fiestaturbo.com

[jayrs]

looks very nice mate

[moondustka]

I've dinked the paintwork already but out came the can again and all was good Half the reason for doing this paint, for ease of touch up!

I've made a list of what's left to get the car running! Here's how I'm getting on:

Throttle cable
Gearbox oil
Reverse light switch
Drain last of oil in sump
Oil sandwich plate & oil temp/pressure senders
Oil filter
Earth from block to chassis
Fuel lines up to rail and return from regulator
Driveshafts
Coolant Hoses
Fit Radiator
Mount fans & Wire
Fit Intercooler
Boost pipes
Bleed clutch
Engine mangement (Solder some focus plugs on/lengthen/fit!)
Vacuum Hoses
Starter motor & Wiring
Alternator Wiring
HT leads
Coolant
Oil
Cut/weld flange onto exhaust to meet FRS de cat pipe
Fit Exhaust
Headlights & HID kit
Bumper
Wheels

I stole this list idea off another forum

Anything in green is what I've done

[allinking]

Looking good I hate lists I find they tend to get longer as you start to cross things off and find more bits that need doing

[jayrs]

nothing too major left to do then mate

[moondustka]

Throttle cable
Gearbox oil
Reverse light switch
Drain last of oil in sump
Oil sandwich plate & oil temp/pressure senders
Oil filter
Earth from block to chassis
Fuel lines up to rail and return from regulator
Driveshafts
Coolant Hoses
Fit Radiator
Mount fans & Wire
Fit Intercooler
Boost pipes
Bleed clutch
Engine mangement (Solder some focus plugs on/lengthen/fit!)
Vacuum Hoses
Starter motor & Wiring
Alternator Wiring
HT leads
Coolant
Oil
Cut/weld flange onto exhaust to meet FRS de cat pipe
Fit Exhaust
Headlights & HID kit
Bumper
Wheels
Bonnet cable

Also had to change 2 ball joints on my lower arms. Silly me had left them underneath the hubs and the rubbers split!

[moondustka]

Photos

Reverse switch changed



Then I started making up this coolant pipe from the oil cooler in copper as the std one had seen better days plus I could do with it longer. I'm actually using it in a different place to where it is on the focus!



You can probably see I've twisted the oil cooler round to attempt to make the outlets in better positions for me..





New ball joints.. 2 years ago these lower arms were mint! I gave them 2 thick coats of the hammerrite (brushed not sprayed) and now look at them! Rusty! I'm not bothering anymore



Then, when I filled the engine with oil I noticed I had a leak... from here! (this silly dent, so new one on it's way)



Boost controller solenoid and map sensor in place



I've also done the management wiring and it's now complete (for now - thinking about doing something with the injector loom after it's all running)

Then I set about getting the exhaust on as I had to cut it and get it to fit the FRS downpipe!

The the end off my custom one..



Cut the flange off this piece of FRS exhaust that came with engine..



Put exhaust and flange on the car..





I then measured the gap and cut my flexi out with the correct length of exhaust and tack welded it in.

Then welded it all together!



Fitted it all back to the car, after I'd turned all the lights off and shined and torch round the welds to check for holes!! Which there were a few on both welds. So had to go round both welds thoroughly again.. which then made the welds dead ugly!! but better that than a leaky exhaust!

Now on the car

[moondustka]

Getting there!!

Throttle cable
Gearbox oil
Reverse light switch
Drain last of oil in sump
Oil sandwich plate & oil temp/pressure senders
Oil filter
Earth from block to chassis
Fuel lines up to rail and return from regulator
Ball joints
Driveshafts
Coolant Hoses
Fit Radiator
Mount fans & Wire
Fit Intercooler
Boost pipes
Bleed clutch
Engine mangement (Solder some focus plugs on/lengthen/fit!)
Vacuum Hoses
Starter motor & Wiring
Alternator Wiring
HT leads
Coolant
Oil
Cut/weld flange onto exhaust to meet FRS de cat pipe
Fit Exhaust
Headlights & HID kit
Bumper
Wheels
Bonnet cable

Radiator should be on its way this week coolant hoses are going to be the most difficult part I think! And boost pipes aren't going to be much better!

[jayrs]

getting there mate, its these loose ends that can be a pain but once you complete one you know your nearing the end and it makes it not seem so bad, if you know what i mean.
i look at the xr2 and think, fcuk, i got shed loads to do, the little bits like what your doing is where i wanna be at

[moondustka]

First start should be next weekend!

