Cookie F2 RSF MK3.5 Fiesta (escort maxi rally car inspired)

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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby RS1800-Cookie on Mon Oct 06, 2014 10:31 pm

Finally started building the engine after having the wrong pistons. Arp studs in mains and crower bolts in rods hopefully it's going to be rather strong.

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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby rsturbonutter on Wed Oct 08, 2014 5:56 pm

Is it my eyes or are the pistons sitting rather proud
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby Smo on Wed Oct 08, 2014 6:43 pm

Sexy pistons!

What CR are you aiming for?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby RS1800-Cookie on Wed Oct 08, 2014 11:07 pm

rsturbonutter wrote:Is it my eyes or are the pistons sitting rather proud


Hi rsturbonutter, it's not your eyes chap 8) these are high compression forged pistons designed with a crown that fills some volume of the cylinder head.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby RS1800-Cookie on Wed Oct 08, 2014 11:13 pm

Smo wrote:Sexy pistons!

What CR are you aiming for?


Cheers Smo :) I took some arty pics as it's pure engine pawn tbh and once built never gets seen.

The compression ratio will be 12.8:1 any higher than that and you have to ideally run racing fuels 115 Ron n that ain't cheap lol!

The engine is being developed with help from scholar engines, power output should be between 250-300bhp dependent on fuel and mapping
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby rsturbonutter on Thu Oct 09, 2014 10:52 am

RS1800-Cookie wrote:
rsturbonutter wrote:Is it my eyes or are the pistons sitting rather proud


Hi rsturbonutter, it's not your eyes chap 8) these are high compression forged pistons designed with a crown that fills some volume of the cylinder head.



Have just read the thread from the beginning and now realise that its not going to be turbocharged got to say those pistons make me hard
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby RS1800-Cookie on Thu Oct 09, 2014 6:06 pm

rsturbonutter wrote:
RS1800-Cookie wrote:
rsturbonutter wrote:Is it my eyes or are the pistons sitting rather proud


Hi rsturbonutter, it's not your eyes chap 8) these are high compression forged pistons designed with a crown that fills some volume of the cylinder head.



Have just read the thread from the beginning and now realise that its not going to be turbocharged got to say those pistons make me hard



llama. Don't get me wrong turbos are cool but there's something about NA I prefer. Anyone can get proper power using turbos, it takes a lot of work to get an NA to perform.

I'm hoping to get it done for June 15 or ford fair 2015
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 13/10/14 seat mock fit

Postby RS1800-Cookie on Mon Oct 13, 2014 3:02 pm

... bit of an update the seat covers are now in the hands of my local sewing and embroidery company who are going to make completely new covers.

I decided to look at how to mount the seats. As my girlfriend is so adiment she wants to drive this too I'm going to put sliders on the seats.

I trial fitted the mounts on the old seat sliders. These will work however I am going to look and find a way to lower the seat as they are a little too high

We decided to do a cheesy selfie!

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I am trialing the idea of making gussets for door bars atm I made a upper and side so far, not sure weather to do all, top n bottom or side to side... opinions??? ImageImage
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/10/14 engine building

Postby RS1800-Cookie on Thu Nov 06, 2014 1:08 am

Hi everyone :)

Bit of an update, I decided that the easiest way to get over seat height was to make the base cushion thinner. Girlfriend took this cheeky pic if me checking seats lol Image

The cushions for road as I will make a poly bead seat mould to my bum for track.

Finally got idea of what seats will look like. Opinions????
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I have done a photoshop of planned look of car bar few tweaks. This gives an idea of final look. Obviously inside will be track spec.

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The rollcage is being fully welded in by my brother in law this weekend, so hopefully paint will be applied to car by end of the month.

I got bits back from scholar for the heart. Few graveyard shifts this week n it's looking more like an engine. Will need to go back to have the custom camshafts done and mechanical bucket conversion.

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I have one concern. ... The room for gearshift between seats. I'm thinking of mounting this on a raiser and wedging the linkage tunnel to provide clearance. Any suggestions???

Hope to have the car painted and as a rolling shell by end of dec. Depending on funds I am trying to aim for FITP 2015 completion. If not Ford fair
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/11/14

Postby Dazza on Thu Nov 06, 2014 6:24 pm

Some nice work there Cookie, not seen this post before.

Regards to the AP racing MG 4pots, what additional work was carried out to allow fitment as I know these are not bolt on.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/11/14

Postby FRSJON on Thu Nov 06, 2014 9:04 pm

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this is what i did to mine if it helps...had a alloy threaded section glued in the original holes,then redrilled to fit the fiesta and a threaded insert fitted
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/11/14

Postby Dazza on Thu Nov 06, 2014 9:45 pm

Thanks for that John. What size discs are running with those?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/11/14

Postby RS1800-Cookie on Fri Nov 07, 2014 9:44 pm

FRSJON wrote:Image


this is what i did to mine if it helps...had a alloy threaded section glued in the original holes,then redrilled to fit the fiesta and a threaded insert fitted


Lol Jon you beat me too it. I did exactly the same, however is had the holes alloy welded first.

