fiestaturbo.com

[Excursion]

I use Cillt Bang in all the chassis rails, it removes the dirt and Dwarf colonies, it also turns rust to gold. Amazing stuff.

[heeman10]

I use Cillt Bang in all the chassis rails, it removes the dirt and Dwarf colonies, it also turns rust to gold. Amazing stuff.

:lol::lol::lol::lol: This is exactly what I'm saying you have to filter out at the intrvw

[Sphinx]

Its because the Etch primer is still slightly porous (sp) so will let moisture in untill painted, where as the rust converter is totally inpeniterable giving a better protection.

Yeah I read that afterwards

Look what it does to this penny!
Look what it does to this penny!
GOOD AS NEW!!
GOOD AS NEW!!
GOOD AS GOOD AS GOOD AS NEW!!

[Max M4X WW]

Ill let Mark explain muz Once he has returned from the asylum!

[SimonT]

Looking sharp Mark

[Excursion]

ENGINE MOUNTS

O/S
I've taken the opportunity to join the chassis rail to the inner wing for increased strength around the turret area.


The existing turret was cut and then filled in with plate which was seam welded behind in the wheel arch.



N/S
This was considerably more time consuming.
I had to remove a lot of metal from the turret and 5mm from the top of the chassis rail so I could mount a plate to sit the new mount on. No less than 5 pieces of sheet metal join inside the chassis leg (it's a Mk3.5 with the internal steel saftey cage!). The area underneath the new plate is all gusseted and welded to the chassis leg itself (I drilled holes in the top and plug welded them)


All boxed in at the back.


Access hole for a socket to bolt up the engine mount. I cut some tube in to quarters and welded it to the sheet to put the radius on the edge, looks a bit neater than a 90 degree join I think.


Finished:

[Excursion]

ENGINE MOUNTS

O/S
I've taken the opportunity to join the chassis rail to the inner wing for increased strength around the turret area.


The existing turret was cut and then filled in with plate which was seam welded behind in the wheel arch.



N/S
This was considerably more time consuming.
I had to remove a lot of metal from the turret and 5mm from the top of the chassis rail so I could mount a plate to sit the new mount on. No less than 5 pieces of sheet metal join inside the chassis leg (it's a Mk3.5 with the internal steel saftey cage!). The area underneath the new plate is all gusseted and welded to the chassis leg itself (I drilled holes in the top and plug welded them)


All boxed in at the back.


Access hole for a socket to bolt up the engine mount. I cut some tube in to quarters and welded it to the sheet to put the radius on the edge, looks a bit neater than a 90 degree join I think.


Finished:

[Mikee_RS]

so good you posted it twice

well done

[muz]

Top work as ever.

[mk3modda]

looks so tidy and precise top work

[Brammer]

Can't wait until this is complete, its one hell of a car

[Ollybee]

........and it progresses

[jimmyesh]

Nice fabrication mate! Coming along nicely!

[ianFRST]

........and it progresses

at last

[heeman10]

You double-posting 94Ylord!

Good on you for faffing to make the socket access "hole" neat, it would've looked a bit rallycross otherwise, keep that up and this will be a joy to behold when painted! I shouldn't imagine you get too much flex associated with the gap between the chassis rails and inner wings hey? But boy, you'll surely notice an enormous different to the chassis's stiffness with all these touches! Will the engine be mapped on an engine dyno, rollers or on a track? Have you settled on engine management yet?

[Excursion]

Due to slight retardation, I have not had any updates of note for quite some time time. July last year! That's a really long time. I've actually done a fair bit but not updated this thread.

This about sums up where I am:


Engine is in with new mounts made,
Tunnel from S3 in place.

I've had a change of plan, I've ordered the front end of a Mk5 new from Ford, along with a lot of the floor pan and chassis rails. I'm going to utilise the best bits of the Mk5 (chassis from front seats forward) and keep the looks of the Mk3 - which I prefer.

I'm in the middle of making a jig at the moment to ensure the new front end is all in place where it should be.

