Fiesta Build - 09/12/06 - :( Page 2

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Fiesta Build - 09/12/06 - :( Page 2

Postby ScottP on Sun May 14, 2006 7:37 pm

Well you will have seen me knocking around on the forum asking questions, mainly about Mk3 Fiestas. I am 16 and I am an Apprentice Plumbing and Heating Engineer. I was supposed to be buying a Red Mk3 1.1 Azura on a P Plate, low miles, immaculate shell and no sunroof. An ideal base for what I want to do, but was gazumped by the bloke I had agreed to buy it off. So I am currently looking for a similar example, but since I have a few months before I will need the car, I am going to take my time and stockpile the parts I need.
Please feel free to leave any comments or suggestions, and any help on enquiries would be great. Also, if anyone wants any specific photos, feel free to ask and I will do my best to get them.

Thanks

Saturday 6th May 2006

I went to Ford Salvage in Barnsley today to enquire about a Zetec S Rear Beam, some V6 Mondeo Front Disks and Focus 2.0 Rear Brakes with the Stub Axles.
They had a Street KA in, which has the same rear beam as a Zetec S, so I paid for that.

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They also had a V6 Cougar in, which shares its Front brakes with the Mondeo, bargain! I paid for them too.

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Unfortunately they did not have a 2.0 Focus in for the rear brakes.
I then went to my Uncle’s Scrap yard as he had an XR2i 16v in. I got there and immediately removed the front lower strut brace from the car. A lot easier said then done. The silly captive bolts are a gammon slipper to get off, and I only managed to get one off before the heavens opened. They have a square base and are held by two prongs of metal. They needed prising off, but the left side was very tricky to get to. It looked very similar to this one when I got it (forgot to take a picture of mine)

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The XR2i had been in a front end smash, so the front bumper was damaged. Someone had already taken the Rear Bumper. I went looking around the yard, and came across a crappy Fiesta with a RS Turbo bumper. It was a real mess, and very badly painted, but is ideal for experimentation so I got that too. There is a Focus 2.0 there too, but I didn’t get time to take the stub axles and discs off. For some reason one of the rear callipers is missing (the Drivers Side) so I will have to source one of those too. Probably means I need a new set of pads too, as I will have to be really lucky to find one with evenly worn pads. I will be taking the rear brakes off the car in the next couple of weeks.

Sunday 7th May 2006

I cleaned the Lower Strut Brace today. After accumulating over 14 years of dirt, grime and grease, it wasn’t a simple wipe clean. I started out by using a sponge and some soapy water so clean the thick layer of mud from the surface. I then scraped off the grease. With a rag and some petrol, I rubbed down the rest of the brace and it came up quite nicely.

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When scraping off the grease, I scratched the surface of the brace, so be careful if you are doing the same thing. I will be painting it, so no problem for me. It had two exhaust brackets bolted to it, so I took those off and cleaned them.
I have noticed though, that most peoples only have holes for one bracket, why is this??
I got all the bolts cleaned up too; my old electric toothbrush worked a treat. They are all reusable, so that’s saved me some messing about.

Wednesday 10th May 2006

Collected the Zetec S/KA Rear Beam and got cracking with the rear drums. These will be replaced with Focus 2.0 rear stub axles, callipers and discs shortly. This makes the beam around 20mm wider each side than a standard Fiesta Beam. To remove the drums, I removed the four big (19mm IIRC) bolts from the reverse of the drum. It then moved, but was stuck by something. I then removed the ABS sensor with an 8 or 9mm socket. The drivers’ side was a little more problematic, as one of the shoes was stuck on, stopping the outer part of the drum being removed. A few good whacks and some prising it popped off nicely. The rest of the drum is then held on by 2 rivets either side, so I drilled the heads off them, and knocked them out with a hammer and a long nail. Once this was done, the whole drum assembly was removed, and the beam is ready for the Focus brakes. I also gave the beam a quick clean, but it was taken from a very new car, so it is more or less immaculate.

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The Rear Drums made by AP Racing! – For Sale if anyone wants them, open to offers.

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Thursday 11th May 2006

Not a very big update. I have collected the passenger Cougar brake from Ford Salvage, as they weren’t off the car when I went last time and they still hadn’t taken the passenger one off, as I said I would be there on Saturday. They are in very good condition and there is plenty of meat left on the pads, so I am very pleased.

