubs.

 

Amazing job! Must be a quick xr2 in the end and suprising some people along the way

 

So nows the time to see if the cosworth v6 fits, so took out the old V6, converted the 24v to manual gear box and back in.





Looks big in the fiesta



Oh, looks like the sleeper look is out the question, sticks out the bonnet.

 

Cut the top turrets to take adjustable top mounts.
The roll cage will pick up these later.

 

Nice welding on there.

 

That's gonna be mega fun

 

While at the front I thought I'd have a go at building my own front suspension and this is the end result. The ball joint is a MK3 escort, 5 pound off ebay so cheap to replace, and polybush the inner due to the poor road conditions around here small amount of give compare to rose joint.

 

Next the front brakes, the E38 BMW calipers and Rs Focus discs. I can use these because I have Xr4x4 hubs and the tabs to the disc have the correct offset, compared to cosworth 4x4 have different hubs. There is nothing new with this setup, but for the cost its amazing.

 

Seats arrived this week.



Also so did my CDS tube. I can't be the only person to get excited about some tube , home made roll cage here I come.

 

Looking good, how will you weld the cage with the roof in place?

 

Good question because the plan I had was to put a carbon fibre roof on, but they seem not to be available any more😡. So I either drop it though the floor weld it and then reposition it or find another roof. I'd like to fit another roof so I can get rid off the sunroof. Two stones one bird😃

 

take it the sleeper looks totally gone due to the engine/bonnet. Maybe get bonnet raisers of some sort or even a clio bonnet bulge to try get that look back.

Are you able to keep the wheels inside the archs or is this getting wider xr2 arch kit or something?

Good work and keep the progress coming

 

Hi, I haven't made a decision for bonnet yet. I'm going to fabricate a new intake manifold with skyline throttle body then see what's sticking out. The fiesta has a bulge shape already in it which I may extend for a sleeper plus look Wheel arch I would have love for it to fit under standard arches but it's not happening. I got the few options but finish rear suspension then decide.

 

do the brembos bolt straight on to the xr4 hubs or do you need a bracket to space them out for the discs? looking awesome so far!

 

Welding in a roll cage with a roof still on is very simple . Wot you do is put the main hoop in And the front bars tack them all together then you cut a hole next to the hoop then you put a ratchet strap on the hoop and pull it together so the hoop drops throw the holes witch as the cage is lower in the car it gives you the room to weld the top of the cage . Then lift the cage back up undo the strap and weld the floor up job done

 

Thanks for your comments
Yes you still need a bracket as show below. When looking the bolts are an odd thread so I found it cheaper to buy a kits, £56 of ebay can't beat it.

 

Thanks for the advice, I have done that before and it works well. I have made the decided that making a carbon fiber roof is the only way I will be happy. I have found the only way to learn is by doing, so big learning curve coming soon.

 

Im loving this project. The front brakes are cool too. How much did the brake kit cost you? Ie calipers discs pads brackets.