fiestaturbo.com

[jimmyesh]

Good progress mate, coming along well! Did you have much trouble fitting the steering linkage in the end? How much modification did you have to do to the original hole?

Happy new year!

Lee

CheeRS Lee - same to you mate , no real problems but the hole had to be enlarged as I said before, I did it using a mallet & drift because that way I managed to roll the edges of the hole inwards and retain strength in the bulkhead. I've still got to bother my arse to go and get a grommet from a Fez Si steering column and try and fit that on mine in place of the b*stardised mk3 manual grommet I still have in there! Definitely something that needs addressing before the engine's dropped in in the next week or two

Right, I'm off to get intoxicated in preparation for 2009 starting now!

[paulgrs2]

Happy new year jim.
Wooow you have been cracking on and your welding looks good these days lol. Looking good mate, well done!!!!!

Just a quicky, do you think a mondeo mk3 bellhousing will fit a RS2000 MTX75 or do you know/think there could be the same issues you had with the FRS box?

[jimmyesh]

Happy new year jim.
Wooow you have been cracking on and your welding looks good these days lol. Looking good mate, well done!!!!!

Just a quicky, do you think a mondeo mk3 bellhousing will fit a RS2000 MTX75 or do you know/think there could be the same issues you had with the FRS box?

Hi Paul, happy new year to you too my old fruit! Yeah become a bit more adept with the Mig (about time! ).

Yeah I'm pretty sure that the earlier Escort MTX75 'casing won't fit the Mondeo MK3 "Duratec" MTX75 bellhousing as the Focus RS 'box was about the same age as my Mondy Duratec 'box and there were still differences between the two casings even then - best thing to do would be just try it, a bit of alloy TIG action could rectify the differences if a piece was welded in and holes put in to line up with those of the older casing (as in those pics I showed where there was a distinct gap at the bottom of the casing).

Made a box up for the boot-mounted battery today and ran the wiring into the engine bay then used a Mini exhaust centre-mount to use as the remote live-terminal, photos to follow...

[Brammer]

Happy new year

Great progress mate

[jimmyesh]

Happy new year

Great progress mate

Cheers mate, same to you

[jimmyesh]

The battery is now residing in the boot - here's a couple of pics of how I went about it...

I used a Mini centre exhaust mount as a remote "live" terminal to hook up all the usual live connections to where the battery would normally live.



The wire back to the battery in the boot goes into the bulkead via this grommet, then under the interior sill trims all held in place by the plastic cable clips already put in place by Ford.



Here's my battery box that I made yesterday - I'm a tight bugger and won't pay £20 0r £30 for one when mine cost £0.00! It's bolted to the boot floor, the holes are painted and sealed.



Waiting for the big-ass ANL fuse holder that's coming in the post (hence the + wire being left doing nothing in the pic). I have a 300A ANL fuse going in there to safeguard against potential shorts/fires May fit a cut-off switch at some point too...


Not exactly the most earth-shattering of updates but is still a step forward nonetheless Should have some more significant updates this week, bye for now

[FRSJON]

nice one.. that blue cable looks familiar....army issue??..

[jimmyesh]

nice one.. that blue cable looks familiar....army issue??..

Not at all - that'd be theft!

[FRSJON]

buy the way...happy birthday mate...

[Ghost]

One excellent bit of craftsmanship!!

Been keeping an eye on this project since it has begun and am going to keeping checking the updates as much as I can with great interest!!

[jayrs]

after all you have spent on this and you wont pay £20 for a battery box!

nice touch

[jimmyesh]

buy the way...happy birthday mate...

Cheers mate , I'm on the wrong side of 30 now it's all downhill from here!

One excellent bit of craftsmanship!!

Been keeping an eye on this project since it has begun and am going to keeping checking the updates as much as I can with great interest!!

Cheers mate, hopefully I'll be showing it in the flesh in a few month's time

after all you have spent on this and you wont pay £20 for a battery box!

nice touch

Ha, fair one Jay - my reasoning is a bit flawed!

I did my big spending online while I was in Afghan and had lots of extra spare cash but now I'm just scrimping and saving to get it done what with the impending house-move and the Christmas/New Year blowout - If I can't afford something I won't buy it, I'll just save until I can. Any fool can just bung it all on a credit card.

[jimmyesh]

Bit of an update I spent a couple of hours in a snow-covered scrap yard today freezing my nads off tring to remove the rear gearbox mounting bracket and mount from a MK3 Mondeo 2.0 Duratec, It was made all the more difficult with ice and muddy slush everywhere, the fact the car was ground-mounted with no wheels on and my pink, frozen mong-hands not working properly!

