Fiesta cosworth. a few years later...

Post pics of your Fiesta here.

Fiesta cosworth. a few years later...

Postby luke_mk3_st on Sat Jul 03, 2010 10:49 pm

hello everyone i think its about time i started my project thread for my zetec turbo project.
i did have alot of pictures but the comp crashed so lost them but think i still have some on the camera and in my phone so will try and get them on here.
plan of the project is to have a high power "450" bhp car but not a track car like the most have the nice bits aswell.
right so this is what im going to be doing.

ENGINE - GEARBOX:
2.0 liter blacktop bottom end
diamond racing pistons
eagal rods
arp bolts
custom breather
st170 cylinder head
area six inlet manifold
area six exhaust manifold
area six headwork to allow 8200 rpm safely
gt35 dual roller bearing turbo
zetec mtx gearbox / quaife diff
custom driveshafts
custom engine mounts,
pectel / omex managment

COOLING:
alloy rad
rs500 intercooler
oil cooler
pas cooler
samco hoses

BRAKES:
wilwood 4 pot calipers, probably cosworth discs
focus rear calipers and discs
braided brake lines

STEERING & SUSPENSION:
avo gtz coilovers
mk5 zetec s front hubs
racing bearing adjustable lower arms
zetec s rear beam
adjustable drop links
powerflex bushes were neeeded
power steering, rs1800 rack, 2.0 focus pump, racing track rods, custom pipework and cooler


BODYWORK:
the car is at surface processing now as we speak being acid dipped to get rid of absoloutly every bit of rot on the car the only thing left will be the solid steal. i have ready to go on the car new g/ford scuttle panel, new g/ford front panel, new g/ford front wings, the whole front end including the front panel is removable, n/s and o/s g/ford rear quarters, new seals, and will make up whatever else needs replacing. also going to seam weld everything, the car will then go back for another dip to remove any surface rust etc it will then be put in a full immersion tank to be coated, not e-coat as they dont do this anymore but another product that is much better!
then the car will be prepped and painted etc etc as usuall then be painted! no funny body kits etc notmall rst kit!

WHEELS:
rs acessories 5 spoke mondeo style alloys

INTERIOR:
as for the interior everything is going to dynamated, going to keep the frst recaros but retrimed in full black leather! may keep standard dash, but may put a mk6 "st" dash in it with center consol "maybe". black carped, black headlineing, everything timmed nice. opb floor mounted pedal box with bias adjuster mounted in dash. nice high quality sound system.

some of these things will probably change along the way but i do have alot of the bits already.

now for some opinions please... the 2 black trims that run along the side of the roof should i get rid of these completly welding in fresh steel and smoothing it off like they was never there ??? or cut the 2 seal bits off in there so there is 2 dips running down the sides but smooth ones, or keep black trims ?
also smooth arial or keep it ? and have also thought about removing the sun roof!

i will try and get some pics up sooon as i can. comment please on what i have written so far any comments welcome and suggestions.
thanks.
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Sun Jul 04, 2010 8:51 am

just some pics iv recovered of it on the A frame and showing some of the rust off :wink: haha
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on its way to surface processing
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Re: finaly my j343 kbj zetec turbo project

Postby leighk2010 on Sun Jul 04, 2010 10:23 am

hey mate sounds like its going to be very nice, iv also started a zetec turbo build but going take long than yours and im only hopining for 220 ish bhp
like the idea of keeping all the fancy bits in the car too as most cars which are stipped etc only see the track now and then and seems bit of a waste to have everythink out keep up the good work

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Re: finaly my j343 kbj zetec turbo project

Postby Excursion on Sun Jul 04, 2010 10:50 am

I see SPL stopped using the E-Coat, and have moved to a black coloured finish. What are the benefits of the new finish?

I tried Mk4/5 hubs on a Mk3 before and they do fit (I wanted to use them for the ABS sensors to run traction control), but I never checked geometry. The rack sits differently in the Mk5 so I suspect there's the possibility that bump steer characteristics will be changed if you run the hubs in a Mk3.

If you want the ABS sensors then a better option is late Ka or Sport Ka hubs - they are identical to Mk3.5 hubs but with the provision of ABS sensors.

ST CV's will fit Mk3.5 hubs BTW.
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Re: finaly my j343 kbj zetec turbo project

Postby Excursion on Sun Jul 04, 2010 10:51 am

PS don't loose the roof strips, they are a nice feature IMO. On my project I am removing the aerial from the front and placing a VW one at the rear (move the wind noise away from the front seat area!).
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Sun Jul 04, 2010 3:46 pm

thanks.
the reason i went for the mk5 zetec s hubs is because they use a much better bearing than the mk3 fiesta ones.... plus i could get them. bump steer isnt realy a hard problem to get around with a bit of adjustment.

as for the e-coat that was the black coating they had he showed it to me wilst i was there. the new product is a zinc or nickle coating cant remember witch one. it has a much higher contact rate to the metal. ecoat sticks at 1.6 megapixals and the new stuff is 6.0! thats how well it grabs the metal. its what is used in areospace etc. they give some guy 100 year guarentee against anti corrosion on pipes he has had covered. and this stuff just makes the steel look shinny.

