Kneller's Focus RS Mk1 project thread
 

Hi guys, I've been on here a while but haven't posted much, so I thought I'd try and become a bit more active and get a project thread up.

Apologies in advance, it's a fairly substantial read, but there are lots of pictures!

I bought it on 21/01/2011 from the brother of a friend from work, so I knew it had been looked after!

Most of it will be copied over from another forum, so appologies in advance if it's a bit confusing!

First of all, here's a list of it's current spec and future plans:

Mods:

- Graham Goode Racing tubular 4-1 manifold
- Decat
- BCS Automotive full 3" exhaust system
- CPE Group A air filter relocated to behind passenger headlight
- Custom spec Pro Alloy intercooler
- AE+ Tuna remap
- Forge adjustable actuator
- Gizzmo MS-IBC boost controller (22psi highest setting)
- Compbrake recirc valve
- Various Roose hoses
- ST170 deflector panel for air filter
- Front fogs removed for brake ducting
- Scangauge II
- Stack boost gauge
- Rear 12.5mm axle spacers
- FK adjustable coilovers
- Vredestein Ultrac Sessanta tyres at the front
- Goodyear Eagle F1 Asymmetric 2 tyres at the back (soon to be all-round)
- Ferodo DS2500 front pads
- EBC Redstuff rear pads
- Smoked headlights
- Smoked side repeaters and front indicators
- Genuine carbon fibre fog light surrounds
- Genuine carbon fibre front splitter (resprayed black after being repaired)
- Private plate
- Wheels refurbed in standard silver
- US Spec rear lights
- Euro spec reverse light
- DMB carbon/chrome badge overlays
- Colour coded door handles and front grille surround
- Ghia intermittent wiper stalk
- Ghia map light
- Carbon fibre effect stereo surround

I'll start from the beginning :D

A few pics from the previous owner before I picked her up:
https://farm6.static.flickr.com/5287...b75cc3ef50.jpg
https://farm6.static.flickr.com/5203...e38ed2605b.jpg
https://farm6.static.flickr.com/5041...780cb41382.jpg

The first bits I bought (before I'd even picked the car up):
https://i66.photobucket.com/albums/h...4/IMG_2634.jpg
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And from a couple of days after I picked it up, went for a photoshoot with Lee (Challis)
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I then fitted my HIDs, sidelights, and full size front plate:
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I then painted my rear calipers silver to match the fronts:
Before:
https://farm6.static.flickr.com/5293...5def11d5_b.jpg

After:
https://farm6.static.flickr.com/5017...32328b59_b.jpg

I also got a spare set of headlights from a friend at work, which I sprayed satin black.

Before:
https://farm6.static.flickr.com/5094...821d5494_b.jpg

After:
https://i66.photobucket.com/albums/h...4/2ba48b42.jpg
https://farm6.static.flickr.com/5013...f4411400_b.jpg

Then I fitted my new flexi and decat pipe:
https://i66.photobucket.com/albums/h...4/b3976d7d.jpg

Fitted some LED number plate lights:
Attachment 139777

Then I noticed the car wasn't driving properly, felt like it had a boost leak. So I ordered and fitted the following:
- Blue Roose replacement non-return valve hoses
- Blue Roose recirc valve hose
- Blue vacuum tubing
- Compbrake billet aluminium recirc valve (FRS' don't like atmospheric DV's)

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Then I went to AMD, got her on the rollers and made 277.2bhp and 324.3lb/ft. Most people said I wouldn't make over 300lb/ft, so I was pretty pleased!

A quick pic of the graph :D
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I then fitted a Filler Phil easy adjust actuator :D set up to run direct 22psi :P

Then I ordered and fitted some DMB carbon/chrome overlays:
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And removed the Armourfend from the front end....
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Then the car sat for a couple of days looking like this:
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Until this happened:
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Went for standard silver as I'd had black on my last 3 cars..