Here's the rear mount and the block bracket:



Also managed to acquire a crank sensor as mine was broken.



Finally got back into the workshop and knocked up some turbo coolant pipes using some spare power steering pipe and some M14/1.5 Banjos, taking care not to get them in the way of where the oil lines will go (still waiting for them to arrive) and also the actuator.



Rear view.



I'll hopefully be putting the engine & 'box in the car in the next couple of days, although the finish line is still a long way off!

[jayrs]

cold muddy scrap yards, aint they the best

what they charge for the mount out of interest mate?

[jimmyesh]

cold muddy scrap yards, aint they the best

what they charge for the mount out of interest mate?

Yeah they rock don't they?! You sure appreciate a hot brew, a good meal and a hot bath after a few hours of scrap yard tinkering. I love catching the funny looks of the neighbours when I come home looking like a disgusting hobo!!

They charged me £20 for the mount, bracket, mk3 Fez o/s wheelarch liner and the Mondy crank sensor.

[jayrs]

i likes a can of diet coke, a hot sausage roll (to balance out the diet coke ) and a roll up after the scrappy, and i mean after the scrappy as the shop is next door

£20 for all that aint too bad, but what did you nick? there has to be something, its the un written law that everyone pockets something from the scrappy

[Captain Tightpants]

Not sure if you know or not, but that sensor gap has to be pretty exact. They cause all sorts of bloody trouble if fitted even slightly out. When new they even come with a little gap jig. A couple of minutes now can save a good old headache later!

Good progress mate. Love it.

Steve

[jimmyesh]

Not sure if you know or not, but that sensor gap has to be pretty exact. They cause all sorts of bloody trouble if fitted even slightly out. When new they even come with a little gap jig. A couple of minutes now can save a good old headache later!

Good progress mate. Love it.

Steve

Cheers Steve, I'll check it out mate There doesn't seem to be a great deal of room for any adjustment though, it's just two bolts - I haven't looked at whether the holes are elongated yet

but what did you nick? there has to be something, its the un written law that everyone pockets something from the scrappy

Ha, yeah I have taken a few bits over the years mate! I think the biggest thing I took was an alternator and my toolbag was all heavy and bulging at one end as I lugged it out of the yard!
I normally just pilfer small, poxy things that I can't be arsed to order from Ford - clips, connectors, bolts, etc. To be honest though, they're nice guys at the scrappy I use and they're not greedy so I tend to be honest with them

Been looking more into what engine management to use as well. After originally considering the Omex710 (£900 + Loom so best part of £1k ) I looked on Jamsport's site and noticed that the Gotech Pro-X system has all the features of the Omex (i.e can drive all 4 of my coils etc) for about half the price!

After a quick email conflab, they even said they'd install a base map (for £100) onto the unit suitable for my engine spec so that I can get it started in my workshop at the end of the build, then if I trailer it up to them they will discount it from the final mapping price - Top blokes!

[jayrs]

even ifs a few small bits it dont matter it all counts

look like you got you self, or will get your serlf a deal with the management mate

[Ruishy1]

bloody hell this is some amount of progress you have got through in such a short space of time

Top work mate, was just looking at how close the downpipe is gonna be to the ALT. are you making up a heat shield to protect it ?

[jimmyesh]

bloody hell this is some amount of progress you have got through in such a short space of time

Top work mate, was just looking at how close the downpipe is gonna be to the ALT. are you making up a heat shield to protect it ?

Yeah that's already on my (massive ) to-do list mate! Gonna need to protect a few bits at the back of the engine bay for sure.

Here's my new back brakes - RS2000 270mm rear discs Got the whole lot for £55 inc. Delivery



Some surface rust but the discs have absolutely no wear, I'll be stripping them down, cleaning them up and fitting new pads & shoes (these have a "drum" in the hub for the handbrake). After looking through Heeman10's thread I thought these would be a good, cost-effective rearbrake choice

[Ruishy1]

ah, excellent mate, cannot wait to se this car finished, it is the mutts danglies

What you doing for front brakes ? going for 4 pots ?
it would be easy enough to take the likes of pug brembo calipers and discs and make them fit, i see the calipers go for around 150 quid on the bay

[jimmyesh]

What you doing for front brakes ? going for 4 pots ?
it would be easy enough to take the likes of pug brembo calipers and discs and make them fit, i see the calipers go for around 150 quid on the bay

Was gonna try the usual Escort Cossie front brake route but yeah if I do happen across any fancy 4-pots for good money then I'll take the plunge - they have to go behind 15" rims though!

Fitted the fuse and fuse holder to my boot-mounted battery setup today.



Also painted my front inner wings behind where I'd welded and wherever there was any bare metal using silver hammerite, then re-fitted the inner wheelarch liners.