Getting there slowly but surely - just have to do one thing and complete it then move onto the next.. I can't wait to have this thing mapped!

[jayrs]

no i bet ya cant mate.

[jonyb4]

making good progress there mate, i had similar issues with my exhuast being a zetec in a mk4, it be the same design for you, retrofitting a cat for mot purposes is gonna be a pain, how you plan to go about it?
im hoing i can just cut the pipe after the cat and have it fit into my system and just swap the cat down pipe with decat one

[moondustka]

making good progress there mate, i had similar issues with my exhuast being a zetec in a mk4, it be the same design for you, retrofitting a cat for mot purposes is gonna be a pain, how you plan to go about it?
im hoing i can just cut the pipe after the cat and have it fit into my system and just swap the cat down pipe with decat one

Erm.. I don't mate!

They have 2 problems MOT ing my car for emissions and that's that they can't select KA RS on their system so they can't do proper emissions test, only basic CO2. I think they can fail it for not having a cat because the engine and car now are both new enough that they need one.

My car was over the limit last time, but what can I say - it makes it easier if it's a friendly garage (not sure I want to be posting that!)

[moondustka]

Couple more pics

I've done a couple more things on the list - but instead of keep posting it I'll just update it when I've done more!

Red cable is the one from alternator to battery when it arrives and it's now all tied into position for battery even though photo doesn't show it!



And new sump one that doesn't leak! I put the other one up to the light and I could see the holes in it !!

[Sphinx]

I'm getting tired of saying this but 'great work!'

[jayrs]

f**k me is that wire thick enough

[knuckles]

very impressed

[jonyb4]

lol thats kinda good thena s they cant select 97 fiesta mk4 1.8 petrol either

[moondustka]

f**k me is that wire thick enough

You laugh lol but the alternator puts out 80 amps, and it's about the right size cable really. Don't want anything smaller


Thanks for comments!

and by the way, did the fuel lines tonight and couple of other bits and now ......



She runs!!!!

[dangerousdave]

we want proof



top work dude

[Ruishy1]

agree with dave, proof is needed

[jayrs]

always better to have wire thats over kill than under kill mate, nothing worst than smelling burning plastic and thinking, wtf is that

[jonyb4]

wooot gratz on it running, like theys aid proof pleassse

[moondustka]

I don't have anything I can take a video with

Maybe if a couple of mates come round tomorrow night I can use a phone to get a vid!

It doesn't run very well, missing all over the shop! But it is on my old CVH map Overfuelling like a Bic™!

Waiting on the radiator from pro alloy and this battery that should have turned up days ago will have to call them tomorrow.

Once I get these 2 parts - I can finish everything else! I hate getting held up!

[jayrs]

I don't have anything I can take a video with

what sort of phone you got then even a basic phone 5 years old will do a video
just messing, but really, have you not got a phone that will do video

[Sphinx]

I don't have anything I can take a video with

Maybe if a couple of mates come round tomorrow night I can use a phone to get a vid!

It doesn't run very well, missing all over the shop! But it is on my old CVH map Overfuelling like a Bic™!

Waiting on the radiator from pro alloy and this battery that should have turned up days ago will have to call them tomorrow.

Once I get these 2 parts - I can finish everything else! I hate getting held up!

Got to agree with Jay on this, it's a poor effort to not have something that takes videos these days You're just making that up aren't you until it running perfectly

As for being held up, this does seem to have been built in a matter days so waiting around can't be something you're used to.

Again, top job on all of this. I'm more impressed by the welding and fabrication you've done seeing as you say it's your first attempt

[moondustka]

I don't have anything I can take a video with

what sort of phone you got then even a basic phone 5 years old will do a video
just messing, but really, have you not got a phone that will do video

iPhone, anything less than the current one won't take video - and up until this point I'v never needed it!! But yes, my last 3-4 phones all had video over the last 5 or so years

As for being held up, this does seem to have been built in a matter days so waiting around can't be something you're used to.

7 weeks or so at the moment! Pretty quick I guess! I'm so impatient it's silly.

Again, top job on all of this. I'm more impressed by the welding and fabrication you've done seeing as you say it's your first attempt

Yea.. I got the hang of it really quickly The more you do the easier it gets!

[dontpannic]

You can download an app that does Video for the earlier iPhones

[moondustka]

You can download an app that does Video for the earlier iPhones

Ah! Cheers dude! Will look into that! Have never really needed it so never looked even though I love everything apple

Update on list (pics to follow!!)

