M K

iTrader: (9)

Thanks for the kind comments guys


I know what you mean about putting a disc on top of the powder coat but i have had all my hubs done like this on previous cars and never had any problems with disc run out or feedback through the pedal when braking etc, its only a very light coat on the face,


Cheers Andy, the engine mounts are powder coated in Aluminium Pearl Silver and the speedo drive housing is wet painted in Aluma-Blast

It cost a fair few quid as there was a hell of a lot of stuff that had to be done put it that way lol and theres still a bit more i need doing!

M K

iTrader: (9)

Finally started to put a few things back together after months of stripping them down and taking them apart lol

It's not a lot but it's a start



Got the Citroen Saxo electric power steering pump built back up


Also pressed the alloy bushes into the newly coated gear lever cradle


Roll bar blades bolted onto front and rear bars, just need to get the drop links and brackets anodised


Steering rack fitted with alloy bushes bolted to newly coated x-member, and home made Aeroquip adapters fitted along with plated cooling pipes


And last but not least, speedo drive housing and sump cross shaft re fitted to big wing sump, just need to order a new Viton oil seal


Problem i have now is because the parts are ready but the car is not ready to fit them too, i am seriously running out of room lol

whizzisat114

iTrader: (2)

Nice parts Mark its gonna be one of the best fiesta's out there

fezzajsy

iTrader: (9)

very nice

M K

iTrader: (9)

Thanks guys

Next real big step is paint, which will give me a bit of breathing space, just waiting on a date for that,

Thinking if going grey now the same a rich's cossie, Audi Lava Grey I think it's called

c20tbo

iTrader: (1)

Its all the little things that take the time bud.

M K

iTrader: (9)

Few more parts back together today,

The horrendously messy job of building back up the driveshafts after the bars were powder coated is done, i HATE cv grease



Wrc rear link arms and rear compression struts and also front compression struts and tca's built back up and all threads copper slipped,
just need to order some new rose joints and adjusters for the tca's,



Slowly but surely

focus 4x4

Nice progress Marc , defo go gery with this one bud . itll be the nuts.

M K

iTrader: (9)

Cheers Simon

Gaz who is going to do the painting should be back Monday week so hopefully soon il have a date for paint

M K

iTrader: (9)

I de-tango'd the facelift headlights as suggested and it looks much better now,

I also re fitted the intercooler/rad/fan set up see how much i have the space it down so the bonnet shuts fully as it was touching before when bolted up fully,

few pics













When i got my carbon bonnet ages ago i noticed it didn't sit well on my panels, not sure i this is down to the bonnet being moulded badly of whether is the front end, but i think that is unlikely as Andrew lined it all up pukka and in the pics with one of his metal bonnets it lines up nice so not sure what to do with this bonnet

see that the front headlight edge sits nice and the scuttle panel sits nice but in the middle of the wing it sits proud! as if the bonnet has been curved to much when moulded id say



Gonna have to source a proper ford item to try and then probably out the carbon one or just have as a spare

Thanks
Marc

dingla rs

iTrader: (2)

aero catch above the light on each side job sortd

M K

iTrader: (9)

Also can anybody with Aero dynamic knowledge tell me the main advantages of having these air scoops under the front splitter, i assume it is to direct air from under the car creating a kind of vacuum or am i way off???

the scoops go from under the splitter at the front each side




And are directed out of the small vent at the far sides of the bumper


All the other jwrc kits i have seen cars fitted with dont have this

Always interested to learn about things like Aero dynamics

focus 4x4

Looks "FAT" , gonna be awesome in paint Marc.

focus 4x4

Either brake cooling or Extra front end down force at a guess mate

M K

iTrader: (9)

Not using Aerocatches, and also there is nothing behind the light there to fix to, just air lol, may see what its like with bonnet pins fitted a bit further across where the rubber stops used to go originally

zetaboostboy522bhp

hi mark i sure the vents in the front bumper were fitted as air duct for the massive brakes fitted to the jwrc cars because of the width of the arches not allowing any air in , i dont think its anything to do with aeros but i might be wrong
good work by the way mark it always looks better each time i visit your thread and well done for the machine work , its always nice to make your own items

cheers paul

JonnyBravo

I'd say brake cooling Marc.

Cheers for the PM back btw

gus

iTrader: (1)

doesnt vent to brakes tho does it chick?

in front bumper out under the splitter

fezzajsy

iTrader: (9)

MK what size bolts did you use to bolt down the steering rack to c.member pliz?
ps.good progress

wellens7

great project

the lower duct has nothing to do with brake cooling as it doesnt feed the wheel arch with air on the s1600 fiesta (jwrc) it was supposed to create a small depression under the front of the car to provide some downforce , the air passes the side of the bumper and creates a depression in the duct and draws air from under the front splitter , though as soon as the splitter saw a stage it was damaged or ripped off .

i would change your cooling package as your spending so much money on the rest of the car , since early 2000 no wrc car has had rad / intercooler together as they influence each others temperatures , also you can make a cooler more efficent by running at a angle as this slows the cool air down so cools better , see pic below to show you the current setup on the fiesta wrc the coolers are the same size as 2006 on focus wrc


also the tuning scene is so far behind motorsport, all the intercoolers / pipes and throttlebodies decreased in size on 2006 on wrc to improve response and there for build boost quicker ( bigger isnt always best ) all around 50mm inc throttle body , you may say but cause they are restricted they dont have big power , however for a pr event in abu dhabi we removed the restricter on a focus and remapped it on decent fuel and it had over 600bhp and out dragged a f1 car ( its on youtube ) with out putting a bigger intercooler or throttle body etc , im not having a dig im just telling you how different the tuning scene thinks is the right path and top level motorsport design is different

back of fiesta wrc cooling package and charge pipes



also compression ratio talk always makes me hit my head against a wall , lower the compression because your running more boost , yeah make it even less driveable ! the 05 focus wrc actual ( not the spec you get in magazines ) cr was 12:1 and it ran 3 bar of boost (4 bar if you include atmospheric pressure ) just by having good qualiy management with knock control and the right fuel .