I'm using 300mm ST170 discs on mine, dunno what Jons got.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 6/11/14

Postby FRSJON on Fri Nov 07, 2014 9:51 pm

yep st170 discs :)
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 1:07 pm

Hi everyone, hope you all had a good Xmas :)

I dont have a lot too update atm, tho the cage is now fully welded in and the door gussets are in place.
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I have decided that way too much money is going into this car now.... and on that note this has become a toy rather than a daily drive. I just bought a 56 plate mondeo 2.2 tdci with all the gadgets as my new daily bus.
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due to the cold weather and as the girlfriend is getting cold (not working enough! lol) i have bought myself a diesel/kero space heater..... its effective!

the engine has gone back to scholar to have the cams and buckets done. once they are done it will be all set to build fully and get on the engine test bed. hoping to get the engine done by feb 15

got my clutch too AP Racing goodness mmmmmm one catch need to uprate the clutch pedal as its too heavy for my one!
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have a great new year all and hopefully next year will show serious progress and update due to my ambition to get built by june 15 ot worst case ford fair 15. :D
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Smo on Fri Dec 26, 2014 3:36 pm

Looking good, so far! :)

Are you still intending to use an iB5 box? If so, what release bearing are you going to use? Correct me if I'm wrong, but the release bearing for the flat fingers of that pressure plate will be the round surface BC-style bearing which won't fit in an iB5 box, and I don't think the flat surface iB5 bearing will interact smoothly/correctly with the flat fingers of a BC type pressure plate like what you have there?

Just something I've come across in the past myself while switching between iB5 and BC boxes!
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 5:18 pm

I'm going to be using a BC gearbox but with a IB5 housing. Not straight away tho.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Excursion on Fri Dec 26, 2014 7:24 pm

Great project - keep it up. What power do you expect? What's the max RPM?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 8:04 pm

Excursion wrote:Great project - keep it up. What power do you expect? What's the max RPM?


Hi Excursion, thanks for the feedback :) The expected power is bit of a grey area, see I origanally had an idea for a high spec engine... or so I thought till I spoke to scholar. When I told them my plans the response was "is that it!, thought you wanted balls out?" .... this was promptley followed on by showing me a ex BTCC development programme from 94-95.

I knew this was where i wanted to be, so my plans changed. the engine in 94 made 252bhp but the torque from it was insane for a NA 200lbs ft . It was a trade off from bhp vs torque.

The reason its a grey area is that some of the components im using are better than their original development engine.

*throttle bodies are much better flow
* Con Rods are I beam which are lighter than H beam, this means the engine will respond quicker.
*Con Rods are Blacktop (140mm) not silvertop (136mm) so longer. this aparently will help create more torque.

Im aiming for power between 250-300bhp but torque over 200 lbs ft

the engine will only be revving to 8000rpm, the peak window for cams is 3000-7500. I could go for more RPM but tbh its not necessary and would mean having to go stage 3 dry sump not stage 2 due to
the fact the oil gears will not take the abuse.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Excursion on Fri Dec 26, 2014 8:14 pm

RS1800-Cookie wrote:
Excursion wrote:Great project - keep it up. What power do you expect? What's the max RPM?
Interesting stuff...


Sounds awesome! Like you I would probably swing towards a BC but really an iB5 would be ideal. Your torque will be relatively high up compared with the Turbo engines which have trashed Bc/iB5s around 200lb/ft, and it will come in more progressively so the weight penalty of the MTX probably isn't worth it. The rod change BC/iB5 'boxes couple with decent engine mounts are also a joy to use. I think you'll have a fantastic package when you're done.

Are you looking to save weight overall? Any plans for that beyond just stripping it out?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 9:27 pm

The car will go through development over time of ownership. my plan is to drastically shed weight. at the moment im aiming to carbon the roof, bonnet and tailgate. If i can get the right people interested in a group buy i will be looking into doors, rear quarter panels and even front wings. I will be looking into even doing a carbon rear boot floor, hence i decided to use a very intrusive cage to begin with.

The whole lot is being fixed with vibra technics mounts and if needed additional braces as development continues. The BC box i have is a RS1800 one so it benefits having the larger bearings.