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Saturday 13th May 2006

My dad picked up the passenger side brake from Ford Salvage. I had asked Lee to keep the brake lines and everything with it, so that I could trial fit before I bought new discs, pads and hoses. It must not have been him who took it off, as the lines have been cut and one of the pads is missing. No harm done really.

Sunday 14th May 2006

I went through to Sheffield today to pick up an Escort S2 RST Gearbox (Thanks IANS2RST on passionford.com). Ian told me it was whining in 3rd and 4th, but that doesn’t really bother me.

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This is what I wanted though; you can just see it, the LSD.

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I am going to strip it down to remove the Diff and then the box will be sold on, either without a diff, or with the diff from the Diesel box when I exchange them. I am also getting some degreaser, so the box will be made spotless. This will be up for sale, so any offers are welcome!
Anyone know what grade of oil I should put in the box?
Last edited by ScottP on Sat Dec 09, 2006 7:55 pm, edited 11 times in total.
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Postby rob pace on Mon May 15, 2006 6:13 pm

make sure you use the mondeo endura mk2 engine.
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Postby ScottP on Mon May 15, 2006 6:57 pm

it doesnt really matter which engine i use, i can use one from a mondeo or an escort. most mondeo engines have done high milage anyway,

thanks
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Postby rob pace on Tue May 16, 2006 10:30 am

ScottP wrote:it doesnt really matter which engine i use, i can use one from a mondeo or an escort. most mondeo engines have done high milage anyway,

thanks


i believ escort is a 70ps engine and a mondeo is 90ps engine, more power full.

if you get the 1.8 diesel engine, which says 1.8 diesel on the rocker cover you will have problems dropping the engine in.

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Postby fiesta_mk4_project3 on Tue May 16, 2006 11:24 am

love the carpet mate :lol:
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Postby ScottP on Tue May 16, 2006 4:27 pm

Only the best for the shed.

late Escort TD's are 88ps and mondeos are 90ps as you said. Not much difference other than the price.

cheers for the comments anyway.

thanks
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Postby rob pace on Tue May 16, 2006 5:10 pm

ScottP wrote:Only the best for the shed.

late Escort TD's are 88ps and mondeos are 90ps as you said. Not much difference other than the price.

cheers for the comments anyway.

thanks


what does it say on your rocker cover? endura or 1.8 diesel?
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Postby ScottP on Tue May 16, 2006 6:13 pm

I think it will be just diesel but i have not seen it yet, why?
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Postby rob pace on Tue May 16, 2006 7:05 pm

ScottP wrote:I think it will be just diesel but i have not seen it yet, why?


read excursions guide to this, the 1.8 diesel you will have problems with, the mk2 mondeo endura engine you wont have problems.
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Postby ScottP on Tue May 16, 2006 7:49 pm

My bro fitted the same engine into his so it will fit, the only thing which needed doing was removing the EGR, which mark (excursion) did anyhow.

Are 70ps TD's the ones without an intercooler?
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Postby rob pace on Tue May 16, 2006 7:55 pm

ScottP wrote:My bro fitted the same engine into his so it will fit, the only thing which needed doing was removing the EGR, which mark (excursion) did anyhow.

Are 70ps TD's the ones without an intercooler?


no mark tells you about it, he used the 90ps mondeo endura engine which i had as well :D - ghost has purchased the engine off me. the egr on this is on the inlet, but you have to use a mk1 mondeo inlet anyway as it fouls the fiesta suspension turrett.

the egr hits the brake bar with the 1.8 diesel engine as its connected to the manifold some way or another- well along them lines..
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Postby ScottP on Thu May 25, 2006 4:05 pm

Bought a car yesterday, going to pick it up at the weekend (hopefully)

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... %3AIT&rd=1

I asked the buyer to end the item soon for a very reasonable price! More pics when I collect it. Opinions Please :)
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Postby Kartracer69 on Thu May 25, 2006 5:35 pm

are you really 16 :o thats some serious top work going on there, where you learn all this stuff?

nice one mate, looks a good example of a car, doesn't matter if the brakes are crap does it if you are replacing them all
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Postby ScottP on Thu May 25, 2006 5:44 pm

learn by doing - that what im doing, lol

just looking at the costs of new discs, pads, hoses, the lot (I work myself to pay for all of this, not a penny is paid for by my parents!)

http://www.azmotors.co.uk - Good site
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Postby ScottP on Sun May 28, 2006 8:53 pm

Got the car today, lovely bloke - he put it back on his insurance for the day so we were legal on the way home.