Then I fitted my Scangauge. Essential on the RS as it has no water temp gauge and no way of monitoring inlet temps..
Attachment 139799

Then went to Ford Fair and had a blast round track :D
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Then had a custom exhaust tip welded onto my 'Goose system:
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I then fitted a new boost gauge:
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Got my calipers painted :D they need a couple of coats of lacquer still, but the painting is finished. I'll also be getting some orange Brembo decals to go on :)

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Also gave the throttle elbow a coat of paint too, as well as giving the engine bay a very quick tidy!

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Cheers, was a very quick clean, I'm getting all of the bits cleaned up and painted to get them all looking new again!

Managed to get a few other bits done today :D

First of all, got my calipers lacquered:

Attachment 139813

Then I sprayed the RS logo onto the chargecooler rad:

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I then re-fitted my throttle elbow:

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And got some caps etc painted up:

Attachment 139818


I then got in contact with Nigel at BCS Automotive and managed to sort a VERY good price on a full 3" exhaust system :D

For anyone who doesn't know, Nigel used to work at Blueflame, but has since started BCS Automotive alongside someone else and they are now creating exhausts for lots of different cars.

Their exhausts have got very good reviews from the few people that have them fitted (there aren't a lot of mk1 FRS owners at the minute, but I'm hoping to get their name out there a bit more)

The system is full 3" bore, as opposed to my current 2.75". This should benefit me when it comes to fitting the hybrid turbo. It's also made from 304 grade stainless steel and is fully TIG welded, so looks the part too!

First of all, I'm getting the flexi, and 2 box system (this should help keep the noise down on track days), but Nigel is going to supply me with a centre box delete pipe and decat/100 cell sports cat at some point next year!

The system isn't due until the end of January unfortunately due to high demand and their development of new systems.

Anyway, here are a few pics of the exhaust and their system fitted to another mk1 RS:

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Wow, I haven't updated this in a while! Since my last post I've added quite a few new mods (fairly major ones at that), so here we go!

Again, this has been copied over from another forum, so apologies if bits don't make sense!

Got some new pictures after the last update on here:

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Then I ordered some new bits in preparation for the turbo etc:

ist of bits:
- New 3" gaskets
- New nuts and bolts for exhaust
- New turbo to downpipe gasket
- Rear Poweflex exhaust mounts
- New standard front exhaust mounts
- New turbo oil return
- New turbo oil return gasket
- New chargecooler bushes
- 12.5mm axle spacers
- 40mm bolts for axle spacers

Attachment 139832
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And a quick picture of how destroyed my old chargecooler bushes were!

Attachment 139834

Then had some issues!

"I ordered some new leads and plugs, due to a slight misfire at peak boost. I drove the car down to the shops the other day (no further than 3 miles) and it drove absolutely fine. I then went back to the car to drive home and it started misfiring when I put any sort of load on the engine.

I replaced the leads and coil pack and was still waiting for the new plugs to turn up, cleaning the ones that are in there until they did. This seemed to make it a bit better, then all of a sudden the car wouldnt start

It sort of fired up (still with a slight misfire), but even holding the revs up, it just cut out.

Tried a couple of times and the car would run for about 2-3 seconds and then just suddenly die

Anyway, today I tried disconnecting the MAF sensor, to see if it made any difference. It now idles (albeit not very smoothly with the sensor disconnected), which means I had to fork out £80 for one sensor.

I'm happy I've sorted it and glad I replaced the leads, plugs and coil pack anyway, but just wish I hadn't had to dip into my turbo fund, which I could have ordered this week if this hadn't cropped up!"

^^old post so ignore the dates etc

Anyway, I fitted the new MAF sensor and all was cured!

And some more bits..

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Modified spacer:

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Before:
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After:
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As you can see, it looks a lot better as the wheels actually fill the wide arches now!

Then this turned up!

