Donny1

Hi all,

often read the threads on here but never post (don't have a ford). Me and a couple of friends all got track cars last year,i got a peugeot (stop sniggering at the back).

My friend bought a mk5 zetec S there's a thread on pistonheads but thought there might be some interest here.








Rough Spec

1.7 puma engine (exhaust induction kit)
Striped out
New bucket seats and harnesses
New AP coilovers
New discs and pads
Front upper and lower Strut Braces
Half Cage
3 sets of wheels with track tyres

He got the bug and started modifying it last year. Mainly making it lighter (as he hates spending money) and the usual maintenance.









Fibreglass boot and bonnet (absolutely shocking quality) lots of grinding and drilling.

I painted up the bonnet and boot for him and being called martin he picked some amusing graphics.






We were questioning some of his modifications, main one being a half cage with no door support and as is often the case with older fiestas the amount of rust on floor/underside.

Around November last year he gave in and started looking for a full cage secondhand obviously.

gcfcos

Looks Awesome fun that. Like the 309 in the background

Rowe

M3 tow car........... someones got alot of money! hahaha

Donny1

thanks the 309 is mine

no towbar on the m3 sadly lol.

Turns out not long after he started looking this came up for sale 10 miles away at a stupidly cheap price.




Spec

full cage
fully seam welded
seat rails lowered and welded in
sill stand points
2 new quarters
brand new sills

most of the fabrication work was done and it also came with alot of parts.

2 new front wings
2 doors
2 spare sills
boot
front bumper
brand new st rear disc set up
lightened/strengthened and powder coated front subframe and rear axle
rear axle spacers
powder coated wishbones, hubs etc
full set of brand new black series poly bushes
1.6 engine and gear box

At this point i agreed to help him as long as spent some money on it, he grudgingly agreed.

The seats and half cage were sold and it was basically paid for.

So around December time we got to work on it a couple of nights a week and the odd weekend.

The following isn't exactly in order.

He got ordering some parts, been looking for good quality second hand.

seats,harnesses,oz wheels, new radiator with built in tank as rollcage is in the way.












Knocked up some sill stands



Did lots of little bits of welding. Finishing off quarters, sorting some rust, getting seats to fit, plating holes. Test fitting doors. made front end and wings bolt on.













Stripped the underside







Made a start on rear quarters/arches, flared alot before a light skim of filler.

gcfcos

lol I noticed that!

STeve

iTrader: (11)

nice project this

Donny1

Some more 309 for you




and both on track early last year

Glenn_

iTrader: (1)

Cool track car.

Donny1

Engine bay prepping for paint and underside sealed/stone chipped.










Some more work on the arches and some paint.













Assembled the front subframe, rear axle and painted the tank






Made it roll for the first time










engine in so we can get an idea of how much to flare the front wings

youngben

iTrader: (2)

Any updates?

Donny1

Doesn't seem to be letting me post any

Donny1

The spam filter was apparently stopping my post. Should be sorted now so I'll update tomorrow.

Donny1

Progress has been slow but there has been some.

Underside and engine bay sealed, primed, stonechipped and painted.

jonfoc

Lovely looking work, well done. What's the plan for the engine?

Donny1

Thanks, ive only been helping on the agreement he buys decent parts so "just putting in a full rollcage" has cost alot more than expected ha.

Plan is get it all together and working by the end of this year with the puma lump (all the bolts ons plus lsd and some cams if he can find some cheap)

Then think about an engine later.

To be honest it was surprisingly quick before, around knockhill he was dicing with the modded clios and civics.

jonfoc

Yeah there's no weight in those little fiestas. Tell him to spend good money on the suspension too. I work at Leda

jonfoc

Is the 309 getting some love too?

Donny1

Sorry just getting the AP's swapped over from the old car for now.

Donny1

Its just going up for sale actually. Sold my daily civic and bought a GT86 which i want to do a few track days in so not going to use it.

Donny1

We Then got it rolling for the first time

Always fun putting nice shiny parts together

All new bushes, brakes, bearings etc

Gave the tank a rub down and spray.














Got the engine in so we can set up the ride height and how much we need to flare the front wings. (we already had the back axle on with no shocks to get the rear arches right)

The shell seems to have modified front strut tops that sit higher than standard?

youngben

iTrader: (2)

Nice work! Giving me motivation to do mine.

Donny1

And to bring us up to date.

Trimmed and test fitted dash. (this will be getting flocked)



Had to make a bracket to support the middle.



Lots of sanding.





Then sealer, primer and topcoat.









First time i've painted a cage like that, never again. Turned out better than i was expecting though.

jonfoc

Bloody hell thats some cage! I'm loving this project. Has your mate got his head around spending yet?

Donny1

He's bought all the big things/raw materials so there's only another couple of hundred pounds in dash flocking, bolts and fluids. (im working on persuading him into a new exhaust and cams).

Brake and fuel lines are ordered and paid for just need to send over measurements.

gcfcos

That looks a great finish inside. Love the
Wheels

Donny1

Thanks, thought that id get light patches, moisture bubbles, runs and dry texture everywhere.

Don't get me wrong its far from prefect but in a dirty garage with a cheap gun, small compressor (big one blew up a couple of weeks ago) and my lack of skill im happy.

Glenn_

iTrader: (1)

Top work your doing.

PumaJay

Thats look really good, great project!

Donny1

Got a big chunk of bodywork Done on Saturday afternoon.

The reason for the lacquer peel on the roof became clear, a previous questionable repair.

Although both quarters were new the driver side has had a few knocks sitting in the previous owners workshop so was a bit of a mess.

Its going to have a few ripples but at the end of the day its a track car and white paint always helps














Next on the list is to make a warped, bent and cracked fibreglass boot fit as i don't fancy doing on on a freshly painted car.

Hopefully get the shell in primer next weekend.

Donny1

Been a while but finally got a bit more work done.

Got the boot fitting alot better, still need to fibreglass it back together though....




Flared the front arches and gave them a 1st fill.










Thought it was about time to get some paint on the shell






Then guide coat and wet and dry











Passenger side sanded down, some filler lines on the arch im not happy with, so will need more work. Being a novice was hard to tell before it had a bit of shine :/

Donny1

Been a while since i've updated this. Made a little progress.

Car painted White



Rear poly windows, lights, steering column, pedals, seals





Brake system and Braided lines.






Then we started on the engine and also the looms.



Heat Wrapped mainfold, painted Rocker cover and engine



All new gaskets, belts, water pump







fuel tank/lines, gear linkage





thanks

Cameron

excellent work on that, you'll have some great fun in that!
Makes me wish i never sold my old ZS

Churtz

Looks good!! You'll definitely have some fun in it.

I've got a MK4 track car which i cant bring myself to let go. Had it for ages and every time i think of selling i just add some more power. LOL.

NEIL A

iTrader: (6)

Looks like a very nice build , hope to see use out on track with it this year at Knockhill.
Does Hutchy still have the focus or the fez ? or is he happy slumming in it the beetle

Glenn_

iTrader: (1)

Looking good. I would love to rebuild a car from scratch.

Donny1

Hi, still got the red space frame focus and blue mk6 fez (both for sale but not really advertised yet)

hes happy with beetle, heading over to spa again with it early next month.

Not sure if this fiesta will see knockhill this year as we are just having fun building it and in no rush.

j19dly

Twins

iTrader: (18)

That looks fantastic