im sure people will disagree with these coments but when you work in motorsport for years and years you get to know the tweeks it it good to pass them on

mark keep up the good work

M K

iTrader: (9)

Will check for you tomorrow mate as can't remember right now,

Wellens7 - some great info there

As for the cooling package, it is still possible for me to change so by looking at what you have posted i will certainly look into it, whether it be sooner or later and see what is possible with the room i have, these things will be what makes the difference if i am ever to race the car properly in any sort of event as you can not just pull in the pits for 10mins to let it cool down unless you want to be lapped by every man and his dog lol

In your photo of the current wrc fiesta, am i right in saying the top is the intercooler and the lower slanted is the radiator?

As for engine comression ratio's i have no idea, that will all be left to Tommy @ Field Motorsport to sort out as he is building/dyno'ing and mapping the engine

Thanks
Marc

M K

iTrader: (9)

Forgot to mention tonight i was browsing ebay and spotted a complete AP 7.25" twin plate clutch for a cosworth complete with flywheel,

Need to get the clutch plates re-done or buy new but that is still well cheap as a flywheel alone to suit a 7.25" clutch would cost more than that and i had provisionally budgeted Ł800 in my head for clutch and flywheel so happy with that

erjones

Still loving this project and always keep an eye on it!

For cooling like you mention, take you looked at the Rallycross one then? As guess they are closer to your set up

M K

iTrader: (9)

Thanks mate

Nearly all rallycross boys on all the cars, not just fiesta's run the rad in the boot and that is not an option for me

wellens7

hi mark,

the rad is at the bottom and the intercooler is on top you could use your current rad just repostioned

i could help out if your interested in some new ap clutch plates if so pm me at a good price

my compression rant wasnt at you it was just a general rant

OldDan

Would love to see more pictures that you have wellens - I guess you work at M-Sport? What is it you do there?

M K

iTrader: (9)

Built the front hubs back up with the new bearings,

I will switch to grp a uprights at a later date im sure but for now i will have to stick with these and probable change to grp a after the cars first few months on the track as i can use my tca's and comp struts and bilsteins i already have and will just have to get the actual uprights



Also drilled and tapped the 7.5" rear diff casing for the oil cooler/pump feed and return, ready for -8 x M16x1.5 fittings

return is on the top right hand of the casing, and the feed is at the bottom right of the back plate as low down as i can go, can't go any lower as the bar for mounting the diff sits below the black pen line,

jigsaw

i just love your attention to detail - i'm just itching to see it built, as i'm sure you are

i would love to build one of these to this sort of spec - simply amazing

Mint FRST

iTrader: (1)

Do you have the link?

Great progress Mark BTW

Edit: Found it!

http://www.youtube.com/watch?v=zsvLAjAZXbg

wellens7

old dan

im a no1 mechanic for said wrc team

just a few pics dont want to take away from marks great build

donkey

handbrake and diff release

turbo location

front upright and damper

rear suspension

focus wrc cam and crank expensive !!

OldDan

Wow, what a serious bit of kit. Love the cams. I guess you had a hand in building a few of them? Looks impressive. Thanks.

erjones

Sorry to go off topic but guess M-Sport bit more relaxed on pictures? Some impressive bits of kit in those pictures and would love that job! I do get to see some nice new things when at work which is Ford Dunton but they are very strict on photography which i understand why seeing as its prototype parts/cars.

COLEYST200

iTrader: (3)

O MY GOD that lot is just a work of art

wellens7

there is always a spoil sport ; ) i believe there is a fiesta wrc at the dunton soon for a show or some event

erjones

lol I haven't a problem with it, end of the day if not you will be a private team

Yeah mid July i believe for Duntons Vehicle Enthusuasts day, was the Focus last year with Latvala doing passenger rides for a select few along with Tom Chilton in his Focus

whizzisat114

iTrader: (2)

Thanks for sharing m8 nice to see the very fore front of motorsport evolution.
Truely inspiring

BlairM

Coming along very nicely Marc, don't comment much but always enjoy having a look to see what you're latest bit of engineering is. Top notch fella.

Nice to see the WRC stuff there as well.

whizzisat114

iTrader: (2)

wellens7

Does the wrc car have a diff release attatched to the handbrake so it dissenables the drive through the diff when there doing handbrake turns?
Sorry if it's a dumb question just not seen it before.

M K

iTrader: (9)

Yes mate all the wrc and 99% of grp a cars run handbrake release

wellens7

on current s2000 and wrc cars there is no centre diff , so there is a clutch pack built in the rear diff , when you pull the handbrake it acts on the diff release first then the brake cylinder otherwise if it doesnt work when the handbrake is pulled all four wheels lock as there is no centre diff

on active centre diffs ie escort late grpa wrc , focus wrc there is no clutch pack in the rear diff when you pull the handbrake it acts a electrical position switch which releases the hydrualic pressure which is adding preload to the diff by way of a piston acting on the diff plates , you pull the handbrake and it supplies no pressure to the diff so the diff is open so the rear wheels can lock .