The blokes finish early tomorrow so I'm gonna get on the ramps/use the crane (the heirachy get narked off if Civvy cars are on the ramps during work hours and to compound the problem Mrs Esh gets the hump if I go there in the evenings - bless her! ). I don't go back to work until the 12th but loads of them started back yesterday so I haven't got my own personal workshop anymore!

Fingers crossed there should be some interesting pics up before Thursday morning...

[jimmyesh]

No you're not seeing things - that's a 2.3 Duratec-HE Turbo in a 1992 MK3 Fiesta

Had a mad moment last night and after my wife & daughter went to bed, I cracked on through the night to get this lot done















Doesn't even sit any lower than when the CVH was in there!





Bonnet still shuts (was having horrible thoughts that it wouldnt! ) need to still adjust it to sit straight yet...



Rear gearbox mount fitted.





Lined up on the lower crossmember.



A jiffy with the MIG later...



You can see more clearly here why I needed to modify the front panel to clear the oil filter housing!



There's no chance of it touching - the photos don't quite illustrate how much room there actually is, plus the way these engines mount, they can't lunge fore/aft like the CVH's used to - knocking chunks out of the rad/bonnet!



Starter motor fitted.



As you can see, the actuator bracket needs some trimming! There's plenty of room to "contour" its shape around the brake linkage bar so that the two never meet.



When the power steering pump was re-fitted, it became apparent that I need to use a remote reservoir though as the pump-mounted Fiesa ST item is just too tall for my diminutive MK3!

Obviously it's fingers-crossed time for the inlet plenum - I'll see whether it takes weld next week if I can when my mate who's good a TIG is back.

The updates won't be so thick and fast now as my leave is coming to an end and we have loads of typical Army bullsh*t to look forward to over the coming weeks I've been on leave so long, I'd almost forgot I actually had a job!

[jonboisescort]

well done mate

the green cam cover looks awsome and suits the car

[FlashXR2i]

Excellent job Jimmy!

Now I feel better...

[Sphinx]

All looks great, can I ask why you didn't come off the original gearbox cradle area for that gearbox mount?

[jmeBDC]

Whoa thats brilliant!

[jimmyesh]

Cheers for the kind words fellas I didn't get in from the workshop until 0230 this morning, then woke up at 1030! Going back to work's going to be hard!

Sphinx: I like the way the powertrains are mounted in the Focus/Mondeo and I mounted the last engine (the ST170 one in the Manj) like this too. The later MTX75 casings did have some changes so I didn't want to entertain the idea of fitting MK5 Escort cradle-type mounts. I guess I'm just sticking to what I know

[Excursion]

That is a great installation, wwell done to you. Look at it it up at the front now - that's some weight saving right there!

[CrAzY kAyLL]

Am going to crack open a beer for you because that looks like a job well done shame your leave is nearly over before you get to really enjoy your hard work

[jimmyesh]

That is a great installation, wwell done to you. Look at it it up at the front now - that's some weight saving right there!

Ha, fair one mate!

I know the Duratec is lighter by a few kilos than a CVH or Zetec but I'd be very surprised if it wasn't heavier now, what with the turbo, power steering kit, plus the intercooler and all the other bits that are still waiting to be installed

Am going to crack open a beer for you because that looks like a job well done shame your leave is nearly over before you get to really enjoy your hard work

Cheers mate, might even sip a couple myself tonight! Got a lot of hard work in front of me now though and it's going to be even harder to find time to get on with it Am mega-happy with how it's all going so far though

[Excursion]

That is a great installation, wwell done to you. Look at it it up at the front now - that's some weight saving right there!

Ha, fair one mate!

I know the Duratec is lighter by a few kilos than a CVH or Zetec but I'd be very surprised if it wasn't heavier now, what with the turbo, power steering kit, plus the intercooler and all the other bits that are still waiting to be installed

It should be a fair bit lighter IMO, and should feel it from the passenger seat. The power steering kit doesn't weigh a whole lot, not compared to the savings you've got from that alloy block. I struggle to lift a CVH short motor, but the Duratec is a hell of a lot lighter. I think it will drive very nicely!

Job well done.

[Project_XR2i_Trackcar]

Kin ell Jim, thats come on leaps and bounds, and in such a short time too

Looking really good, I'm quite envious of the facilities and background you posess there mate.

Perks of the job eh I need a UK posting with an LAD

And to top it all, you are getting paid to do it LOL

[RS rob]

amazing progress and your ability to do something thats never been done before is excellent
me being a fussy bugger aswell i cant see any cut corners, the finish of the job is great,

you must be soo chuffed!!