fiestaturbo.com

[EUFez]

I love it! Must be so much fun to drive...

[moondustka]

it is.. a lot!

[jonyb4]

perfect, i absolutely love this car mate

so inspiring too just finised reading the lot, great read

[moondustka]

Thanks

Took a fair amount of time to get things right! Wow, must have taken a while to read!

[jonyb4]

took me aobut 3 hours, but i read all up untill 2/3 then just looked at the pics and associated text

[moondustka]

:D took me aobut 3 hours, but i read all up untill 2/3 then just looked at the pics and associated text

don't blame you! 3 hours! I would have given up before then!

Pretty pleased with the gauge pods though! Want to get all that silver painted parts of the dash flocked in a similar colour..

[mrorange2]

I think this is great mate very good work keep it up.

[moondustka]

Thanks for comments

Time for the remaining winter update.

Got a Stack boost gauge for christmas. Brilliant gauge, uses it's own map sensor! within 2% accuracy which on 20 psi is 0.4!

Can see the small map sensor on the left there.



I got a bit anal when I wired it



Re-calibrates itself every time you start the ignition



I then ordered these, which are amazing for what they are - need to be amped really.



And heres to fitting:





These are now for sale.. £20 posted



There will be massive updates over the next couple of months!

This engine is now provisionally sold! (It's not even out of the car yet!)



Hopefully I'll have updates within the next couple of weeks..

[jonyb4]

oh god i forgot how goregous that engine bay was mate, looks the nuts

[Smo]

Absolutely love your Ka. Makes me want one to replace the Fiesta!

[Ruishy1]

if your selling the engine, whats the plans then mate ?
i dont like pink, but for some reason it really does work

[moondustka]

I will try to keep as much of the colour with the new engine as poss. All the purple hoses are staying. Might just have to go with a black and purple theme.

I will reveal engine choice when I have a picture

Let the guesses commence...

[Smo]

Focus RS or Zetec Turbo (much the same thing really!)?

[Ratspeed]

good ol 1.3 endura?

[Smo]

good ol 1.3 endura?

Ah, with a Van Aaken turbo conversion

[jonyb4]

lol yea im gonna guess a Zetec Turbo lol, only common way up from a RST lump

[moondustka]

Focus RS or Zetec Turbo (much the same thing really!)?

Wow, thought this would at least last past a day!

Well done this man! Yea I've got a Focus RS Lump on its way soon hopefully. My brother has one already and he's already got his engine out!

[jonyb4]

f**k me 212bhp in a Ka and im sure you'd take it futher lol

your mental llama

[Smo]

Focus RS or Zetec Turbo (much the same thing really!)?

Wow, thought this would at least last past a day!

Well done this man! Yea I've got a Focus RS Lump on its way soon hopefully. My brother has one already and he's already got his engine out!

Excellent! Nice and reliable base with plenty more to be had if needed

[Ruishy1]

bet thats gonna be fun to drive

[moondustka]

I'm already on omex.. So should be no trouble at all to get 250bhp on standard boost, as it's been done before! That's what I'm aiming for and will just up boost a tad if needed to get the 250. I won't accept anything less! The hardest part is getting the engine in there. Got to re-arrange the brake bar! Let alone fitting the rad at the front!

[jonyb4]

my god yea thats gonna be real tight

[moondustka]

Well it's all now under way and more.. Loads of pictures from the past few weeks - I've been slow to update this thread!

Decided that the FRST engine had to go after wanting more power and having to spend thousands on it to get it anywhere near 250bhp, the Focus RS engine seemed like the best option!

So here goes:

Last pics of engine before it came out..





Burnt out the rubber from mine and my brothers rear gearbox mount to be made solid no one does uprated engine mounts for the Ka



Focus engine when we got it (still waiting on another!! - for my brother)



Dan's Ka



and mine facing it:



I set about stripping the Focus engine down of all the stuff I don't need Although I used the alternator and PAS mount (but that one was broken - got another one)



Looking a bit better





Injector looms - one omex adapted FRST (right) and one FRS (left) - unsure what to use, either adapt the Focus one or just use the FRST one.



Focus one is nicer:



I then set about cutting my car apart - as far as I know, no one has fitted a Focus RS engine in a Ka with the radiator in the front! Still, first i cut the slam panel out - it's always been in the way even with the FRST engine there. Caused me grief and a lot of cursing at times! So time to make my own









Scary stuff..

Different shapes don't help!





Then I started making up the new one - and I've never welded before (only watched) So nothing better than to practice on your own car!!



This side was difficult because the metal just after the bend is so thin.. Hard not to blow holes if you get to trigger happy!





Headlight test fit..



The other side - and I think my welding is getting marginally better! Still not great I know!



Finished the passenger side



Then I chopped the cross member out because there isn't enough room for the rad in front of the turbo otherwise!