Shell will be going off to these people in the summer: http://www.surfaceprocessing.co.uk/for-cars.html for a full acid/alkaline dip and new coat of electrostatically applied primer. It's the only way to go, my shell was new in 99 but there is still surface rust in the seams - and there's no way a normal resto will cure that.

More updates in a month probably.

[Captain Tightpants]

Love the sound of the DIP mate. Will be cool when it's at that stage!

Steve

[Ollybee]

Onwards!!!!!!!!!!!!!!

[Brammer]

Agree with Steve, should look cool at that stage

[jayrs]

forgot all about this, any more pics of work so far?

[Max M4X WW]

Looking great! By Mk5 do you mean Mk4/5 or is the Mk5 better than the Mk4? I need to back my current car when people moan about its headlights

[Excursion]

Guys is there a pic in my post, above? There should be one showing the tunnel in place.

Max - The chassis were improved in 1999, when the Mk4 got digital dials and the Mk5 style seats - this was the base for the Mk5's.

[heeman10]

That is not an Audi S3 transmission tunnel. That is a Ford accessory part which you have clearly bought and bolted straight in via the centre console, heater matrix and handbrake bolts. You can't fool me, that is a factory fit part!

Crack on cowboy

[Max M4X WW]

Max - The chassis were improved in 1999, when the Mk4 got digital dials and the Mk5 style seats - this was the base for the Mk5's.

Balls Its being sold

[Excursion]

Small update, picked up a Mk5 front end this weekend with the help of my Dad:







Got a Mk5 floor pan and chassis rails on order. Solves a few problems for me:

Hydraulic clutch master cylinder access hole;
Mk4/5 blower motor/ pollen filter aperture;
Bracing to brake pedal and master cylinder;
Strengthen front end;
Loose the Mk3 suspension;
Fabricate sub frame.

The Mk5 front end is considerably stronger, so are the floor pan and chassis legs. I'll loose 20mm width in the engine bay by using the Mk5 front end, so I'll need to do some modifications. The front chassis legs also need shortening and the inner wings modifying to suit Mk3 wings. All pretty straight forward bar the actual fitment of the front end.


cut and shut reference
A cut and shut is a weld straight across the front/rear end of a car which misses critical chassis seams and areas hidden within box sections. I'm going to recreate the front of my car in exactly the same way it was built - only using Mk5 parts.

1) The entire front end is available, in separate pieces, Ford - in fact this is the route I was going to take but I've saved £400 and hours of measuring by buying the front end complete
2) I will be un-picking all Mk5 seams and joining to my car in exactly the place they fit on the Mk5 - the Mk5 after all is simply a Mk3 with revisions.

[Ollybee]

This has got cut-and-shut written all over it!

[mike_wall15]

Smooth stuff!

What's the pulling car? Is it yours? What car(s) you drive at the mo bro?

[Max M4X WW]

Nice find!

What's that small silver 'car' with alloy wheels in the pics

[Excursion]

I knew a cut and shut reference would come up, so I'll explain here why this isn't one:

1) The entire front end is available, in separate pieces, Ford - in fact this is the route I was going to take but I've saved £400 and hours of measuring by buying the front end complete
2) I will be un-picking all Mk5 seams and joining to my car in exactly the place they fit on the Mk3 - the Mk5 after all is simply a Mk3 with revisions.

A cut and shut is a weld straight across the front/rear end of a car which misses critical chassis seams and areas hidden within box sections. I'm going to recreate the front of my car in exactly the same way it was built - only using Mk5 parts.

[mike_wall15]

Maybe it's a colt?

[Excursion]

It's my Mum's Corsa, the new one. 1.7CDTi SXi. Pretty nice!

Very firm suspension though, I like it personally - similar stiffness to the FRST when it was new.

[mike_wall15]

Ah ok, looks quite big for a corsa!

[Excursion]

It's massive! Cars seem to be getting bigger and bigger!

[Max M4X WW]

I knew it was a Corsa, Just didn't think it was very you or your parents after seeing countless beemers

I'm sure Mike was joking at the cut and shut thing, I think everyone knows coming from you this car will be nothing of the sort!

[Ollybee]

I think everyone knows coming from you this car will be nothing of the sort!