demolition_man

I've been doing this project for three years now while i'm at uni - progress has been slow due to a lack of funds
and the fact that the car is in cheshire and i'm at uni in coventry. However with my final exams in the next few

weeks and summer planned in the garage, there should be some real progress soon

I bought the shell off ebay for a bargain £211 it was sold as an "autograss car" but basically it is a RWD converted shell based on mk2 escort running gear. The shell was amazingly solid, all of the uncovered areas had a smattering of surface rust, but other than that it was good. However, at some point the roof has been replaced and it was a bodge job, so I had to redo that.

I knew I wanted a turbo engine in it, just because i wanted it to be special for weekends, and only a turbo engine would give me that, plus i was at the pod a lot seeing that blue mk2 escort doing 11s and it blew me away!

Originally the plan was to put a cosworth turbo in it, however after much deliberation I decided that a zetec turbo was the better option as the cosworths are so expensive that I could build a much stronger zetec engine, with more power for less money.

At this point I have had the car for three years, which has been about 3 months working on the car and the rest saving money to buy parts!

I'll get on with the pictures, as there are many

When i first bought the shell, in a lockup in Coventry - very dusty!:




The first job was to strip a number of layers of paint from the interior and engine bay, and then strip all of the

surface rust from underneith, which was left unprotected:


(in this pic u can see the shagged roof)



in this picture the tin foil was a failed attempt at making fibreglass headlights, if anyone has mk2 fiesta quads

then let me know PLEASE! it also shows the front valance removed, all of the wings and front/rear valance are kevlar





These pictures are the engine bay freshly coated in zinc primer, as you can see the entire engine bay is bespoke, using a chopped cross member to allow the engine to be mounted further back but extend the track forwards. The massive hole in the passenger footwell area was where the exhaust manifold previously entered the cabin!

The underside was stripped (horrible job) and then coated with zinc primer and hammerite, just to protect it





The hole in the above picture is behind where the passenger seat would be, where the exhaust exitted the cabin



This shows the back end, it is six linked and the boot floor has been replaced with this frame setup - which i was damn glad of as the mk2 floors rot like no tomorrow.

So that is a bit of an intro - that was three years ago, I did a bit of research about these fiestas, and i found only 4 including my own, all done obviously by the same company as they are identical, the best of which was shown to me by TIFF off this site, he said it was his friends fiesta and, needless to say it put a big smile on my face:

http://img.photobucket.com/albums/06...RWDfiesta1.jpg
http://img.photobucket.com/albums/06...RWDfiesta6.jpg
http://img.photobucket.com/albums/06...RWDfiesta2.jpg
http://img.photobucket.com/albums/06...RWDfiesta3.jpg
http://img.photobucket.com/albums/06...RWDfiesta4.jpg
http://img.photobucket.com/albums/06...RWDfiesta7.jpg
http://img.photobucket.com/albums/06...RWDfiesta8.jpg
http://img.photobucket.com/albums/06...WDfiesta11.jpg
http://img.photobucket.com/albums/06...WDfiesta10.jpg
http://img.photobucket.com/albums/06...RWDfiesta9.jpg
http://img.photobucket.com/albums/06...atDonnopit.jpg

If mine comes out anything like that one I will be a happy man although I will try to do something different with

the headlights as I'm not a huge fan of these smoothed ones really.