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And had this:

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New BCS system fitted:

Attachment 139844

Then got a Gizzmo MS-IBC boost controller, car drives much better now!

http://tunertools.com/prodimages/Gizzmo/G9021_large.jpg
https://i66.photobucket.com/albums/h.../WP_000528.jpg
Attachment 139845

Then got some FK coilovers :D

Attachment 139846

Fitted, it's settled a bit more since:

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Then fitted some new tyres to the back. Goodyear Eagle F1 Asymmetric 2's :D

http://www.eurocarnews.com/media/pic...3/4867-web.jpg

Then I got in contact with Alex at Pro Alloy (a friend of a friend) and got talking to him about a custom spec intercooler. He offered me a price I couldn't refuse, so ordered that and went to pick it up the other week :D

https://i66.photobucket.com/albums/h...4/IMG_4089.jpg
Attachment 139849
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I also ordered a CPE Group A air filter and relocation kit, so here's a pic showing the size of the filter:

Attachment 139852

And I got these, should be a bit different:

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Got my custom RS mug :D

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Then I got to fitting the intercooler and filter last weekend:

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And that's how she currently stands!

I'm now waiting for the new spec of hybrid turbos to be released so I can spend some more money lol

Cheers for reading!

Wow. Some time and effort spent there. Looks great !

Cheers :D yeah spent a fair amount recently, having a break from spending for the rest of this month though!

Fooking loving that mate,well done.

Looks nice mate :clap:

these are soo tempting!

Cheers guys!

I'm hoping I'll be able to get a full feature with one of the Ford mags at some point this year :)

nice work bud, wat turbo you going for next.

Looks stunning mate, i see you driving about a fair bit think we live down same road;-)


Brian

Cheers, as for turbo, I'll either go for a hybrid (there are two new specs due to be released soon so I'm waiting on results and figures from them, or a GT2876RS :)

Hmm, what do you drive? I may have seen you around!

Performance blue ST estate, Red TDCi Mondeo i am up the hill near the woods


Brian

Oh yeah just had a look at your thread about cleaning the ST :)

Next time you see me about give me a toot or a wave or something!

Yeah will do mate i always drive past yours to get out on to A13, i am always out side cleaning one of the cars if not cleaning them am working on my mk2 Fiesta


Brian

Nice one, I've got a few mates that live in your direction so no doubt I'll see you if I drive past at some point!

Lovely car...
Good move with the silver wheels - i think they look so right with standard wheels on albeit spaced out, i'd never noticed how they fitted with/without spacers before!

Keep us posted on the new turbo!

Cheers! Yeah I'm pleased I went for silver wheels, they look much better, especially spaced out :)

Yep I'll keep this thread updated every time I add/change something..

That's could be weekly with bits here and there but what about your sticker ;-) see us later in my very dirty rs to get them leads

Haha still haven't got the sticker on!

Yeah mate I'll let you know what time I'll be down, it all depends on what time I manage to get off work.

I'll text you when I'm 20mins or so away :D

Awesome Car!!

Cheers Jack, sorry to hear about yours :(

go for the 28 mate, wats your plans for the car mate, track days or street car?

Yeah I've been having a think and the 28 is becoming more and more appealing!

The car is my daily but is also used on track :D

I'm looking at getting a diesel runaround so I can take this off the road and spend some time taking the whole underside apart and getting it all cleaned up..

yea they do work well on these motors, ian howell does a loverly gt28 hybrid thats doing some good figuers, its good to get them apart and check every thing is ok and not rooting away

Cracking car :DD: looks like you've spent a load of money and time on it in the last year, the results make it all worth it :clap:

I've been having a look at the SCC spec 28, but I'll have a look into Ian Howell's one :) cheers mate!

Finally got the RS back on the rollers today to see what she's making.

I was hoping for 300bhp and 325lb/ft and I made....

327.3bhp and 404.9lb/ft (548Nm!)

Very happy I've finally broken the 300bhp barrier, by a considerable amount all on the standard turbo!

Very happy :D

bloody good figues mate, well done... heeps of torque too:grin:

Top job you've done there mate! :top:

Cheers guys!

Good figures mate :top:




Brian

:top::top:

Just a bit of torque there, pulls nicely then:-)

thats one hell of a transformation.love the work you put into it..though not to fond of tuning the cars,but still ..good stuff:)looks alot cleaner now:)

Very nice, where did you get the boost gauge holder from?