Fiesta RS Project - *29.9.06* - f**k IT, I GIVE UP!!!
Fiesta RS Project - *29.9.06* - f**k IT, I GIVE UP!!!
my poor car as it stands 2day
poor engine bay
im having the engine bay fully sanded back and resprayed before the engine goes in, i just need 2 get a compressor 2 wack the suspension off and ill get on with stripping it. ill also be doin the inside of the arches aswell
also trying 2 replace everything in there, like horn, washer bottle, header tank, all new hoses, new arms, acc/clutch cables etc etc
the 2L 16v mondeo engine that will be goin in
will get more pics up when i put all the chrome bits on it
Bernie stage 2 box & alcon 6 paddle clutch
decided 2 buy a new clutch ratchet thingy aswell, thought i was getting new everthing else so y not this aswell
EVERY single bolt in engine bay and engine replaced (theres easily 100+ ive bought) all from ford aswell
freshly L&B skimmed flywheel with new bolts
roll cage that needs 2 be put in
so all i need 2 do is sort out the inlet
which is now in the hands of ian howell 2 modify for me
im going 2 be taking the engine off the stand tomorrow, and ill be putting the engine all together this week
so i gota wack the flywheel on, torque the nuts up, then do the same for the clutch and plate
and then wack the gearbox on aswell
hopefully aim 2 have the car on the road again this summer
cant wait
**APRIL 21st 2005**
spent the past couple of days working on the car, ive cut the front panel off for the grs cooler. good old gr4inder power helped out alot
ive nicely managed 2 make it look quite professional, instead of a wonky ege the grinder would have left. i heated the metal up, and gently beated it to a nice curve kinda thing
the rest of the time ive been prepping the engine bay, sanded back all the flaking rust (even little chips have been sanded back) 2 bare metal and given it 3 / 4 coats of primer. and then wet & dry'd ready for paint, well i hope anyway
got a bit more 2 do in prepping the bay yet, 1 more patch ive missed. HOPEFULLY it will be all sprayed this weekend (fingers crossed) even the arches have been prepped, so they should be done aswell
also started 2 clean the underside
what a messy job that was
not looking forward 2 peeling all the old wax shyte off
thats the middle bit of the underside. no rust at all
more updates 1 day next week
*UPDATE JULY 19th*
fiesta has taken a back seat for ages, but i eventually got round 2 prepping the engine bay properly this weekend, and wooooop, it was sprayed on sunday night
well happy with the outcome. few runs in it, but thats [ERRR] of my crappy prep work
even managed 2 spray the inner wings
sanded back all the scabs 2 bare metal, 2 coats of primer, then 3 coats of that antichip paint. then a final waft over with diamond white
on the whole im well pleased. and thanks 2 my mate for doin it, and not even asking for a penny
**update 27.7.05**
woooooop. fitted the roll cage last night. thought it would be easy
oh how i was wrong
took about 3 hours in the end. trying to line it up, then getting the side bars in, then realising the front roof bar should go in before the side do, blah blah. so ment taking it out about 3 times, then had trouble getting bolts in to bolt it up etc
frigging nightmare
anyway, looks really good now its fitted. even managed to bolt (albeit only 1 out of 3) of the rear cages feet to the floor
oh yeah, also got my inlet
and also got some water pipes off streetdragster. cheers dude
steadily getting there
********august 5th 2005*******
the car is now officially a shell
took off the rear beam yesterday along with the wheels and suspension. those arches look a bit dirty, so i though id give em a goin over
rear arches have now been painted
a good 15 minutes underneath with a jet wash, then about 10 mins of hand washing with engine degreaser, followed by another blast of jet washing.
the rusty bits at the bottom of the arch sanded back to metal, primered up and sprayed. then whole arch given a nice coat of hammerite
will give it another coat before the beam and wheels go back on
also got a few bits powder coated the ford rs blue colour
well pleased when i picked them up.
im now gona get the rear beam, petrol tank and front hubs done. they are gona do my wheels aswell
********august 13th********
more parts bough - 4 new cv joints. more bolts. more bits. £70odd spent at ford again
more powder coated bits - cam cover - inlet etc
car also had a clean
1st time in over a year. poor car
********september 13th***********
got the dash board in now, also got the rear seats in aswell.