So, unfortunately i have lost a load of pictures due to my hard disk giving up, but they were mainly bits of running gear that i had bought, and the progress pics from swapping the roof, but I may be able to find them on a CD or something and i'll upload them at a later date

The running gear i have purchased so far consists of:

Front:
big fat bilstein coilovers
eccentric top mounts
adjustable track control arms
adjustable compression struts
alloy hubs
2wd cosworth 4 pots and discs
rose jointed throughout
put a quick rack in it as well, and heavy duty steering coupling

(i'm lucky as i live close to R.A.C.E so all the escort parts are easily found)

rear:
coilovers
NOTHING ELSE :S
will have watts linkage and 4 link although these will be bought with the axle (chaching)

Transmission:
Cosworth T5
6 paddle clutch
NO AXLE! :S
need to get money together for an axle (they aint cheap) so undecided on either an atlas or this new Hercules from rally design, going to wait and hear peoples opinions.
Need to get a custom prop to suit the axle as and when i get it


Anyway, my mum set out conditions when i bought the car, that it would have to go in a garage, as she didnt want the place turning into a scrap yard (no respect, but ultimately correct) so my first major expense was a concrete sectional garage, never had a garage to work in before and it really is bliss however after doing the roof the place was a fooookin mess with about an inch of dust covering everything, so on monday i decided that enough was enough and it needed to be cleaned out so I put the front end on wheels and rolled it out of the garage for the

first time in two years

These are up to date pictures of the shell:











Its sitting very high at the front as, being a numpty, i set the comp struts/tcas when the sus struts were drooped - so it's forcing the shell upwards :S nevermind, would have been nice to drop it on its arse for the pictures!

You can see it's going to need some bad ass offset on the wheels as these standard fiesta offset 17s are lost in the arches, u can see the fibreglass boot lid as well and the mk4 fiesta dash fits snugly

well, i'm getting pretty tired of typing now! I have all of the components i need for the engine, except a suitable inlet system and a TTV flywheel to mate the zetec and the T5 (which i will order shortly).

Originally i had a 2.0 zetec engine which i stripped and i bought some accralite forged pistons and eagle steel rods, however when i came to buying a turbo i met Austin Ward who explained to me that the pistons werent suitable, the Burton website is pretty missleading and these pistons are too high compression to use with silvertop rods, I think they are meant for a zvh rather than a zetec turbo.

In anycase, I bought Austins T34 and external wastegate along with his block and crank, it made sense to buy the parts that I knew where done right and i knew would produce the kind of power i was looking for (he ran this engine at around 400bhp)

So my next problem was pistons, Austin put me in touch with Ian Howell who ordered me some custom CP pistons from the states to suit my eagle rods, and they're lovely should say a big thank u to Austin as he has helped me a lot with the engine, and a lot of the parts have been bought from him sooo... THANKS!

I then sent the block off to be honed and bought bits and bobs such as bearings and Ians turbo spec exhaust cam, it's probably easiest to just show u the pictures as there is a lot to go through:



the head will go on in standard form (probably) ian told me that with a standard head and his exhaust cam i should

see 350bhp, which in my first turbo car, and my first rwd car, is more than enough - i plan to up the power once i have got used to the car.
The head has been stripped and i've cleaned it and obviously all new valve stem seals etc



CP Pistons, 7.4-1 compression


this is the exhaust off Austins Westfield, it will have to be modified to fit the fiesta, i want it to pop out just behind the wheel, in this pic there is also a pulsar GTI-R plenum i've been playing with as an inlet option, although i've pretty much abandoned the idea now.


burton rwd conversion baffled and gated sump


external wastegate and screamer pipe


again and u can also see the carb inlet that i might use as part of an inlet system


turbo - T34 with .48


again, with a my friends phone there for a size comparison


cosworth throttle body and GTIR bodies, depending on which route i go, will probably use the single body.


HD cam belt, denso iridium plugs, HD valve springs, cosworth breather


piper verniers


bearings


machined block






cams, havent taken the new one out of its packaging incase it corrodes whilst it is standing


random gaskets, not sure about the quality of these so i might look into some differnet ones


multi layer steel head gasket


charge cooler - sposed to be good for 1200bhp so, more than capable of satisfying my cooling needs, fooking huge though!