Am i right i saying early IB5 boxes as in escort gti etc were cable operated? the differance being a stronger casing and shaft?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Smo on Fri Dec 26, 2014 10:07 pm

All rod operated in the Escorts :) I used a GTi iB5 for a couple of years - the iB5s take abuse a lot better than the RS1800 (and similar) boxes! :)

Can't wait to see what your engine makes!
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Excursion on Fri Dec 26, 2014 10:22 pm

RS1800-Cookie wrote:The car will go through development over time of ownership. my plan is to drastically shed weight. at the moment im aiming to carbon the roof, bonnet and tailgate. If i can get the right people interested in a group buy i will be looking into doors, rear quarter panels and even front wings. I will be looking into even doing a carbon rear boot floor, hence i decided to use a very intrusive cage to begin with.

The whole lot is being fixed with vibra technics mounts and if needed additional braces as development continues. The BC box i have is a RS1800 one so it benefits having the larger bearings.

Am i right i saying early IB5 boxes as in escort gti etc were cable operated? the differance being a stronger casing and shaft?


I have my doubts that a Mk3 carbon roof has any real benefit for a non-sunroof model; I think its just an image thing really as the OEM skin is paper thin. Likewise with front wings, and to a lesser degree the boot floor. The rear quarters are technically structural on the Mk3 but don't weigh much either, however the doors and tailgate would be very good to get!

A lot of the real weight in the Mk3 is around the suspension.

As per SMO the early boxes were rod change with a stronger case and bearings compard with BC. The shaft I think was uprated prior to the iB5, in BC 'boxes with a 92WT code on the bellhousing section of the case.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 10:55 pm

Excursion wrote:I have my doubts that a Mk3 carbon roof has any real benefit for a non-sunroof model; I think its just an image thing really as the OEM skin is paper thin. Likewise with front wings, and to a lesser degree the boot floor. The rear quarters are technically structural on the Mk3 but don't weigh much either, however the doors and tailgate would be very good to get!

A lot of the real weight in the Mk3 is around the suspension.

As per SMO the early boxes were rod change with a stronger case and bearings compard with BC. The shaft I think was uprated prior to the iB5, in BC 'boxes with a 92WT code on the bellhousing section of the case.


The roof skins are thin i agree, however there is no debating that a sheet of steel weighs more than a sheet of infused carbon. reducing weight high up will lower the Centre Of Gravity. IIRC the sunroof skin was 19kg, a plain was about 6kg and a carbon was 2.2kg!

i will check my box tommorrow now lol. i found this on your thread hence noticed the ib5 case looks stronger Image
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Fri Dec 26, 2014 11:04 pm

can this casing be used with BC gearing?
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby Excursion on Sun Dec 28, 2014 12:13 pm

RS1800-Cookie wrote:The roof skins are thin i agree, however there is no debating that a sheet of steel weighs more than a sheet of infused carbon. reducing weight high up will lower the Centre Of Gravity. IIRC the sunroof skin was 19kg, a plain was about 6kg and a carbon was 2.2kg!


I think those weights are wrong. Sunroof skin is around 5.5kg, and non-sunroof 3Kg. Remember that the Mk3 Carbon roofs aren't full panels - just rectangles that get bonded over the existing panel with a hole cut in the centre, so by the time you've added the bonding adhesive you're just as heavy as the original (non-sunroof) roof skin. If you can get a complete panel made up including the sections bonded to the side panels/roof gutter, you may save a few hundred grams.

RS1800-Cookie wrote:can this casing be used with BC gearing?

Assuming you have the larger shaft and bearings, yes, it could.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Mon Dec 29, 2014 10:28 pm

either way it made welding the cage at the top much more easy than it would have been. as you say it looks nice too.

Yes i do have the larger bearing box. just bought an ib5 escort gti box ready to swap bit across.

been to workshop tonight, Ive modified the clutch pedal to work with the AP Racing clutch. Basically i had to cut a section off the quadrant, chop a mk5/6 escort pedel (allen key adjustment) and change shape so it sat correctly

I started finishing the cage off for paint hoping to do in next few weeks.

the seat brackets have been modified too as I was not happy with the position. after a trial fit with steering wheel i have now decided to chop and modify steering coloum as it does not sit 100% in the centre of the seating position, it is slightly to the left.
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby s1chris on Wed Dec 31, 2014 8:42 pm

Bravo sir, great build so far.

Too many comments from me on this so just to summarise, i love it (still prefer a turbo though lol)

I've seen in recent weeks GRP boots and bonnets for the mk3 on eBay.
Taking repair costs into account (you may find the Armco, who knows?) it may make more sense to use these for the only modest weight saving you are going to get using Carbon panels. Especially versus GRP. Not only that but if your feeling advenagerous you could make them yourself using the originals as moulds. Check out the "build your own kit car/haynes roadster book" for a pretty good guide on how to do it. I would have a set off you if you made them that's for sure.

I may have missed it in previous posts but are you also using Poly windows?
I want to use them all round but also want to retain the opening rear window so will probably give it a miss as I want the car to remain standard looking from outside and it would look odd.