The car runs perfect so ive got a 1.1 engine freshly serviced with a new exhaust and plugs for sale if anyones interested? offers of course

and also a set of five 13"'s with 175/70 firestones (no odballs) if anyone wants.

I'll post some pics tomorrow. I think i gonna put some 15" focus twin five spokes on, what do you guys think??

Cheers
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Postby adz on Sun May 28, 2006 10:37 pm

just seen this projects. sounds really cool..

car looks tidy mate. get that rust sorted so you hav a nice shell to put the bits in.

focus twin 5spokes will go on, however you need to space them out about 15mm as the offset is way out. this means longer wheel studs and hubcentric spacers which is when it gets pricey, also the tyres would need changing so probably easier to look for something similar in the right offset.

hope this helps :)
i'll keep checking the updates :)

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Postby ScottP on Sun May 28, 2006 10:40 pm

cheers adz, didnt knoe i needed all that, looks like ill stick to zetec s alloys then :)

the dreaded rust will be sorted asap

thanks
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Postby ScottP on Wed May 31, 2006 2:23 pm

Sorry for the delay in posting, I have been working, but I have managed to get some little bits done. I cut the Ariel down as I thought it looked odd, I cut about half a foot off:

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My next task was to get rid of the horrible black side strips. I used a credit card (or store card, make sure it has expired!) and a hair dryer. It just takes a lot of heat and patients to get it done. I then used white spirit to get the rest of the glue off.

Before:

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After:

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I then moved on to the tailgate. The Ford and Fiesta Classic badges were removed using the same method. It all still needs a good polish.

Before:

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After:

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I bought some Recaro seats as well. mrorange2 delivered them (thanks mate!) this morning at about 10. Finished putting them in about half 12 so I don’t think we did too bad. As it’s a mk3.5 the sub frames needed changing round, and after a little head scratching it was all sorted, I am going to write up a guide for this and will post the link when it is done. I have been told they don’t fit, but this ‘theory’ has been proved wrong!

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I have also ordered a brand new RS2000 Handbrake cable to fit my rear discs, and a new front fiesta one as it was too cheap to miss!

That’s about it for now, oh and I have received my brand new set of Facom Axle stands, should be ideal while I am changing the whole suspension setup.

Thanks!
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Postby chris-fiesta on Wed May 31, 2006 2:28 pm

what a bargain m8, nice lil project you got on your hands :Q
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Postby Ghost on Wed May 31, 2006 2:38 pm

mate, this 'theory' about recaros in a mk3.5 has been proven loads of times and there is already a guide on how to do it :wink:

could of saved you a lot of head scratching :lol:

in fact ive had them in mine for about 6 months

also, i should be doing the conversion in about a month if work goes well, so i should be able to give you a hand, but mine will be a lot easier as you are not using a diesel base

it has been done and the guide is there, so good luck with it, and it looks like you are starting off well

i like the idea of cutting the ariel down aswell, ill have a little look into that myself :Q
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Postby Pez on Wed May 31, 2006 2:41 pm

Excellent stuff, really good to see youngsters getting into the thick of it, thinking about what they are doing, and doing it properly rather just monkeying around with half arsed bodykits and filler. Good on you mate, illb e keeping an eye on this :)
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Postby ScottP on Wed May 31, 2006 2:53 pm

Ghost wrote:i like the idea of cutting the ariel down aswell, ill have a little look into that myself :Q


all i did was take the rubber tip off (i used my teeth!) then snipped it with some wire cutters. under the rubber bit was bare metal, so i used some emery cloth to get it all down to bare metal on the end again. the radio signal has not been affected.

thanks for the positive comments!!
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Postby Max M4X WW on Wed May 31, 2006 4:45 pm

Looks clean! Needs some wider wheels, be that steels or alloys, and a bit of a drop!

Copycat with the cutting of ariel :lol: Mine was a lot more work though being a mk4/5 one, had to cut the bit off with a knife, dremmel the end down a bit and glue it back on!..

Before..

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After..

