fiestaturbo.com

[allinking]

Sounds like this is gonna be one safe mk3/3.5/4/5 fiesta only thing is arnt they designed to give way in certain ways rather than put the force of a crash through you so making it stronger just moves the force further back towards the driver? Love the work though and has made me start putting my are back together

[niracka]

oh I know you'v not designed any ot the parts for this build.

I was referring to this

i reckon you could design and make a whole new car from scratch if you had the time

he has

It does sound like you are going to be building a very safe aswell as fast car then mate. I guess all this extra welding and strengthening will enevitably make the car stiffer and provide a positive effect on handling aswell.

ollie

[Excursion]

only thing is arnt they designed to give way in certain ways rather than put the force of a crash through you so making it stronger just moves the force further back towards the driver?

The passenger cell should never be compromised, crumble zones are fore and aft of the driver The stronger the A pillars are, the better.

[J-Dee]

OH DEAR GOD!!

Jesus man ive jus found this thread, looks fkin amazin mate! Eager to see a finished result, doubt that'll be for a while tho aye
How did u even come up with this idea? I think the plannin alone wudda put me off it haha

[niracka]

Your right about the wont be finnished anytime soon bit

He's been at it for ages and everytime the thread pops up again its gone ever more crazy.

[Excursion]

My hectic work and social lives don't help the project - I'm still in the office typing this It's more of a relaxtion therapy for me when I want to drive north and escape the city for a weekend

It will be done though, I've had a couple of years break from car projects and I'm now enjoying it once more.

[muz]

Car project to most of us means a black dash and colour coded door handles though Mark This is off the scale.

[Excursion]

lol

[FlashXR2i]

well...

the words are not enough...

knowing Mark's approach, there's no doubt - this will be one mad mad more-than-factory-quality fiesta.

thumb up!

[niracka]

Well I have said this pleanty of times Mark, but I hope you will take me for a bit of a drive in this when its finnished

keep updates coming

ollie

[Excursion]

I only had Sunday afternoon free this weekend unfortunately.

Starting with my shell the next task was to clean up the seams that would join it to the Mk5 front end. I'd only made rough cuts to remove my front end, so I had to drill out more spot welds and remove scrap sections of floor pan, inner wings etc.

As it started off.
If you look closely here you can just make out a section of inner wing welded to the A Pillar, just forward of the top door hinge. Lots of tidying up to do:


Plenty of waste metal left that had to be carefully un-picked.
Interestingly the Mk5 doesn't have the gusset that you can see in the bottom of this image, which joins the sills to the wheelarch. I'm leaving this in place for added strength:


A Pillar tidied up along the factory seams:


Inside the A Pillar with remaining section of inner wing removed.
The A Pillars are of 3 piece construction; a thinner outer skin, a thicker central reinforcing piece that the door hinges are welded to, and a rear cover:


Mk3 inner wing outer sections removed from the A Pillar:


Finished and prepped with weld-through primer:



I've got the same to do on the O/S then I'm ready to trail fit the Mk5 front end!

[rstirl]

tidy afternoons work!!

amazing project lad, only been following it for a few weeks now but ive read through the whole thing, fair play.

[Excursion]

It might be useful if I explain the structural chassis differences that I've found so far:

1989: Mk3.

• First inception of this platform, continually developed through to the Mk5 in 2000.

1994: Mk3.5

• Front seat cross member modified and reinforced
• Gussets from A pillars to upper bulkhead crossmember
• Gussets from sills to wheel arches
• Internal, high tensile steel safety cage
• Inner wing outer sections now extend for the full length of the inner wing inners
• Modified bulkhead
• Modified Floor pan
• Modified lower bulkhead crossmember
• Modified rear turrets
• Under-floor chassis rails now run the full length of the floor pan

1995: Mk4

• 100% of the car is changed from the bulkhead forward, incorporating substantially stouter chassis legs and a new one piece sub frame for the steering rack and lower arms.
• Delete - Gussets from A pillars to upper bulkhead crossmember
• Delete - Gussets from sills to wheel arches
• Modified A pillar inners
• Modified bulkhead
• Modified floor pan
• Modified rear top mounts
• Under-floor chassis rails now twice the width of the Mk3.5, and are extended to cover both rear seat mounting points

1999:Mk4 Phase 2 and 2000: Mk5

• Minor changes to suspension and front sub frame/lower arms

The basic shell and design remained the same from the Mk3, hence why a Mk4/5 rear beam bolts up to a Mk3/3,5. A Puma is simply a Mk4/5 but with a different upper structure.

The rear beam and suspension mounting points are the main reference points that I'm using to align the Mk5 front end.