(no pic im afraid)
got a few more bits powder coated
zetec s rear beam, front & rear strut braces, engine mount, both gearbox mounts, alternator arm and hanging bracket
engine is mow about complete, need to get a couple more nuts and bolts ive missed, but all looks good
got me a set of new focus rear disks and pads
still aint got stub axels or calipers yet tho
also got a new set of wiper blades, wiper arms and nuts bolts (£59
)
*******september 15th*******
now i just need to do these
**update** december 2nd
sadly ive not touched the car for ages
spent soooo much time gettin rid of that clio it was unbelievable.
also spent the post 3 weeks clearing out the garage so that the car can get tucked away for the cold winter
so hopefully, it shall be nicely away this weekend.
i totally 100% recommend this car cover. £40 from argos, its the best ive ever had. breathable, and keeps the car totally dry. even keeps the car damp free inside
went to see mr ford today, 1st time in months
2 new front wheel bearings, 16 new wheel nuts, 16 new wheels studs, new bodykit rivets, and rear beam bolts. all that came to over £100 again
the old rear beam will be going back on tomorrow, so that we can pull the car into the garage
then lift the car up, and lower it onto the engine
the one major thing, the engine is now ready to go in, may even go in this weekend
but thats only because i have no where else to put the foooker
**update 3.12.05**
well what a knackering day
if any1 has ever removed a rear beam on there own, just think how hard it is to put one back on your own. took me absolutely ages
my back kills
had to put the old beam on so the rear could roll back into the garage
oooh, 1st time the wheels have seen the car in ages
crap pic i know, but the black wheels look really good on the car
dragged the fooooooker into the garage
and here she is all tucked up
lol
********january 12th********
fitted the grs front mount today
and yes, the radiator is held in by the screwdriver
i need to make up some brackets for it, so the screwdriver was just temporary
6 centimeters of clerance for the fan and the bonnet catch to fit in
and the view from the back.
also need to find some decent nuts and bolts to fasten it properly
*******january 21st 2006*******
**SHOCK HORROR** 21.1.06
after 3 hours of fiddling this morning, the engine was ready to go in, and so it did
now all i need to do is choose a filter
ithink i might opt for the 2L zetec item over the smaller renault 5 turbo one. might see if i can get a clio 16v one, that would be inbetween the 2? i think there is enough room for the 2L item
also go tmy ZS rear beam all fixed up
********feb 01 2006*******
samco full water hose kit / roose motorsport ERST bottom boost hose, 2 90degree bends for the top intercooler, and the straight reducer was suppose 2 be another 90degree bend for the throttle body, but was sent the wrong bit
(not in picture) the water pump > radiator > header tank hose is off being modified at the local hose place to accept the larger diameter zetec waterpump
not done alot else really, as this lot cost me just over 250
getting kinda skint now
****update**** 10.2.06
parts off H707 DEG will live on
picked my parcel up from nottingham (man what a long story that was
) that andy sent me on the 27th of january, on a 48 hour parcel force thing. any way, ive eventually got my hands on it
avo coilovers, need a clean but will do me
also got the spal radiator fan, and a pillar pod to go in my car
also i sorted out the top radiator hose yesterday
more pics on sunday when the suspension and the zetec s beam go on

poor engine bay
im having the engine bay fully sanded back and resprayed before the engine goes in, i just need 2 get a compressor 2 wack the suspension off and ill get on with stripping it. ill also be doin the inside of the arches aswell
the 2L 16v mondeo engine that will be goin in
will get more pics up when i put all the chrome bits on it
Bernie stage 2 box & alcon 6 paddle clutch
decided 2 buy a new clutch ratchet thingy aswell, thought i was getting new everthing else so y not this aswell
EVERY single bolt in engine bay and engine replaced (theres easily 100+ ive bought) all from ford aswell
freshly L&B skimmed flywheel with new bolts
roll cage that needs 2 be put in
so all i need 2 do is sort out the inlet
which is now in the hands of ian howell 2 modify for me
im going 2 be taking the engine off the stand tomorrow, and ill be putting the engine all together this week
hopefully aim 2 have the car on the road again this summer
**APRIL 21st 2005**
spent the past couple of days working on the car, ive cut the front panel off for the grs cooler. good old gr4inder power helped out alot
ive nicely managed 2 make it look quite professional, instead of a wonky ege the grinder would have left. i heated the metal up, and gently beated it to a nice curve kinda thing
the rest of the time ive been prepping the engine bay, sanded back all the flaking rust (even little chips have been sanded back) 2 bare metal and given it 3 / 4 coats of primer. and then wet & dry'd ready for paint, well i hope anyway
got a bit more 2 do in prepping the bay yet, 1 more patch ive missed. HOPEFULLY it will be all sprayed this weekend (fingers crossed) even the arches have been prepped, so they should be done aswell
also started 2 clean the underside
thats the middle bit of the underside. no rust at all
more updates 1 day next week
*UPDATE JULY 19th*
even managed 2 spray the inner wings
on the whole im well pleased. and thanks 2 my mate for doin it, and not even asking for a penny
**update 27.7.05**
woooooop. fitted the roll cage last night. thought it would be easy
took about 3 hours in the end. trying to line it up, then getting the side bars in, then realising the front roof bar should go in before the side do, blah blah. so ment taking it out about 3 times, then had trouble getting bolts in to bolt it up etc
anyway, looks really good now its fitted. even managed to bolt (albeit only 1 out of 3) of the rear cages feet to the floor
oh yeah, also got my inlet
and also got some water pipes off streetdragster. cheers dude
steadily getting there
********august 5th 2005*******
the car is now officially a shell
rear arches have now been painted
a good 15 minutes underneath with a jet wash, then about 10 mins of hand washing with engine degreaser, followed by another blast of jet washing.