as for the roof strips thats the dilema im in... i think the 2 black strips look good but the plastic trims i think are actually rubbish.... iv never seen one smoothed off before has anybody done it on here ??
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Re: finaly my j343 kbj zetec turbo project

Postby Excursion on Sun Jul 04, 2010 6:11 pm

luke_mk3_st wrote:thanks.
the reason i went for the mk5 zetec s hubs is because they use a much better bearing than the mk3 fiesta ones.... plus i could get them. bump steer isnt realy a hard problem to get around with a bit of adjustment.

as for the e-coat that was the black coating they had he showed it to me wilst i was there. the new product is a zinc or nickle coating cant remember witch one. it has a much higher contact rate to the metal. ecoat sticks at 1.6 megapixals and the new stuff is 6.0! thats how well it grabs the metal. its what is used in areospace etc. they give some guy 100 year guarentee against anti corrosion on pipes he has had covered. and this stuff just makes the steel look shinny.

as for the roof strips thats the dilema im in... i think the 2 black strips look good but the plastic trims i think are actually rubbish.... iv never seen one smoothed off before has anybody done it on here ??


The Mk3.5 has much bigger bearings than the Mk3 btw -so they are also an option.

The new coat sounds awesome, I'm glad it's come in before mines ready to get dipped.
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Sun Jul 04, 2010 6:30 pm

ye there actualy going to be using the product begining of next month i think.
o they have roller taper bearings tho or ball bearings ?
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Re: finaly my j343 kbj zetec turbo project

Postby Excursion on Sun Jul 04, 2010 6:57 pm

luke_mk3_st wrote:ye there actualy going to be using the product begining of next month i think.
o they have roller taper bearings tho or ball bearings ?


Roller taper.
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Sun Jul 04, 2010 9:15 pm

Excursion wrote:
luke_mk3_st wrote:ye there actualy going to be using the product begining of next month i think.
o they have roller taper bearings tho or ball bearings ?


Roller taper.



which is why i went for the mk5 ones they use a much better roller bearing. :D
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Re: finaly my j343 kbj zetec turbo project

Postby Excursion on Sun Jul 04, 2010 10:33 pm

luke_mk3_st wrote:
Excursion wrote:
luke_mk3_st wrote:ye there actualy going to be using the product begining of next month i think.
o they have roller taper bearings tho or ball bearings ?


Roller taper.



which is why i went for the mk5 ones they use a much better roller bearing. :D


Cool, but Mk3.5 ones don't give any problems. I assume you're going to run some heavy wheels?

Let me know how the hub measurements stack up against the Mk3, particularly the strut inclanation angle. If everything is the same as Mk3 then I'll probably put some on my Si.

Cheers.
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Mon Jul 05, 2010 7:46 am

its just a matter of the strains etc put on a bearing imo i think there better.
and i will do mate when all the running gear goes back on il take pics aswell. everything will be put on here.
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Re: finaly my j343 kbj zetec turbo project

Postby luke_mk3_st on Thu Jul 22, 2010 8:25 pm

finaly got the photos off my phone! also the car has had its 1st dip at surface processing, i will be picking it up this week and photos will be up as soon as i have it "lets see how many holes it has" lol
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Re: j343 kbj zetec turbo project "photo update"

Postby Ruishy1 on Thu Jul 22, 2010 9:01 pm

good start to your project mate :Q
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Re: j343 kbj zetec turbo project "photo update"

Postby luke_mk3_st on Fri Jul 23, 2010 7:57 pm

thanks mate, i should have the car back on wedensday so there will be more updates then. and then the metal work begins :D
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Re: j343 kbj zetec turbo project "photo update"

Postby FRSJON on Sat Jul 24, 2010 10:00 pm

lovely spec and being properly done,will be watching closely :Q
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Re: j343 kbj zetec turbo project ACID DIPPED :D

Postby luke_mk3_st on Wed Jul 28, 2010 10:42 pm

got the car back from surface processing today and am pretty happy the car is better then i thought :D i advise anyone to get this done its an excellent service. i will take proper pictures tommorow but for now i only have some off the phone just thought id show you how it looks tho enjoy :)
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also i see this peice of road today in sutton in surry and i was so disgusted and confused i stopped to take a photo.....
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i still dont understand after looking at the photo. no signs just this in the road!
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Re: j343 kbj zetec turbo project ACID DIPPPED =D

Postby Excursion on Thu Jul 29, 2010 1:26 pm

Superb! The only way to do it IMO :D
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Re: j343 kbj zetec turbo project ACID DIPPPED =D

Postby luke_mk3_st on Thu Jul 29, 2010 10:27 pm

definatly mate its brillant start from a clean slate no exactly what your left with!
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Re: j343 kbj zetec turbo project something to smile about

Postby luke_mk3_st on Tue Sep 28, 2010 9:08 pm

There will be a pretty big update coming soon but come home to this today and just thought I would let everyone see =D

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Garrett GT3582R

Like I said couple weeks there will be a big update, keep my spirits up people.
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby Excursion on Thu Sep 30, 2010 10:02 am

