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fiesta rs turbo rebuild (56K, NO NO) updated 3/11/08 finshed!

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Old 19-06-2006 | 10:17 PM
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right up-date time, got my block, piston and crank back, will start to rebuild the engine nearer the week end as im away for a couple of days this week, how ever there are still things to do like put the new battery tray in, repaint under the car fit the tanks back etc etc but if all goes well it should be back on 4 wheels and running again within a couple of weeks i hope.

then its just body work to do then like fit the new wing, couple of doors ( loads of door marks and a bad hinge on the drivers door)

well pleased with the crank, new mains, new big end and thrust bearings plus the regrind, £135

block rebore and fit all 4 pistons to the rods £140.

painted the block tonight as i got it back at 6pm this evening so paints still wet in the pic's.

painted up some other bits as your see in the pics below.
the wing was a ebay bargin, £10.50 and its a gen ford part, i won that ages ago but had to get a uncle to pick it up and i collected it from him along with my crank (as it was cheaper regrind over near him) on sat just gone.

for anyone intersted hears some pic's of the bits and some new bits i got from fords. (4 rubber pads for the fuels tank, 4 bolts for fuel tank and a oil cooler hose, was given the wrong one but may as well keep it for £3 but ive orded the right one now)
i also painted the EFI part on the top of the inlet, didnt paint or polish the inlet just cleaned it up with a wire brush, same as the thermostat housing.
talking of which, the thermostat was fine as i checked it but i fitted a new rubber seal and spring clip.
still waiting for 2 new rubber donuts for the front shocks, a oil cooler pipe and spring nuts for the petrol tank to come in at fords.
also got a pair of front ARB drop links on there way off of ebay, new of corse

BTW i havent cleaned the bores, it still has honeing paste in it.


before repaint

ater













got all of the bits packed up ready to be taken over to my parents house where the engine will be rebuilt
Old 22-06-2006 | 10:48 PM
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take it know ones intersted anymore but fock it ill still post up.

few little bits today to finish off, also got 3 therostat housing bolts on order and2 covers for the ball joints.

focking guy in ford tried to rip me again by saying they had to order a min of 10 i wouls would have to pay for all 10, i told him in the nicest way to kiss my ass and he got the message and oreded 3, 1 word, JOBSWORTH!

anyhow all thje bits are together now so the rebuild can now begin

pic of what i got today, but the seal for the down pipe went back as it was to small and they didnt have another, but i aint paying fords £12 plus vat for it when i dont really need it
Old 23-06-2006 | 10:02 AM
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nice updates matey
Old 23-06-2006 | 12:48 PM
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Keep the updates coming in, good to see the work you are doing! When do you estimate you will be done?
Old 23-06-2006 | 01:11 PM
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Jay the cars cming along nicely keep the updates coming
Old 23-06-2006 | 03:39 PM
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cheers guys, as for when its done, ive been a bit lazy this week so hopfully it shouls be on 4 wheels and running within a couple of weeks as the under side still hase to be painted and the front panle has a load of surface rust thats got to be sorted etc before i put engine in, well thats still got to be built but that will only take half a day or so.
Old 24-06-2006 | 10:45 AM
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good to see it moving on Jay
Old 25-06-2006 | 12:45 AM
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cheers bud, still loads to do but all the bits are in 1 place---ish now so can get on with it, after i fix someones car monday and get a MOT on my sisters one tuesday

got a couple of other bits from fords the other day, nothing major, 3 thermostat bolts, and 2 shaped cover plates (pic's to follow)which have never been on my car since the day i got it, and TBH im not sure they were every on the fez, its a little metal plate that clips to the bottom of the hub housing and will sit between that and the rubber of the ball joint, seems to be a good idea so decided to go with it and got a couple, works out to just over £6 with thepair so they best fit

also won a pair of complete bottom arms/wishbones for £18.98 off ebay, brand new and that inc post!!
bargin, because when i removed my passange side arm ( which is 5 years old) the rear bush fell out so that was naffe, and for 2 rear and 2 front (best to of done both arms) all 4 bushes from fors would of cost me £18.25 with the vat, so for a extra 73p i got brand new bottom arms, there not a gen ford part and the ball joint on them although is not a FRST one it is the type i use on my fez to combat the camber problem due to being lowered so a good deal even if the ball joint part last a year, as i have a couple of new ones in the shed
Old 26-06-2006 | 08:04 PM
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some good stuff, what are you using to lift the engine out some old rope and ?
Old 26-06-2006 | 08:56 PM
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and my big strong arms got a engine hoist mate, well its my old mans really but hey, whats his is mine
Old 27-06-2006 | 07:21 AM
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Looking good Jay, went through your entire post and was surprised how well your arches looked when your removed your bodykit. Mine suffered from all the salt the councils put on the roads up here in winter i think.
Old 27-06-2006 | 03:00 PM
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apart from some surface rust under the panit there as sold as a rock mate, we all know the rear arches are a bad area but i always make sure they get a blast when i wash the car and clean the mud away so it dont build up and rust it.