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Postby ScottP on Mon Jun 05, 2006 5:35 pm

Another Update. I went to my Uncle’s Scrap yard again on Saturday, to hunt for some more parts. First on the list was the XR2i Anti Roll Bar I had left the previous time. It was quite fiddly to get off, as the drop link bolts had seized and the bushing mounts are hard to get to, but it came off eventually. As a note to anyone removing one, it is easier to remove it from the side furthest from the gearbox, as there is less for it to snag on. Also, the drop links will have to be removed completely. I left the drop links there, as I am buying some brand new ones before I fit it.

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I had taken off a RST front bumper, which was on a very badly painted late model Mk3, the last time I went to the yard, but didn’t have anywhere to put it in the car, but I picked it up this time. The Fog lights have been blanked off with 2 plates and the paint is so shabby that you can peel it off with your finger nail, but it want painting anyway. I may even use this one for some experimentation, since I got it for free.

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I (finally!) got the rear brakes and stub axles off the Focus 2.0 at the yard. The drivers’ side calliper is missing, but locating a replacement shouldn’t be a problem. They were absolutely horrible to take off, as they were still on the full car. In the end we melted off one of the suspension bolts (even the snap on impact wrench would not budge it) and took more or less the full beam off. This allowed us to pivot the stub axle around, giving a good angle to get at the four bolts on either side. After that they were off in no time.

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They are in quite good condition, but a new set of disks and pads will be used once the car is on the road, these will be used just to get the car rolling.
I also got some other little bits, such as a seatbelt surround (where it goes through the doorcard) as mine was missing, and a stereo surround, as the one I had was messed up and scratched.

My brother brought me a present from work the other day:

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It’s a Mondeo TD Inlet Manifold. I need to change the direction to boost pipe will enter it, so that I can use a front mount intercooler (eventually). One problem this does cause though is the exhaust gas recirculation (EGR) port. This is used to regulate the inlet temperature by circulating exhaust gas into the inlet. While this works okay, major gains can be had by removing the system, namely reduced charge temperatures, meaning more power (with increased fuelling). So I did this:

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Its only a cardboard template at the moment, but I will make one from some plate steel and bolt it up, using some gasket sealer to make sure it’s a proper seal.

My handbrake cable also arrived, I think it is the right one, but I will have to find out when it comes to fitting it to the rear beam once I have my rear suspension. The first picture is where it attaches to the front part of the cable, and the second picture is where it hooks onto the calliper.

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I got round to unwrapping my axle stands. They are just what I needed, and are really high. The jack will need choking up to get them to their full height.

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That’s about it for now, should get some more done soon, but I am busy with my exams at the moment.

Thanks!
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Postby ScottP on Mon Jun 05, 2006 9:26 pm

Another small update. Had a little time spare in between revising, so I thought I’d let off a little steam and have a mess about with the Fiesta.
As I will be changing the wheels and brakes, the spare wheel will be useless, so I decided to get rid of it, and the hanger for it. The bolt for the hanger cannot be taken out, so I just cut it down with a hacksaw. The hanger is now in its proper place, which also has wheels:

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After fitting my Recaro interior, I thought the horrible rubber gear gaiter needed to be rid. As I have not found a FRST (or Escort) leather one yet, I had a wonderful idea. The MK4 Golf GTi gear knob and gaiter were collecting dust in the garage, so I separated them (they are permanently fixed together) and used the gaiter. I think it looks quite good, but I am only using this until I get my RST one, or something a little more special (all will be revealed)

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And I think that’s all, will be another update soon.

Thanks!
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Postby Ghost on Tue Jun 06, 2006 12:15 am

argh, ya git, i still need a mk1 inlet manifold :x :lol:

whats this about the EGR port?? care to explain a little, im all for extra power :D

are you just bocling up the hole.........as i havent got the inlet manifold yet icant see what your doing, any help appreciated mate :D
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Postby ScottP on Tue Jun 06, 2006 7:32 am

I think it is mainly for emmisions as it keeps a more constant inlet temp, But i doubt Exhaust gas is any good for power output!!

I will just cut that template out in sheet steel and bolt it on with some gasket seal between it.

When doing this, i.e. changing the manifold, you have to do away with the EGR anyway.