6 paddle cosworth clutch


10mm quad core leads


t5 box


my engine laid out


doors off the donor (my beloved first car )


Ford performance white, the brightest of the whites

The colour scheme will be white, with blue stripes down the sides - like on the ST fiestas. something along those

lines anyway


random snap of the timing gauge etc


poly carb windows

Well i've got a headache from writing this so i hope u find it interesting

i've got my exams coming up so there wont be any updates soon but after that it should be thick and fast, please feel free to point out if u think i'm making a mistake or offer help or whatever, i know the cars appearance wont be to everyones tastes, pretty garish etc, but i like it!

Brian

iTrader: (2)

Looks a excellent project

Keep us updated


Brian

lucasdemoley

This is so cool! I'll be watching this one as i love the wee fiesta!

TrevCannon

DITTO!!! ^

XRT_si

iTrader: (2)

WIll be a monster that mate!

Well done

demolition_man

glad u like it

Bomber

Cool project Come on over to www.xrtwo.com forums - plenty of people will want to see this!

arkley

looks mint this mate

Charlie Chalk

iTrader: (1)

SaqsS2turbo

GINGExR2 T

iTrader: (1)

Top stuff mate, gonna be awesome

Fiestamatt

just remembered, they r my beers u git, i want em.

Ha loving it mate
Cant wait to get some long hours working on it over the summer.

Matt

Munch

wow, what a project!


Keep us updated

Hobomassiv

Nice

Red16

nice collection of parts you got there with those and the shell you have it has the potential to be a right beast

bailey1

iTrader: (2)

danrs2k

Thats going to be MENTAL mate

demolition_man

so pleased u like it - it would be easy to say it looks rough, but u can obviously see the potential as i can thanks a lot for the comments

stoo2000

You still located in coventry?

looks like a machine to wipe the smiles of them bleedin chav's around here.....

demolition_man

ha ha, u do see some crap in cov, particularly the centre. I'm still in cov for uni but the car is at home up north

Rab

I'm going to watching this!

cjay2004

looks like a nice project

theres 1 on ebay 4sale atm http://cgi.ebay.co.uk/Ford-Fiesta-rw...QQcmdZViewItem

demolition_man

yeah, i've seen that - my friend is interested in it, looks like it would clean up nicely

luke89

iTrader: (1)

awsome project im just putin a zetec in my saph , what flywheel you using for that clutch i may also go with a t5 insead of a type 9 gear box dose it bolt stright up to the block ? also how much was your sump ? if you dont mind lol

demolition_man

hi mate, the bellhousing bolt pattern is the same as all (i believe) ford bellhousing bolt patterns are the same, so any box would bolt to the zetec it just depends on the flywheel/clutch.

I looked into the options and i found that the only real option was to use a custom flywheel from TTV racing(http://www.ttvracing.com/), which will accept a cosworth clutch and starter motor. The type 9 box wont take that much power and i dont spose the ratios would be right for a turbo car, although u could buy a flywheel from burton power which is suitable for a pinto clutch and type 9 box. I havent ordered mine yet - next on the list.

Technically you could use the standard zetec flywheel with the T5 box but u have to find a suitable starter motor as the bell housing puts the starter in a different position which wont engage the teeth in the zetec flywheel. you can't use the cosworth flywheel as it is a different bolt pattern on the crank. I think that you will pay more for a zetec clutch which will be up to big power as opposed to the more common cosworth clutch, so shelling out for the custom flywheel (£188) is probably cost effective in the long run

The sumps are £470 from burton power, i got mine second hand and i can't remember how much i paid for it - 300 i think but it has had the oil return welded into it as well and it also has the optional extra windage tray. They dont come up very often second hand though, i was looking for a long time.

I noticed that burton have started to sell a cheaper stell sump though so that might be worth a look?

Hope that helps

AustenW

You have a nice collection of bits there.