TBH there isnt much on it, there was a few areas on ther floor thats had to be done in the past and a couple of little holes there now, and there so smal i forced a screwdriver through so there the thickness of that, the rest over the car is surface.
aprat from the norm place, petrol cap, and it started on the piller by the windscreen, and the front lower panle had a hole in but thats getting changed oh and partof the battery tray had a hole in but ive got a nice new one to put on

so yeah its a good sheel mate, the passanger wing is being replaced dude to my own fault of knocking the lip up years ago and not painting where the paint cracked so thats gone all mank.
then there was the score with my drivers door nearly falling off when the bottom hinge divorced the door due to rusted pins but that was welded for the time being so thats doors gunna be replaced and im replacing the passanger one due to loads of door marks thanks to the old fuckers that think its ok to throw there door at yours when they get out of there car
Old 27-06-2006 | 06:50 PM
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forgot to say also that im getting my pace intercooler modded, anyone with one of these knows the top pipe is a too lower angle and it makes the top boost pipe touch and rub the top rad hose, or is it just me anyhow im getting it modded and havng new lugs welded onto it so i can spring mount it as the ligs on it have snapped off.

might leave this till the engines in so i can get a nice angle that makes it all fit nice, but then again i might just get it done this week while i have a little bit of money, and fingers crossed being a 1 off job and me paying cash i might get it for a "drink"
Old 29-06-2006 | 08:36 PM
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little update, despite my back being in a bad way today i got my ass out to my parents place to get some bits done.

first off though i got 2 new bottom arms off ebay the other day £19 inc post, brand new , yeah there a cheap make but a bush fell out of 1 of my old ones and it wasnt much more (75p) to buy these 2 bottom arms to the cost of 4 new bushes (both sides) so even if the ball joints go after 6 month, fuck it, the 2 in my old arms are very good plus i have 2 new ones spare anyway, so a bargin i think as its not norm the arms that give out, its the ball joints.

anyhow, when out my parent i done the fuel tank and the gearbox, i had to scrape the wax off the bottom of the tank and rub it down with thinners to remove it all, then it was on with the red oxide primmer hand painted then top coated with silver hammerite, thick-ish.

lucky it was a very hot day and it dryed real quick so im glade as i didnt think i would get both sides done today.

next up gearbox, what a fucking job that is to clean off anyhow i got it fairly good gave it a wipe over with a rag with thinners and primed it then painted.
i was gunna do it silver but at the last minute i decided to spray it satin black as the block is silver, prob wish i had done it silver but seeing it black reminds me of the day i picked up the recon box years ago
ive had it apart a few time since to fit a different third gear LSD and replace a worn selector arm and change the selector on the first gear to the bigger one it should of had

now i got to replace the diff seals as it was leaking a little oil whilst on the blocks ill drain the oil and fill with some nice new oil too

before anyone asks, there not my disc in the bacground, just old ones from my dads van awaiting the be set in concrete in a week or so

sorry for small pics had to do them on my phone.











Old 03-07-2006 | 09:29 PM
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only done a few bits today as i had to do a,bit of work on ym sisters car for her.

got the battery tray welded in, cleaned up the floor and preped it for painting, primmed some area's etc so tomorrow when i go over it should be a case if spraying the under side (stonchipping) then sorting some bits out like break pipes (wanna repaint them) and dumping some rubbish and grabbing the rear axle and other bits i got at my house, and if its dry enough, start bolting bits back up.

the bottom of the tank is gunna be blasted with stone chip also so that will be black, might even give the top a coat as well after all that work painting it silver
Old 04-07-2006 | 10:15 PM
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right heres the pics of the battery tray then,

still got to paint the inner wing part and clean up the bay but that can and will be done a little later.

got the under side painted, as your see the inner arches are spotless, where as most rust mine are solid as a rock.

the black is under seal that i couldnt wire brush off on the inner arches btw.
decided to do the bottom of the tank as well.
dont worry about the red bits in the pic, its not a bit thats been missed its just how the pic cam out :-? :-?

anyhow dude to having to let that lot dry i didnt do much else today, it was bad enough running out of stonechip and having to to and get another 2 L of it and used it all!











