fiestaturbo.com

[leighk2010]

Hey mate love what your doing after reading the hole thing you have tempted me to do a zetec ka instead of my old and tired mk3 fiesta, how hard is the wiring or do you not really no as you are using the omex i mite go for a mega squirt ecu instead? My plan would be to put a 1.8 or 2.0 zetec in to start and get it running and working fine then build up a turbo lump to put in. As for the rad etc i see you are using the xr2i item would all the pipes from the xr2i/r1800 or si fit or would it be custom pipe work too? Also i bet its fun to drive my mate had a ka slammed on coilovers and it handled just like a go kart it was a smart ka i tryed tell him put a better engine in it but to much work and effort for him what’s it like with all that power in such a small car what kind of cars could you embarrasses in it .

[cowie20]

i spied a st150 qauife box on ebay at nice price....wish i had money to purchase it!!!

yeah mate, i got hold of a plastic one other day.

nice one with frst reg fitting rail. you wouldnt happen to have a spare FRS fuel rail? or is it same fuel rail thats on normal 2ltr blacktops>?

[jonyb4]

Hey mate love what your doing after reading the hole thing you have tempted me to do a zetec ka instead of my old and tired mk3 fiesta, how hard is the wiring or do you not really no as you are using the omex i mite go for a mega squirt ecu instead? My plan would be to put a 1.8 or 2.0 zetec in to start and get it running and working fine then build up a turbo lump to put in. As for the rad etc i see you are using the xr2i item would all the pipes from the xr2i/r1800 or si fit or would it be custom pipe work too? Also i bet its fun to drive my mate had a ka slammed on coilovers and it handled just like a go kart it was a smart ka i tryed tell him put a better engine in it but to much work and effort for him what’s it like with all that power in such a small car what kind of cars could you embarrasses in it .

if its the wiring your concerned about, im pretty sure the mk4/5 fiesta and 1.3 OHV ka's share the same wiring and fusebox layout

if so you can find all you need to do to get a Zetec running in it in my mk4 thread, its early on in the conversion part of it, around page 15 or so

take a look could help you out

click my sig for a link to my thread

[moondustka]

Hey mate love what your doing after reading the hole thing you have tempted me to do a zetec ka instead of my old and tired mk3 fiesta, how hard is the wiring or do you not really no as you are using the omex i mite go for a mega squirt ecu instead? My plan would be to put a 1.8 or 2.0 zetec in to start and get it running and working fine then build up a turbo lump to put in. As for the rad etc i see you are using the xr2i item would all the pipes from the xr2i/r1800 or si fit or would it be custom pipe work too? Also i bet its fun to drive my mate had a ka slammed on coilovers and it handled just like a go kart it was a smart ka i tryed tell him put a better engine in it but to much work and effort for him what’s it like with all that power in such a small car what kind of cars could you embarrasses in it .

Wiring isn't too big a deal.. It's the stripping out of everything in the Ka that is best to do that don't need, air con, power steering etc. Reduces the loom a lot! I ended up with a big ford bag full of wire I didn't need! Plus then you make the car run on 1 ecu, otherwise you end up with 1 ecu for the car and 1 for the engine.. The wiring takes 2-3 solid days!!

Omex is the nuts though

Pipes I'm going to source off other fords down the scrappy for now. Might get some silicone ones eventually.

I don't even know if this rad is going to be good enough, but it fits nicely.

It was really fun to drive and I miss it loads already especially as the weather got much better since I took it apart! Was a shame breaking a perfectly good working car!

I've embarrassed many cars

[moondustka]

i spied a st150 qauife box on ebay at nice price....wish i had money to purchase it!!!

yeah mate, i got hold of a plastic one other day.

nice one with frst reg fitting rail. you wouldnt happen to have a spare FRS fuel rail? or is it same fuel rail thats on normal 2ltr blacktops>?

Cool. No, i don't have one mate, but when I looked at a 2.0 ltr mondeo to get my thermostat housing it's the same rail but different Feed pipe. On the RS it's all metal, and bends nicely round the inlet underneath the rail. Shame I can't use it!