This is going to be an animal! 8200 rpm - what ratios are you planning for the Getrag box?
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby luke_mk3_st on Thu Sep 30, 2010 2:38 pm

Ye I'm going to do a big update on here soon of everything I have collected and the work done so far! Although you seem to be the only person interested Mark lol as for the ratios I'm not sure yet I will be talking to some people for best advice
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby Excursion on Thu Sep 30, 2010 2:44 pm

luke_mk3_st wrote:Ye I'm going to do a big update on here soon of everything I have collected and the work done so far! Although you seem to be the only person interested Mark lol as for the ratios I'm not sure yet I will be talking to some people for best advice


It is unfortunately quiet on here these days mate :( I'm sure you'll get more replies over time, given that it sounds like you'll have the most powerful Mk3 around!
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby luke_mk3_st on Thu Sep 30, 2010 7:36 pm

ye i was hoping for a few more replyes to keep my moral up! but ye it will be powerfull!! maybe post on passionford to. also was hoping for some good hints etc from people :-? ah well well see what happens.
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby FRSJON on Thu Sep 30, 2010 8:14 pm

your doing a great job and the car will be a animal once complete.. its refreshing to see a car being done 100% properly and i think most people would wish they had the funds to do it this way. keep up the good work and more pics ! :Q
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby Excursion on Thu Sep 30, 2010 8:20 pm

luke_mk3_st wrote:ye i was hoping for a few more replyes to keep my moral up! but ye it will be powerfull!! maybe post on passionford to. also was hoping for some good hints etc from people :-? ah well well see what happens.


Just ask the questions mate when you need help and I'm sure people will chime in :)
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby crazycage on Thu Sep 30, 2010 8:25 pm

without a dry sump you will kill the oil pump in no time mate .
why such a big turbo for 450hp? a gt30 will see that power
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby Excursion on Thu Sep 30, 2010 8:31 pm

crazycage wrote:without a dry sump you will kill the oil pump in no time mate .
why such a big turbo for 450hp? a gt30 will see that power


He said FRST with 400 more mate, so about 530?
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby luke_mk3_st on Thu Sep 30, 2010 9:58 pm

Ye me and Ian Howell have had a good convo with his head conversion the management I'm running and turbo etc and other obvious engine work were looking at 500 - 600 bhp as for dry sump that's the route i was going to go, although Ian howell tells me he has built a big spec
St170 turbo like mine last year and the standard pump was fine however I would rather be safe then sorry especially with the higher rpm so something will be done :-)
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby crazycage on Fri Oct 01, 2010 6:23 pm

luke_mk3_st wrote:Ye me and Ian Howell have had a good convo with his head conversion the management I'm running and turbo etc and other obvious engine work were looking at 500 - 600 bhp as for dry sump that's the route i was going to go, although Ian howell tells me he has built a big spec
St170 turbo like mine last year and the standard pump was fine however I would rather be safe then sorry especially with the higher rpm so something will be done :-)

i miss red it then lol.deffo a 600hp turbo a freind of mine runs one on his zetec :D
i smashed the standard pump gears @7800 on my old st170 turbo :(
and ask luca about his!! ian didnt pay out on his engine when the pump let go after about 2k :o
good luck with it tho :)
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby luke_mk3_st on Fri Oct 01, 2010 8:33 pm

ye i remember reading lukes thread and seeing his engine! i have been looking at dry sump options for the last few weeks, i no you can get the billet gears or titanium ones for the standard pump and uprate to a metal pickup and gated / baffeled sump but that obviously wouldnt be as good as a dry sump. with the build im doing its finding somewere to put the tank etc all these bridges need to be crossed hence why im asking for people opinions etc on here as people have done this stuff before. at the end of the day im spending so much on the car anyway if it means i have to save up for x amount of time for a dry sump kit i will do it as it will just cost even more in the long run!
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby SEG1 on Sat Oct 02, 2010 11:34 am

this build is going to be insane :Q

keeping an eye on this one. :D

keep up the good work.
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby jimmyesh on Sat Oct 02, 2010 8:51 pm

Wow, what an awesome build :o The amount of work going into this is amazing :aviator: Please don't be disheartened by the lack of replies, like Excursion said - it gets like that here a bit sometimes. There's still plenty of enthusiasts here that are still interested and happy to share information :)

530 BHP+ is certainly going to grab some attention anyway - can't wait to see/hear the finished article :devil:
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby crazycage on Sun Oct 03, 2010 10:06 am

just a thought ... would you not fit the mtx box ?? the ratios are pants for big power in the getrag :)
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Re: Fiesta rst rebuild with about 400 more hp =D

Postby Excursion on Sun Oct 03, 2010 10:23 am

crazycage wrote:just a thought ... would you not fit the mtx box ?? the ratios are pants for big power in the getrag :)


That's why I sold the getrag 'box when building my last ST170 ZT project: The Fiesta is light enough to pull relatively tall ratios in a 5 speed 'box. The Getrag has 1.08:1 in 6th on 2.88:1 Final drive. That's only 172mph with 15's and an 8200 rev limit!

MTX75 is a good choice.
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