Old 05-07-2006 | 03:18 PM
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got a oil cooler pipe from fords today, ordered it 2 weeks ago and was later told they had to get it from another country, yeah right, but it seems by the lables that were on it when it arrived to day they might of been telling the truth after all


Old 06-07-2006 | 10:27 PM
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got a couple of bits today, walked out of ford funny after being dicked for £32 for some bolts and bits and was in there hour and a half cos the guy serving was a fu cking coc k head and his computer was naff so he had to get use another 1

anyhow if ya told you have to get a pack of 10 bolts, give them a little cr@p and ya get away with it, there was no way i was paying £1.01 per bolt for 10 when i only needed 3, so i orders 3 after telling him 5 times i wasnt gunna have 10
fuc king jobsworth.

any how got some more black spray as i might need it, got some more stone chip to doing the inside of the front arches and the new front panle when its on, and they were selling off some old stock of wax oil for £3 a litre so i got a litre, but the guy is ok in there and let me have it for free

the rest is just stuff i painted up the other day.

will be getting a can of green to paint the brake pipes tomorrow, and if its not raining i can get on with it again
Old 07-07-2006 | 07:51 AM
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Nice updates there ,that gravi tex goes on well have used that on my mates saff resto
Old 07-07-2006 | 04:40 PM
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i know its good stuff, used 3L of it already.

got this one is to do the bits that havent been preped for it yet, like the inner wheel archs bulk head end, and the back side of the rear lower panel, its needs a little bit replaced due to when i had a center exit exhaust (when i was young and foolish )
so once that bits been seam welded back in that can be done.

and i called fords today to see if any of my bits had came in the the stupid cock that ordered it for me put it on a stock order (although they dont stock what ive ordered) so its gunna be mid to late next week, so they fucking dicked me again.
as much as i hate to say it, fords (well my local garage) is really starting to fuck me off!!
be glad when ive finished it so i dont have to keep going in there
Old 07-07-2006 | 08:44 PM
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Old 07-07-2006 | 11:21 PM
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shouldbe getting some more done tomorrow i hope
down the scrappy to get cut some bits out saturday and then i can get them in and get on with it.....i hope

seems every time i make a plan like "blah will be done within 2 weeks" something fucking stops me
Old 08-07-2006 | 10:03 PM
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little update today, didnt get much done as i didnt get to my parents till late, plan was to paint brake lines, paint fuel lines, fit them and fit rear axle bushes and then fit the rear axle.

well it seem someone dont like me as not much of that got done

firts off, i get there, and i forgot the bits to fit the axle bushes so had to find something else which took a while, then i found out i had forgot the brackets that bolt to the car and the axle on that :x :x

so i goes to the green house to get brake lines and fuel lines, only to find 4 small cracked about 3 inch long on my splitter part of my front bumper :x not f ucking happy as i only done it last summer and it saw about 500 miles before car came off road and it was fine when it when in there and no ones been in there so it must of been the heat??

any how, preped the brack lines, primed them and used so much primer as most of it was missing the small pipes i didnt have enough to prime the fuels lines, just aswell cos i left the f ucking silver paint at my house for it :x :x

anyway, got the brake lines painted (sorry for the crap pic) and although i repainted the whole lines the colour match was very good, more so for halfords paint , and its a standard rover green colour

last thing really to do seeing as i had forgoton everything else was to paint up the spare wheel carrier holder i nabbed, oh i mean paid good money for down the scrappy

so really i had a bad day and nothing really went my way but hey ho, tomorrows another day. but ill be back out monday and im taking no s hit, ive got all the bits i forgot packed in a box by the front door ready and waiting




Old 08-07-2006 | 10:14 PM
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Old 08-07-2006 | 11:41 PM
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Coming on really well - very interesting read so far
Old 08-07-2006 | 11:48 PM
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cheers guys.

incase anyone asks what rich did, i repainted the brake line as the bits that go into the rear arches were covered in cr@p and had a few areas of surface rust, nothing major but the lines under car were gren, the bits to rear arches were grey white from dirt and what not so i jusy repainted the whole lot that go under the car, the ones in the engine bay are staying as they are.


fingers crossed i have a better time next week and hope it dont rain cos yet again my "2 weeks" hasn extended....... again
Old 08-07-2006 | 11:53 PM
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really good work mate, looks good, cant wait till the finshed product
Old 09-07-2006 | 12:42 AM
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Originally Posted by sidewayz
really good work mate, looks good, cant wait till the finshed product
you and me both mate
Old 10-07-2006 | 09:09 PM
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yeah they were green from new, some cars have black though

yeah bumper has pi$$ed me off a bit but $hit happens, wont take 5 mins to sort just could of done without it.