Get in touch if you get stuck with anything

luke89

iTrader: (1)

demolition_man
thanks for the info mate realy helps alot , i think i will start off using a rwd cvh flywheel and starter with a erst clutch , only after 220ish from my zetec turbo for the time being will build up a proper spec one soon ( waitin to find out if im goin to be locked away soo no point starting yet ) i think ill have to have a look at some of the burton shit as well as a custom flyhweel for the bigger power engine i will build in the futer

thanks for the help

NEEDFORSPEED

updates!!

demolition_man

he he, like i say i'm not at home at the moment so no updates - i'll be home towards the end of the month so i'll pick it up then. i'm still on the lookout for parts, specifically quads and an inlet system.. i was pointed in the direction of this site:

http://www.rossmachineracing.com/intakeparts.html

i was thinking of getting these bits imported, just cautious as i dont want to get stung with import duty/tax so... does anyone know of a uk distributor or where i may be able to buy similar parts?

thanks a lot

when i get some work done u will be the first to know

Garage19

Demo man,

Would be happy to price you up for fabrication of an inlet manifold with internal trumpets if you get stuck.

Glad you have found the TTV flywheel. I was the one who first approched them with the design as i needed something for a friends car i was working on. With a little help from Alan the design was finallised and he worked his CNC magic. There are photos of the first prototype in my kit car project thread and i also supplied Dan from FastFord with one for his zetec turbo project.

They really are a bargain at £188.

Garage19

I get Alan at TTV racing to make similar parts for my manifolds.

Garage19

My only worry is what rar axle are you going to use to take all this torque?

Or are you going to rely on the light weight, less moment of inertia and spin before breaks theory?

demolition_man

hmm, i'll send ttv an email then - thanks

the 2 choices are a thick tubed atlas with motorsport diff or a "hercules" from rally design - i still havent done any real research into the latter although it's advertised specification looks as though it will be up to the job.

all the big power mk2 escorts are on an atlas, which is great and RACE would build one up for me and it would be more than capable of the power i'll be running but the hercules axle has only just become available - so it may be good and it is cheaper than an atlas - but i need to see some people using it before i can justify buying one.

in either case i'll need to wait til i get a decent job before i can afford to shell out all that money at once... probably end of the summer/winter :S we'll see

wheel spin is the one thing i want to avoid, as fat on the back as possible - in the future i'll look into launch/traction control. but i just want to get it running first and then worry about upgrading it

demolition_man

forgot to ask - does anybody know about the T5 gearbox mount? will the standard one be ok or would i need to buy the uprated one? am i right in saying that the uprated one does away with the rubber bush?

i'll probably end up making a new one entirely but if the standard one will be up to the job i may just use that

thanks a lot

demolition_man

ok, update time... just a small rather dull one but still.

i started work again this week... started off by making up a steering column bractet to mount the escort rack to the original fiesta mounting point.

to me it looks a bit ropey so i'll probably re-do it, althoiugh it wont be in sight so i might not bother. anyway - pics:







after this i decided it was time to bit the bullet and hack out the original engine mounts that had been welded to the chassis legs, took ages with various sizes of grinding disc, a club hammer and a metal drift but eventually both sides were out:







I then offered up one of the new chassis mounts - just for the impression:



Next i welded the mounts together and attached the base plates up to a dummy block, which i will use for test fitting:







Then onto todays job, which was to flat down the interior, apply a couple of coats of primer and then mask up all the seams and apply the seam sealer - it was a dull job but it looks quite neat so happy days
Pics:









that's all for now, i'll attack it again tomorrow - next job is to put the back end of the roll cage in then weld up the drivers seat mount. then it's onto positioning the engine and gearbox and making up a new gearbox mount.

For now though it's off to the pub for the football

arkley

Coming along nicely mate, you might think it's dull but it's all vital and most importantly will be worth it in the long run.
Keep the updates coming

fezzajsy

iTrader: (9)

nice

smitsturbo

some very good work going on there, its going to be a monster

ZTSI

this looks so nice cant wait to see what it will looklike ones its finished,
kepp up the good work mate

COSWORTHFORDS