I'm nearly there!

Throttle cable
Gearbox oil
Reverse light switch
Drain last of oil in sump
Oil sandwich plate & oil temp/pressure senders
Oil filter
Earth from block to chassis
Fuel lines up to rail and return from regulator
Ball joints
Driveshafts
Coolant Hoses
Fit Radiator
Mount fans & Wire
Fit Intercooler
Boost pipes
Bleed clutch
Engine mangement (Solder some focus plugs on/lengthen/fit!)
Vacuum Hoses
Starter motor & Wiring
Alternator Wiring
HT leads
Coolant
Oil
Cut/weld flange onto exhaust to meet FRS de cat pipe
Fit Exhaust
Headlights & HID kit
Bumper
Wheels
Bonnet cable
Oil breather
Battery
Air Filter

Added a couple of things to the list..

Radiator should be with me wednesday and very latest thursday morn! Car is booked in with TOTD on friday!!!! I'm going to up all night thursday me thinks!!

Let's hope for some good results It has to be at least 250bhp or I wont be impressed!

I need to check the clutch still and sort out why I can't select 5th gear with the gear stick. The exhaust hasn't quite sealed wit the gasket where the downpipe meets so that needs sorting and need to tighten rear gearbox mount

[moondustka]

Pics



Dry cell racing battery, weighs 7kgs, 680 CCA and well, you can see the size!

[andymcd]

f*ck thats great work you've been doing, i take my hat of to you

[Ruishy1]

excellent stuff, remeber to take a vid of your first "kill"

[moondustka]

The update I've been waiting to make!

Rad arrived - had my brother collect it so I could fit it wednesday, as car was booked in for mapping friday!!





The fit..



The fans, sadly the biggest I could fit!! But nearest competitor only flowed half as much air as these!



All fitted..





Loads of room!!



Good fit of bottom radiator hose.. (gonna heat wrap that downpipe though!)



Excuse boost system - it was/is temporary!! (I've ordered all the right boost pipes/hoses - although the turbo to intercooler part isn't changing much!)



Back on the ground.. at gone 2:30am friday morn





So, car went to Chris at TOTD friday.. and apologised for bringing him a lash up of boost system/vacuum hoses/engine wiring!

It was soo hot that day, the engine and cooling system did well to survive the 30 odd degrees it was around the dyno!!

Good test of my cooling system which I had no idea how it was going to perform.. but it did well, espesically sitting in traffic on the motorway all the way home!! Never rose above 95.

So, good news and bad news...

The engine made 249 bhp and 291 lbs of torque. It made 197bhp at 7 psi!! Almost standard

However, i bought a 4 paddle of someone here and basically it's fooked, it just kept slipping with the sudden rise in torque as the turbo comes in, so i didn't get a true reading of power..

The actuator can only hold 12 psi of boost because it's gonna flacid

So basically the upshot was, it's a really strong engine producing that power at that boost, and with those ambient temperatures!

But Chris reckoned there's another 20-30bhp and over 300 lbs of torque sitting there if the actuator worked properly and the clutch didnt slip!!

my adivce to anyone is never buy a 2nd hand clutch, EVER!! unless you like changing them and wasting money getting the flywheel re-skimmed!

Lots of fettling to do now!! Some of which i've done!

Vacuum hoses - all sorted properly now..
Boost hoses/pipes - all ordered (with the no money I have!)
Tidy engine injector loom

Slight problem with the cooling system until the thermostat opens.. I've plumbed it slightly wrong so that the flow isn't right. I've got 2 hoses that the water pump usually sucks in from when the thermostat is shut t'd together so that it tries to pull 2 15mm pipes into 1 and it's not enough so the pump pulls the water out of the rad and sucks the air from the header tank down and fills the tank up!! So anyway I'm sorting that with a 15mm t piece that goes into 1 28mm Hopefully that should cure it!

P.S. Car feels rapid even with a turd for a clutch

[Sphinx]

Great news
I love how subtle this car looks until you open the bonnet, real credit to you

So spill then, who did you buy the clutch from?

[jonyb4]

Great news
I love how subtle this car looks until you open the bonnet, real credit to you

So spill then, who did you buy the clutch from?

word for word, took the words out of my mouth

real credit to you mate, astounding work, and not a word i use lightly

[leighk2010]

great results mate bet you are one very happy camper top job