and the luck gets worse

goes out today, and it rains, no matter as i was under the car, couldnt find 1 of the brake pipe clips so wasnt happy (found it at home now) 2 broke, the only 2 i didnt get from ford as they were ok
fits hand brake cable, looks for the C clip, cant find it, looked everywhere and its gone pack of ten from fords, dont think so, scrappy job

so now i though ill put tank together, so pump was fitted back in with the new seal, all rubber isolator pads fitted so ready to go on.........

time to get the nice new spring nuts to fit to the car ready for tank.........well over the last few days since i last looked at them the little fu ckers have grown some legs and f ucked off cos i cant find them anywhere

so know i decide to fit the brackets for the rear axle, 1 gone on nice, the other was going ok till the last bolt, that decided to pick up on some crap in the thread and fock it up, and i never had my tap and dies to sort it out so the rear axle never went on,


so all in all on 1 hand its been a sort of good day but on the other hand its been a $hit one

so i got to find a clip for the hand brake and get 2 clips for the brake pipes and i cant fit tank till these clips have been put on and untill i find or buy more spring nuits for the tank.

oh, and whoever it was thats stole my luck want to bring back before i send bender round

Old 11-07-2006 | 11:54 PM
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right some pics from today, and a odd one of my fuel pump from monday

before going to my parents to do more work on the car today i stopped by fords to pick up any bits that had come in for me and buy some clips
i ordered 4 brake pipe clips for the front inner arch's and a new c clip for the hand brake cable, and seeing as i lost my spring nuts for the tank i got 2 more, they happened to have 3 in stock and funny enough the bag had my name on it as it seem the guy got his nuts chewed for selling me 2 as they had to buy 5 w@nkers!

anyhow as soon as i gpt there i looked at this bag, opened it.........and there were my 2 spring nuts i had "lost"
oh well.

jobs that got done today, not a great deal as it was my youngest 2 sports day at school so i went to that and didnt get out to the car till about 12 give or take.

i cleaned up and painted the fuel lines today, they came up very well and i didnt have to use loads of paint like the brake lines, but it wasnt so windy today

preped the 2 inner wings, passanger side has a bit of surface rust under the lip so ground it off and primed, primed the drivers one 2 as there were a few spots that were real thin in the paint due to pipes rubbing etc, any how primed them both and after a while they were painted, looks gash with new paint and the old paint around it, but the plan is/was to glean the bay and polish it up but im gunna price up 1/4 litre of paint and 2k thinkers and hardner in the morning, if i got enough cash ill get that and repaint the whole bay
didnt want to go to that tbh as it dont need it and after a yeah or 6 months its gunna be a little dirty again anyway but ill see what i feal like, might strip it out and clean and polish it and see how it comes up and go from there, i got some good compound so ill play that by ear for a min.
because of the above i didnt fit the fuel lines today, but i got the rear axle back on, got to clean up the shocks and hubs etc tomorrow for them to go on

i also painted the fuel filter bracket and the servo stabilizer bar







Old 12-07-2006 | 06:17 AM
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Old 12-07-2006 | 07:26 PM
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got out there again today, had to help my dad till 1.30pm so didnt have much time left but i dont mind helping him when i can.

the engine bay repaint will be going ahead now, as i got a price for paint, ok its not ICI, its a cheaper paint but for the bay it will do as it wont get weathered like the outside.

£23.47, 1/4 litre radiant red, 1/2 litre of 2k hardner 1liter 2k thinners, that will do me.

anyhow, got the front shocks off and the calipers, took the brake servo and master cylinder off (complete with all front brake lines still connected )
made a note of what loom clips i need also.

i also celaned up the threaded part of both rear shocks (avo coilovers) and gave them a spray with some black, just to give them some protection, didnt wanna use grease or wax as dirt and grit would stick to it then.

fitted them in, fitted both rear hubs, stopped there as i forgot which way round the caliper brackets when, plus the passanger side one doesnt work very well (handbrake part) so i got to strip that tomorrow, if its fucked then i get another from scrappy
will also be givng them a fresh coat of paint.

had to re adjust the brackets for the rear axle also so done this while shocks were on so thats spot on now, good job to as it had to move 1/8 inch

thats about as far as i could get today as i had to pack up to get a lift home.

not really a geat deal more i can do with the rear end as such at the mo, cant really put the fuel lines up till bay is done, the fule tank will be bolteted up but thats just to get it out of way, final fitting wont happen till bay is done.
might even wait till the filer repair panel is put in, but were see.



also i picked up some bits from fords today, thiese were bits that i ordered last week, but they gave me the wrong clips, or maybe i pointed to the wrong ones on the screen , but i do need one of them anyway and for 30p eatch i might as well keep all 6 of them, if of course they are the right ones as they have a square fitting not a round one but ill find out tomorrow.