[leighk2010]

Hey mate love what your doing after reading the hole thing you have tempted me to do a zetec ka instead of my old and tired mk3 fiesta, how hard is the wiring or do you not really no as you are using the omex i mite go for a mega squirt ecu instead? My plan would be to put a 1.8 or 2.0 zetec in to start and get it running and working fine then build up a turbo lump to put in. As for the rad etc i see you are using the xr2i item would all the pipes from the xr2i/r1800 or si fit or would it be custom pipe work too? Also i bet its fun to drive my mate had a ka slammed on coilovers and it handled just like a go kart it was a smart ka i tryed tell him put a better engine in it but to much work and effort for him what’s it like with all that power in such a small car what kind of cars could you embarrasses in it .

if its the wiring your concerned about, im pretty sure the mk4/5 fiesta and 1.3 OHV ka's share the same wiring and fusebox layout

if so you can find all you need to do to get a Zetec running in it in my mk4 thread, its early on in the conversion part of it, around page 15 or so

take a look could help you out

click my sig for a link to my thread

cheers mate read ya hole thread last nite you have done a good job on the mk4 wiring does not bother me as long as i have the right drawing etc as have wired quite a bit of stuff up b4 love the mk4 mate

[leighk2010]

Hey mate love what your doing after reading the hole thing you have tempted me to do a zetec ka instead of my old and tired mk3 fiesta, how hard is the wiring or do you not really no as you are using the omex i mite go for a mega squirt ecu instead? My plan would be to put a 1.8 or 2.0 zetec in to start and get it running and working fine then build up a turbo lump to put in. As for the rad etc i see you are using the xr2i item would all the pipes from the xr2i/r1800 or si fit or would it be custom pipe work too? Also i bet its fun to drive my mate had a ka slammed on coilovers and it handled just like a go kart it was a smart ka i tryed tell him put a better engine in it but to much work and effort for him what’s it like with all that power in such a small car what kind of cars could you embarrasses in it .

Wiring isn't too big a deal.. It's the stripping out of everything in the Ka that is best to do that don't need, air con, power steering etc. Reduces the loom a lot! I ended up with a big ford bag full of wire I didn't need! Plus then you make the car run on 1 ecu, otherwise you end up with 1 ecu for the car and 1 for the engine.. The wiring takes 2-3 solid days!!

Omex is the nuts though

Pipes I'm going to source off other fords down the scrappy for now. Might get some silicone ones eventually.

I don't even know if this rad is going to be good enough, but it fits nicely.

It was really fun to drive and I miss it loads already especially as the weather got much better since I took it apart! Was a shame breaking a perfectly good working car!

I've embarrassed many cars

cheers mate every one i spoke to has said dont do it to a ka lol but i think its very good car under the bubble looks and they do hand well

[jonyb4]

cheers man

[moondustka]

Small update - this all takes soo long!

Bolt holes drilled and tapped for headlight mounting point..



Will use aluminium spacers for better fit, which reminds me, I need to buy some bar!



Then I set about plating up some open ends..













Then, to aid me in making the radiator brackets in aluminium and round them etc. I went and bought one of these from machine mart! It's pretty good! ..and not a bad price either.



Then cut my welded steel brackets off and drilled and tapped a thread for the aluminium to bolt to





I've made the new brackets but having a mare getting the radiator to sit right with them!

Not sure I can do much now until i can get the engine in to see where everything comes too! For that to happen I need the flywheel back from machinists, bolt it on, clutch on, mounts back for engine and bolt all those on, then the gearbox on and engine in.. only to come back out again to filler and paint

[jayrs]

the joys of such a mod mate , , still, will be worth all the work fcuking about in the end though

[jonyb4]

great work mate, for a crash course in fabrication your doing brillant

[moondustka]

Bit of work last night and today

Skimmed 1.8 zetec flywheel



4 paddle Clutch - 2nd hand, but hardly worn! Just took the shine off the cover plate, as that's what you're meant to do apparently ?!



Then, made up some spacers for the headlight bolts as there's a gap







Then time to make this metalwork a bit nicer. Went over a some P40 fibreglass first, then P38 filler..



















Might need one more going over and then higher grade paper.

Test fit of engine tomorrow!!

[jonyb4]

eek exciting times, good effort on the dressings, will look stunning in satin black

[jayrs]

nice work mate

[Smo]

Lovely work you're doing there

[hb69]

Looks good so far

[MK4 Rick]

im enjoying reading the thread.keep up the good work

[garyhurn77]

looks really good mate glad you and your brother have still got these!!!!

best of luck

[moondustka]

Thanks for all the comments helps make it worth all the effort! I know it will be when I finally thrash it (gently!)!

[moondustka]

One of the big moments I was waiting for!



It's in!

And the standard inlet fits nicely



Sad thing is there are 2 problems!

Here's one:



Can be changed quite easily.. just more work!

And this isn't really a problem, but it's so close it's ridiculous! I also don't have any space for fans with the 'new' cross member I welded. So time for a re-design! And luckily I have a possible solution on the way!

[moondustka]

Also, anyone know whether 1500 M 3/h @ 3.75mm of airflow from fans is any good? means nothing to me

[knuckles]

bloody hell thats close !

no room in front of radiator for a fan ?