Welded the rest of the new 'slam' panel in



With both headlights test fitted



New cross member - needs more strengthening though. For this to fit behind the bumper (and I knew this beforehand) I had to take out the plastic re-inforcement bar behind it. I knew all this and a way of moving the cross member thanks to Joey, who did this conversion, but the rad was in the boot - most of you must have heard/seen it!



This is a dummy fit of the Rad - It's an XR2 rad, fits perfectly between the gap and the right height also! The hangers are a mock up in steel. Think I'll do them in aluminium bar so it looks better! and then need to do steel brackets off my new slam panel to hold it at the top .



Then I fitted the alternator in the better place!! Using the Track Designs kit - perfect stuff



I went to the scrapyard this weekend and got another thermstat housing with the sensor threads in - The Focus RS one doesn't have any!

The omex sensor fits straight in the top and my revotec gauge right in the bottom!





Until I came across one problem!



I think I'll put a couple of washers under it, hope I've got enough thread to seal it!

So this is where I am at the moment!

Flywheel is off getting skimmed and balanced, got a clutch. Hopefully getting the engine mounts back this week! or for this weekend and I'll test fit the engine saturday or sunday! Shame it'll have to come back out again to finished welding, grinding, and painting - and some filler on my slam panel so it looks much more presentable!

Should have a steady flow of updates

[jonyb4]

wow im loving the work man, mental conversion and by god your brave to wanna drive such a small car with that kinda power lol

keep at it man ill keep my eye on this conversion


and the other ka you mentioned with the boot rad, was it the orange/red one i seen last year at fitp? that was fudgekin nuts heard him running it, my god it made a nice tune

[Sphinx]

Looks like you're thinking things through with this conversion
Brave many for doing your first welds on your car I spent about 4 days in the shed with random bits of steel before I went near mine

[cowie20]

i like it mate, very good work. will be a flyier when finished? what flywheel/clutch and box you running mate?

is the engine staying standard? also do you have the rear idler pully from the engine?

cheers

[moondustka]

wow im loving the work man, mental conversion and by god your brave to wanna drive such a small car with that kinda power lol

keep at it man ill keep my eye on this conversion


and the other ka you mentioned with the boot rad, was it the orange/red one i seen last year at fitp? that was fudgekin nuts heard him running it, my god it made a nice tune

Cheers!

Nah, the Ka I'm on about is a black one, had ducts through the rear quarter windows, wide arches and comp wheels.

I cant wait, and I'm being really impatient

[moondustka]

Looks like you're thinking things through with this conversion
Brave many for doing your first welds on your car I spent about 4 days in the shed with random bits of steel before I went near mine

Sort of yea I've spent a lot of time sitting on my brothers Ka, staring at the front end, wondering how this is all going to fit! But i will get the rad in the front! I want my car as a car! I've got a bit better at welding, I'm happy to do the rest of it, with the way its going.

i like it mate, very good work. will be a flyier when finished? what flywheel/clutch and box you running mate?

is the engine staying standard? also do you have the rear idler pully from the engine?

cheers

Thanks! Should go really well, will deffo be getting 250bhp out of it no matter what but the engine is standard apart from decat, intercooler omex management. Should get 250 bhp being mapped properly without raising std boost too much if at all!

Flywheel is a 1.8 zetec one (is currently off getting skimmed and balanced. Got a techniclutch 4 paddle to bolt onto my gbox which is fitted with all new bearings 10K ago, a quaife diff, ST150 gears 1-4 and Ka 5th.

Which idler pully? Not sure which one you're talking about I'm not that familiar with this engine yet. Think I might have some sort of pulley spare, can't remember though - will look when I'm home!

[cowie20]

its the pully a back of engine for the belt that runs alt and water pump and pas i think...you would of removed it for fitting alternator at front.

i need it for fitting my belt on my engine...i didnt want to spend 180 for TD kit. even tho it looks a very nice bit of kit.

can i have you box?

[Minstral]

i love ka's with big engines in, so quick

[knuckles]

mental conversion !

respect

[jonboisescort]

great work if anything happened to my car i would put the engine in a ka

[moondustka]

Cowie, my engine didn't come with the PAS, so not sure whether it was taken off then. I don't have a spare pulley, The only one which came off was the plastic one you see back on in the track designs kit half way up the engine.

Sorry

My box is pretty good! but you can't have it, as I'm using it! Cost me £750 in parts alone, and built it with some help for freee!

[moondustka]

Found out the FRST regulator fits nicely onto the end of the zetec rail to give me adjustable pressure. Thank you Ford!



Update of tonight's antics - I needed to make some tabs for one of the mounting points of the headlights. Not completely finished but basically there. They need a hole and thread in and the metalwork to be tidied up. All which will look good I hope once some filler is applied!

Welding getting better? tabs look awful here, they do get better..









Was a nightmare trying to hold the metal in the right place! Was trying to use a G-clamp but kept slipping off and wasn't holding very well!

[jonyb4]

llama i bet it was hard to hold

awesome effort there though, takes nerves to cut up the cross members all that will look fresh as powder coated in black