Old 13-07-2006 | 11:34 PM
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the engine bay is all stripped out now, just got to prep it, only thing i have remove fully is the loom, im gunna mask it up

hopfully if my daughters sports day dont take to long tomorrow and the weather is good ill get over and prep the bay and if i have time (as its some BBQ or something at my kids school at 6 i have to go to ) it will be painted too.
i hope it happens this way as my parents are away for the weekend and my dad is /was gunna paint the bay for me.
dont get me wrong i can spray, but my dad sprays alot better and i want it done well.


oh i got the paint for the bay today also

the loom will be re wrapped also before it run back in place
Old 14-07-2006 | 08:38 AM
  #114  
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Top read nice to seeing its coming on slowly but surely look forward to seeing it finished
Old 14-07-2006 | 09:02 PM
  #115  
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cheers lou, im looking forward to it too

had a spare few hours so i wet flated the engine bay, came across a few areas of surface rust, nothing major so ground them up.
the front panel has a little surface rust on but cant get the grinder into it anyhow im gunna grab some sand next week and blast it out with my dads sand blasting gun, ill give it some rust treatment too once its been blasted then the bay can be painted.
if it wasnt such a pain i would remove the front box section and replace it but for a bit of surface rust its not worth it, well if im not happy with it once its been blasted then it will be replaced.
engines going in is gunna be a little longer now as i didnt plan of painting the bay by hey ho, if ya gunna do a job, its got to be done right.

putting the engine back together is gunna be put off for a min, just due to the fact that theres no where for it to be put apart from out side and i aint gunna have it sat outside in the way, but its only gunna take a couple of hours to put it back togther and once its back together it can be put back in the bay the same day.

i just hope after all this work some fucking learner driver or old bag dont beat into it and write it off
Old 03-08-2006 | 12:57 AM
  #116  
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right gotta be due for a update seeing as ive been offline for a bit.

tbh not a great deal has been done as most of the time its been f ucking raining but still theres a bit thats been done.

so far.

rear axle, shocks and hubs are on.
fuel lines and brake lines are back on
the fuel tank is back on
the front box section was given a going over as it was covered in surface rust so that was ground off and flated and preped as were both front inner arches, the front box section and both front inner archers were then stone chipped.

the engine bay was stripped, cleaned, rubbed down, then the bay and the inner arches were primed and top coated and i gave it all a fair bit, the 1/4 litre matey said would be ok didnt go far so another 1/2 liter was got and i used the focking lot! so thats done.
the front lower valance panle hasnt been fitted yet but i want to pait the whole of the box section to protect it so that was done and at the same time both sides of the front lower valance was painted, i know the outside bit will need doding again but thepaint was in the gun so it got a good coat to start if off, but it was primed the same time as the bay

i also painted the bulk head panle as it was looking a bit faded

anyhow i left it for a couple of days after it was painted and i will be tomorrow painting the servo, brake bar and brackets front brake lines etc and once there dry there be going in and im waiting for a new throttle cable (as after 15 years the old ones prob streched a bit) and some loom clips to arrive and them the engine can go in, well i got to build it yet, it would of been done by now but having no place to store it apart from in the garden doesnt really do it for me tbh

some pics so far, sorry for being small they were done with my mobile.

oh the hydrovain compressor broke down and my dad wasnt happy so we had to dig his old one out and use that, apart from being nosiy it still worked a treat.

some pic's so far.












Old 03-08-2006 | 08:33 AM
  #117  
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well done matey!!! looks the business

will all come together when the lumps goes in
Old 03-08-2006 | 10:14 AM
  #118  
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yeah it will mate, but untill some other bits have been done im not even gunna go there,

have to say the fuel lines were a right fucker to get back on as 1 of the brake lines runs in the clips with them and im sure since they been taken off 1 had bent a little as 2 clips broke and it would go on right till i tweeked it.
Old 03-08-2006 | 10:32 AM
  #119  
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keep it up matey comming along nicely
Old 03-08-2006 | 11:17 AM
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