the rusty bits at the bottom of the arch sanded back to metal, primered up and sprayed. then whole arch given a nice coat of hammerite
also got a few bits powder coated the ford rs blue colour
im now gona get the rear beam, petrol tank and front hubs done. they are gona do my wheels aswell
********august 13th********
more parts bough - 4 new cv joints. more bolts. more bits. £70odd spent at ford again
more powder coated bits - cam cover - inlet etc
car also had a clean
********september 13th***********
got the dash board in now, also got the rear seats in aswell.
got a few more bits powder coated
engine is mow about complete, need to get a couple more nuts and bolts ive missed, but all looks good
got me a set of new focus rear disks and pads
also got a new set of wiper blades, wiper arms and nuts bolts (£59
*******september 15th*******
now i just need to do these
**update** december 2nd
sadly ive not touched the car for ages
also spent the post 3 weeks clearing out the garage so that the car can get tucked away for the cold winter
i totally 100% recommend this car cover. £40 from argos, its the best ive ever had. breathable, and keeps the car totally dry. even keeps the car damp free inside
went to see mr ford today, 1st time in months
the old rear beam will be going back on tomorrow, so that we can pull the car into the garage
the one major thing, the engine is now ready to go in, may even go in this weekend
**update 3.12.05**
well what a knackering day
had to put the old beam on so the rear could roll back into the garage
oooh, 1st time the wheels have seen the car in ages
dragged the fooooooker into the garage
and here she is all tucked up
********january 12th********
fitted the grs front mount today
6 centimeters of clerance for the fan and the bonnet catch to fit in
and the view from the back.
also need to find some decent nuts and bolts to fasten it properly
*******january 21st 2006*******
**SHOCK HORROR** 21.1.06
after 3 hours of fiddling this morning, the engine was ready to go in, and so it did
now all i need to do is choose a filter
also go tmy ZS rear beam all fixed up
********feb 01 2006*******
samco full water hose kit / roose motorsport ERST bottom boost hose, 2 90degree bends for the top intercooler, and the straight reducer was suppose 2 be another 90degree bend for the throttle body, but was sent the wrong bit
(not in picture) the water pump > radiator > header tank hose is off being modified at the local hose place to accept the larger diameter zetec waterpump
not done alot else really, as this lot cost me just over 250
****update**** 10.2.06
parts off H707 DEG will live on
picked my parcel up from nottingham (man what a long story that was
avo coilovers, need a clean but will do me
also got the spal radiator fan, and a pillar pod to go in my car
also i sorted out the top radiator hose yesterday
more pics on sunday when the suspension and the zetec s beam go on
Last edited by ianFRST on Fri Sep 29, 2006 1:01 pm, edited 31 times in total.
- ianFRST
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good luck with it ian, you got more work to do to your car than i thought lol. at least you have most the bits there 
gone to the dark side, the impreza is hear the fiesta no where near
- luke eversham
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Looking great Ian - glad to see some pictures of it all coming together at last
Well actually - it's good to see any pictures of it full stop! Lazy beggar
Cheers,
Andy
Well actually - it's good to see any pictures of it full stop! Lazy beggar
Cheers,
Andy
Carburetted CVH p-p-powa!
- andyhardy
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Good man Ian...another name change? So many to keep up with these days!
It always seems like a huge amount of work, replacing all the bolts and wires and hoses and blah blah..it really isn't huge though, just a case of keeping up momentum and it all gets done surprisingly fast. It shocked me just how quickly I got things done in the one week I had over easter, there isn't much to our wee Fiestas!