Scott
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Postby ScottP on Wed Jun 07, 2006 9:51 pm

I have got some more stuff done on the car over the past few days in between some exams. I bought some black faux (artificial) suede off eBay, and some upholstery spray adhesive, which came to about £15 in all.
I have recovered the horrible cream B pillar covers, where the seatbelt mounts onto. It was quite difficult to get around the contours and curves, but it come out alright. The material does have quite a lot of leeway in terms of stretching. One of the clips did crack and break off, but I sorted it out with a small screw and some plastic cement.

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I think they look quite good, and go well with the dark Recaros. When I bought the interior, it didn’t come with any doorcards. Here are the ones I had in:

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They were horrible, and didn’t match the seats at all. I have now retrimmed them in the same suede as the B Pillar covers. It has turned out nicely, they are not 100% prefect, as the original leather creased a little when sticking it back down, but it looks good. If anyone has any questions on how I did them, just ask!

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That’s all folks. I have just been cleaning up my rear brakes and stub axles, as there was a little surface rust.

Thanks!
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Postby Sphinx on Wed Jun 07, 2006 10:12 pm

F*ckin top notch!! :D
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Postby RS_Rawli on Wed Jun 07, 2006 10:20 pm

how did you do them door cards, looks spot on :)
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Postby ScottP on Wed Jun 07, 2006 11:08 pm

To do the Doorcards, I did this. I took the Doorcards off, by removing all the related trim (door pockets, handles, window winders and pull handles) and then lifted the door card up and out (after pulling out the plastic clips, which are like push fit holes, around the sides and bottom, which pull out with a bit of force, and then a row of metal ones at the top, this is why you have to lift them up and out).

I took out all the staples from the back (around 6 or 7 each side) and peeled the top cloth back. The padding behind is stuck to the cloth, so this needs to be separated and left on the door card. Where the cloth meets the leather is also glued, but this comes off with a bit of force. Make sure you do not pull the leather too far down. The cloth goes just past the two indented lines (you will know what I mean when you see it), so this is only how much it needs peeling back).

Once the cloth was all removed, I got the suede (any material will work really) and cut around the original piece, try and leave a little more at the top of the door card, as it makes it easier to stick it all down.
Once this is done, the piece can be stuck down. Using some spray adhesive (eBay, around 7 quid for some good stuff) coat between the two indented lines you peeled the leather up from. Stick the suede down once tacky and leave to dry for a few moments. Then, after covering up both the suede and leather at both sides (I used two pieces of card) spray over the suede (again between the indented lines, ensuring the adhesive does not get anywhere else). Stick the leather over the top of the suede, and smooth out any creases before it dries. You may also need some on the reverse of the door card where the staples were (I do not recommend using staples, as these are special ‘short’ staples, as the door card is only very thin).

Turn the door card over, and apply some more adhesive at the top edge. Immediately start sticking the material down, making sure that it is still wet enough to move around, so that all creases can be smoothed out. Keep doing this all the way along until the material is completely stuck down. Some cutting on the edges may be necessary to stop creasing and folding.

Wait until dry, and turn the door card back over. Cut out the door handle hole by creating a x from every corner, and folding the excess to the opposite side of the door card, sticking it down tightly with adhesive, ensuring that the edges are followed perfectly.
Pop the door cards back on, and put all the trim again. Be careful not to pull up the material when dropping it over the top clips.

That's about it really, not too difficult. I recommend two people doing it, as it gets quite fiddly with the sticking and holding the Doorcards. Leave about 1 and a half to 2 hours to get both sides done, more if you are unsure how to get the trim off.

Thanks for the comments!
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Postby Jay on Thu Jun 08, 2006 12:02 am

absolutely awesome mate!

Deffo gonna do my b and c pillar trims now i've seen them :D

Do your headlining mate!

If you want some charcoal grey cloth to do the headlining then PM me and I'll sort you out with some.

I did my headlining and its spot on! Way better than standard look and matches the recaros well ;)
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Postby joe boy on Thu Jun 08, 2006 12:29 am

tidy job there mate looks smart

id like to do my headlining a darker colour but leave the b pillar trims how they are just to break up the colour a bit if u get me

but neway its lookin top mate :D
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Postby ScottP on Thu Jun 08, 2006 7:20 am

Yep, im doing the headlining soon.

Cheers for the positive comments.
6 positive comments in trusted traders topic :)
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Postby paradox on Thu Jun 08, 2006 10:45 am

Interesting project and it seems your tackling it in the right way.
Good luck with the rest of it and i will keep popping back in here to have a look at your future updates
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