[MotorcyclesFish]

You win. You should work for Ford or something.


...oh wait.



This project needs more audi v8 diesel in the boot.

[niracka]

Thats some good work on those pillars mate. Look so much tidier. I'm looking forward to seing how the mk5 front end joins to the mk3 shell.

It's really interesting to see the changes the fiesta has been through over the years. You just can't see most of these things by simply looking at the cars.

Keep the updates coming in man.

[Ollybee]

Interesting.

[*]Delete - Gussets from A pillars to upper bulkhead crossmember[/*]
[*]Delete - Gussets from sills to wheel arches[/*]

[Excursion]

Cheers chaps - yep there were no end of changes!

Olly - Not required, the Mk4/5 front end was substantially stronger on its own, so there was no need for extra reinforcement to meet crash test requirements.

[Max M4X WW]

Olly - Not required, the Mk4/5 front end was substantially stronger on its own, so there was no need for extra reinforcement to meet crash test requirements.

You'd think they would just leave it there for fun though anyway

[niracka]

I can't believe we are talking about gussets

[Excursion]

Ha yeah!

Thing is, multiply the time it takes to fit them by the amount of cars sold, plus the extra cost of materials and you're running a loss nearing millions!

This is important given that Ford makes a loss on every Ka and Fiesta that is sold - they are simply useful for getting younger people into profit making cars such as the Focus and Mondeo. The goal for the New Ka is to break even, and the Fiesta to make a profit again!

[niracka]

I didn't have a clue they were actually losing money on these cars. They are such good sellers

ollie

[Excursion]

Me neither until I started working for Ford Financial. It was a shock! Margins are so small now though, it's crazy. Money is made pretty much on options, servicing and finance.

[xrsi]

i would have thought the fiesta was the second bestmoney maker for ford after the focus, i didnt realise it was a loss leader.

Makes you understand now why they are reluctant to bring out hot versions of cars if the money making is on parts, options and services.

Its supprising how well designed the mk3 fiesta was really if they in comparison to other makers cars were able to retain the same basic monocoque for so long with only minor revisions along the way to update to the newer safty guidlines and also to provide facelifts.

[Excursion]

A few parts have turned up ready for the Easter break:


Ford Mk3.5 wings, Mk5 inner wing outers and a set of Mk5 suspension mounting components.


Steel from my cutting list - this is to make a jig.


A Mk5 Zetec-S.

I'll get the Mk5 front end in place during the next few days

[mike_wall15]

Glad to see it nice and dirty, yours is nice and dirty too!!

[Sphinx]

So Mike, what car have you got now?

[mike_wall15]

So Mike, what car have you got now?

Mark and I did a straight swap. I wanted some cash + BMW for my Zetec S, but Mark knocked me down to just a straight swap in the end. I am quite pleased with the new ride though, it has this funny button you press, and about 20 seconds later there's loads of wind in your hair & lots of noise. Haven't figured it out yet...

Hope it all goes ok tomorrow Mark

[Excursion]

I'm really impressed with the car; it's absolutely ideal for what you bought it for. In fact it's made me think that I'd get one if I didn't do so many long journeys.

[Sphinx]

Mike, may I suggest the nearest wet round about

[Excursion]

May I suggest not! I took a deposit for the car yesterday so need it back in the 100% spotless condition it's in

[Ollybee]

Mike, may I suggest the nearest wet round about

[Max M4X WW]

Mike how many miles has the ZS done and what did you pay for it?

Cant believe you have exchanged cars, Would you have done the same with me Mark?

[Captain Tightpants]

Mark,

All looking pretty good so far, I like it. So does the jig still involve you taking the wings & front panel off the donor Mk5?

Good to chat again the other night, I love our late night chats!

Stripped those shafts out you wanted today, will get them off to you with the tunnel first thing next week matey.

Keep it up,

Love you x

Steve

[Excursion]

Mark,

All looking pretty good so far, I like it. So does the jig still involve you taking the wings & front panel off the donor Mk5?

Good to chat again the other night, I love our late night chats!

Stripped those shafts out you wanted today, will get them off to you with the tunnel first thing next week matey.

Keep it up,

Love you x

Steve

Cheers chief

No I don't need to do that to Mikes car, stop trying to scare him I'll be using the front subframe, suspension top mounts and rear beam mounts for reference points

[mike_wall15]

If I hear any wrong doing with my car then I'll be straight the the nearest roundabout!!

It's bloody snowing near mine today mate, there was a lovely 'bong' sound with the temp flashing at 1 Deg C!!! I was like wtf?!