[moondustka]

bloody hell thats close !

no room in front of radiator for a fan ?

Unfortunately not, because of my 'new' cross member.. But I've had to re-think this and re-design the front again. I've made up 3 pieces of 20mm steel conduit, and double set them each end, then welded them together, still yet to fit this all to the car, but that gives me 100mm between the compressor housing and the new bars.. The rad is 30 and the fans are 60mm at the highest point. This gives a maximum of 10mm between the rad core and the turbo! Hopefully it wont hit when the engine rocks. It wont hit as the engine revs, it'll be when I snap the throttle shut! Got one hard gearbox mount on it's way though, which should help!

[jonyb4]

bloody hell that looks huge in there


"thats what she said.."

im sure you'll sort them niggly problems out, but f**k its tight lol

[jayrs]

thats a bloody tight fit mate.
you could make and fit a engine stabilising bar to ensure it doesnt tw@t the rad

[Dave_B]

looking good benjamin! may well come and see it in person on sunday!

im only after the engine loom but might as well have a nose at the motor!!

rs got a clean bill of health today, good for another year!!

dave

[moondustka]

thats a bloody tight fit mate.
you could make and fit a engine stabilising bar to ensure it doesnt tw@t the rad

By the time I've finished, I should have 10mm between the rad and turbo Got a polyurethane rear gearbox mount coming too. Should help stop it rocking.

To be honest.. it doesn't really fit at all. It's a lot of fabrication to do this. But that's what you get for trying what (as far as i know) no one has done before

Dave:

The RS on omex now?

Yea, come round sunday. I'll be on it all day! Picking up dans FRS lump saturday morning!

[jayrs]

this is all part of the fun mate.

[Dave_B]

Almost mate. Need to build the loom!

Got it through the mot this week though!!

How early you about on Sunday?

[moondustka]

Almost mate. Need to build the loom!

Got it through the mot this week though!!

How early you about on Sunday?

Ah I see Good Stuff.. Hurry up and get omex on it. It'll run nice then

Quite early mate... I need to hurry up myself in building this car

[moondustka]

Lot's of pictures

The re-design begins! Bending these steel conduit tubes with a double set in each end and all 3 the same is damn difficult!! They're not absolutely perfect, but they are hand made turned out pretty well I think.





Put in a temporary bar to help stop chassis legs moving now engine is in... though it still moved a couple of mm. So wedged a bit of wood against gearbox





New bars welded on, and bumper test fit.



And now a jump in progress! To get everything to fit nicely for Rad and fans on the front. Had Joey (previously had black focus RS powered Ka) round Saturday evening/night/early hours of sunday morning! And managed to make up the radiator mountings, so fans and intercooler would fit (Thanks very much joey!)





Much more space for turbo



The tape across the rad is so we could see where the bottom of the fans will sit on the rad. The cardboard is the depth of the fans.





Cored a hole for this - still needs to be a little bigger!



Sundays work - Intercooler mountings and brackets made up to tie the bottom of the rad & intercooler together to make it really sturdy (and I didn't think it would work too well, but it does, because of the way the radiator is mounted at the top and the rigidity of the intercooler top brackets.





Test fit again







Bottom brackets. Currently bolted to the bottom of the radiator, but on the new one, I might weld the brackets to the rad.







And how it's standing at the moment. Now it all needs to come off so the metalwork can be tidied and prepped for painting



Now that everything fits, hopefully the worst part is over! Was fun seeing it come together though. Very excited now!

[jayrs]

some excellent work there mate
are you planning anything for added cooling to the rad? holes/grill in bumper?

[jonyb4]

wow im amased, im loving the sheer skill of your fabrication going into this job, its fantasteg as we'd say in wales

such a sleeper, pity you cant use a beefier cooler as lord knows that zetec will want it


getting me excited for this one mate

[mrorange2]

This is wicked great work mate very impressed.

[moondustka]

some excellent work there mate
are you planning anything for added cooling to the rad? holes/grill in bumper?

Going to see how it goes.. I'm sure I'll have to end up doing something, but will try it first. People have cored holes above the number place in a line. I was thinking (just an idea) of placing the standard ka grille, which has lots of round holes to it as a template and marking which holes I want to drill. It might be more discreet. On the other hand it could look terrible

such a sleeper, pity you cant use a beefier cooler as lord knows that zetec will want it

That intercooler came off an FRS lump that was running 370bhp apparently, so good enough for me We got it with the other FRS lump which came out of a racing puma which was mag featured back in 2004. It came from pumabuild.

Will hopefully be starting more work on the car a bit later - nothing exciting though!