I'm also going for the Custom Cages cage. It looks by far the best, if not only weld-in cage for the Fez.

I've got a build thread running, but CBA to write it on two forums so it's over on the RSOC site.
http://bbs.rsownersclub.co.uk/showthread.php?t=558947

Looking forward to more updates.


Cheers Chris
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 26/12/14

Postby RS1800-Cookie on Thu Jan 01, 2015 6:51 pm

s1chris wrote:Bravo sir, great build so far.

Too many comments from me on this so just to summarise, i love it (still prefer a turbo though lol)

I've seen in recent weeks GRP boots and bonnets for the mk3 on eBay.
Taking repair costs into account (you may find the Armco, who knows?) it may make more sense to use these for the only modest weight saving you are going to get using Carbon panels. Especially versus GRP. Not only that but if your feeling advenagerous you could make them yourself using the originals as moulds. Check out the "build your own kit car/haynes roadster book" for a pretty good guide on how to do it. I would have a set off you if you made them that's for sure.

I may have missed it in previous posts but are you also using Poly windows?
I want to use them all round but also want to retain the opening rear window so will probably give it a miss as I want the car to remain standard looking from outside and it would look odd.

I'm also going for the Custom Cages cage. It looks by far the best, if not only weld-in cage for the Fez.

I've got a build thread running, but CBA to write it on two forums so it's over on the RSOC site.
http://bbs.rsownersclub.co.uk/showthread.php?t=558947

Looking forward to more updates.


Cheers Chris


Thanks Chris for the kind comments :)

Hope everyone got good ford gifts for xmas :lol: and had a workshop free new year !

I saw the trolley grp tailgate go for £82.00 and cried! my phone froze when i tried to bid!!! :x :x :x
I dont fancy making panels myself, would rather leave that to Raj at Autoflock TBH .... top lad he is!
I have considered costs etc and for now will look at doing the bonnet, tailgate, and poss doors if at a good price for now. Armco??? we dont mention that stuff its sinful! :rolleyes: i will not be opening the taps up on track till 1. im happy the corner weights are set and 2. till i get everything spot on and i feel comfortable with how it handles.

I dont intend to use poly windows, i did consider once but seeing as i want pop open rears i have decided to use glass with a protective film on inside.

The custom cages weld in cage is awesome! tho take your time fitting! measure and be prepared to use ratchet straps to compress bars and porta power to press bars apart. ( will need to for dash bar) a cage aparently is better under slight tension so im told by a person who did mini 7 cages. try to make all the bars meet one another for triangulation and points of stress. custom cages give you 110mm tolerance but i found it was possible to make them all meet. Only two modifications made to my cage.

the diagonal above the roof was replaced to a single bar down middle and the X door bars wer fitted a little lower to ease access. if you want some detailed pics of fittment to use as guide then i shall take some of my cage.

will take a peek at your build :)

cheeRS
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 08/01/2015

Postby RS1800-Cookie on Thu Jan 08, 2015 10:25 pm

Today I managed to start the prep to paint the car. I have done one coat of wash primer and sanded down areas ready to put the coat of high build on tommorrow. hoping to have the car painted inside by next week.

the rollcage is going a darker shade of silver (ford machine silver) with the rest of the inside going Radiant red same as outside.

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[imghttps://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfa1/t31.0-8/10818225_10153622663313438_2665180732854028661_o.jpg][/img]
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 08/01/2015

Postby RS1800-Cookie on Thu Jan 08, 2015 10:34 pm

ordered my dry sump tank too, gone for this one.

[imghttp://www.sm-engineering.co.uk/products/dry_sump.jpg][/img]

also got my dry sump pan and pump sorted :D

[imghttps://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xaf1/t31.0-8/10924616_10153622785318438_3906298010390947073_o.jpg][/img]
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE 16/01/2015

Postby RS1800-Cookie on Fri Jan 16, 2015 8:10 pm

I have had some free time on my hands the last few days. the result......

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[imghttps://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10931145_10153642405703438_5002500378390378627_n.jpg?oh=5c868347765841e65d9bb02befcc40be&oe=55676EB8&__gda__=1428659933_3ca89ee3f50c5e9f965261602ba1fa74][/img]

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Now to start building it up!

ford fair! ford fair! ford fair .... keep telling myself this and it might actually happen lol
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE PAINTED 16/01/2015

Postby Dazza on Fri Jan 16, 2015 9:09 pm

Looking good Cookie, nice colour contrast!
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE PAINTED 16/01/2015

Postby Excursion on Tue Jan 20, 2015 2:00 pm

Looks great!
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Re: Cookie's Mk3.5 Fiesta RS1800 UPDATE PAINTED 16/01/2015

Postby 285Andy on Tue Jan 20, 2015 5:36 pm

love the contrasting colours of the red and silver! great project mate!
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285Andy
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