Keep it going matey 
- heeman10
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Car: 2014 BMW M135i
spent the past couple of days working on the car, ive cut the front panel off for the grs cooler. good old gr4inder power helped out alot
ive nicely managed 2 make it look quite professional, instead of a wonky ege the grinder would have left. i heated the metal up, and gently beated it to a nice curve kinda thing
the rest of the time ive been prepping the engine bay, sanded back all the flaking rust (even little chips have been sanded back) 2 bare metal and given it 3 / 4 coats of primer. and then wet & dry'd ready for paint, well i hope anyway
got a bit more 2 do in prepping the bay yet, 1 more patch ive missed. HOPEFULLY it will be all sprayed this weekend (fingers crossed) even the arches have been prepped, so they should be done aswell
also started 2 clean the underside
what a messy job that was
not looking forward 2 peeling all the old wax shyte off
thats the middle bit of the underside. no rust at all
more updates 1 day next week
ive nicely managed 2 make it look quite professional, instead of a wonky ege the grinder would have left. i heated the metal up, and gently beated it to a nice curve kinda thing
the rest of the time ive been prepping the engine bay, sanded back all the flaking rust (even little chips have been sanded back) 2 bare metal and given it 3 / 4 coats of primer. and then wet & dry'd ready for paint, well i hope anyway
got a bit more 2 do in prepping the bay yet, 1 more patch ive missed. HOPEFULLY it will be all sprayed this weekend (fingers crossed) even the arches have been prepped, so they should be done aswell
also started 2 clean the underside
thats the middle bit of the underside. no rust at all
more updates 1 day next week
No longer a FRST owner, or even a Fiesta owner 
- ianFRST
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- Posts: 12982
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nice work ian....
white fiesta's ARE always the best and the fastest

white fiesta's ARE always the best and the fastest
Last edited by Xr_Dub on Fri Apr 22, 2005 1:53 am, edited 1 time in total.
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Car: 1991 Ford Fiesta XR2i Turbo
- RS rob
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******UPDATE********
fiesta has taken a back seat for ages, but i eventually got round 2 prepping the engine bay properly this weekend, and wooooop, it was sprayed on sunday night
well happy with the outcome. few runs in it, but thats [ERRR] of my crappy prep work
even managed 2 spray the inner wings
sanded back all the scabs 2 bare metal, 2 coats of primer, then 3 coats of that antichip paint. then a final waft over with diamond white
on the whole im well pleased. and thanks 2 my mate for doin it, and not even asking for a penny

even managed 2 spray the inner wings
on the whole im well pleased. and thanks 2 my mate for doin it, and not even asking for a penny
No longer a FRST owner, or even a Fiesta owner 
- ianFRST
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Good to see ure doing her once in a while
looks good man.... hope to see the finsh artcile soon then we can have a race when myns done aswell
keep on going
looks good man.... hope to see the finsh artcile soon then we can have a race when myns done aswell
keep on going
- Xr_Dub
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- chris-fiesta
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Well done for taking a few more steps Ian. It can be good to take a bit of a break, but if you take too long away from it it can be a bugger to try and motivate yourself to keep on going! Looking good 
- heeman10
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Car: 1992 Ford Fiesta RS 1800
- Jay
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Car: 1992 Ford Fiesta RS 1800
Re: My fiesta RS Zetec Turbo Build....**19.7.05** bay spraye
ianFRST :
hopefully aim 2 have the car on the road again this summercant wait
Hmm where I have I heard that before
I wanna be an alcoholic
- Mike B
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woooooop. fitted the roll cage last night. thought it would be easy
oh how i was wrong
took about 3 hours in the end. trying to line it up, then getting the side bars in, then realising the front roof bar should go in before the side do, blah blah. so ment taking it out about 3 times, then had trouble getting bolts in to bolt it up etc
frigging nightmare
anyway, looks really good now its fitted. even managed to bolt (albeit only 1 out of 3) of the rear cages feet to the floor

took about 3 hours in the end. trying to line it up, then getting the side bars in, then realising the front roof bar should go in before the side do, blah blah. so ment taking it out about 3 times, then had trouble getting bolts in to bolt it up etc
anyway, looks really good now its fitted. even managed to bolt (albeit only 1 out of 3) of the rear cages feet to the floor
No longer a FRST owner, or even a Fiesta owner 
- ianFRST
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- Posts: 12982
- Joined: Mon Dec 30, 2002 9:32 pm
- Location: Burton on Trent
- chris-fiesta
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- Location: croydon, london Drives: 2.0 16v mk3













