fiestaturbo.com

[Excursion]

I'm now focusing on the engine bay so I can get it painted.

Pulsar inlet stripped down ready for modification.

Throttle plates removed.

Here's a 10mm alloy Zetec inlet flange laid over the top to show the port work involved:


Next up is my Mk2 Focus TC/ABS module (right) compared with the Mk5 Fiesta ABS module (left). Physically they very similar which means the Mk5 mounting bracket can be swapped to the Focus module for relatively easy mounting to the Mk3 bay. The only major difference is the wiring plug, and the fact the Focus module uses a different type of ABS sensor.



Hydraluic clutch conversion. I was going to use the Mk5 pedal box as I wanted the improved brake link bar setup from that model, but I remembered I had a nearly new Sport Ka pedal box which had the same upgrade, and after some examination it's a near enough bolt on part (the Ka is much more closely aligned with the Mk3 than the Mk4/5 are).
Mk5 (left) Ka (centre), Mk3 (right)


Mk3 (left) Ka (centre), Mk5 (right). You can see the entirely different dimensions of the mk5 box:

[jonyb4]

i loved that car max, first car show with the new owner i seen it had a massive scratch up the back bumper (FITP last year) was my idol when i had the mk4

good work mark, can you retain the brakes you have with this new abs system? what you using for rear brakes? cant see you keeping drums

wheres the sensors going to go? most these days are toothed discs and sensors

[jonboisescort]

will be watching closely at the pulsar inlet

[Excursion]

Jon - sensors are in the hubs. I'm using Focus hubs F+R.

jonboisescort - From what I've done so far, it looks like it will work.

[jonyb4]

oh thats new, didnt think they would fit

[Max M4X WW]

They look like Superleggera on your Mk4?

Yea 16x7's

[Excursion]

I've just given Ian H the go-ahead for a big valve head, double valve springs and 500+ capability. Ian hasn't used a GTX yet so I've been looking in to them to see what they offer. The unit in my kind of power range would be the GTX3071R, which would see 550.

It's been mainly the Subaru guys testing these so far and there is some good data out there if you can find it.The GTX3071R has a similar 60mm Turbine to the GT3076R and dyno tests have shown that the GT3071R (60mm) and GT3076R spooled up pretty much the same on the Dyno, so I'd expect the GTX3071R to be very similar.

We always tell customers, buy the turbo that fits your needs and nothing bigger as it will be slower responding for no reason. In the case of the GTX3071r, I see no reason to sell these as it should spool the same and will make less power than the GTX3076. What I would say is this customer should consider buying the GT3076r as it flows about the same and costs much less. Keep in mind I am guessing that the GTX3071 spools just like a GT3071 because of my results I found with the GT3076/GTX3076 comparison, and my GT3071/GT3076 comparison all using the same turbine wheel.

If you want more response than the GT3076r then you need to look at the GT3071r with the smaller 56.5mm turbine wheel. Garrett doesn't offer this with a GTx wheel which is too bad.

The 56.5mm wheel is missing for me at the moment! The one thing that does attract me to the GTX is the noise, or lack of it from the new 11 vane turbine.

The best of the links I found:
http://forums.nasioc.com/forums/showthr ... 277&page=4
http://bbs.scoobynet.com/799025-scoobyc ... er-49.html

I also just found a local powder coating firm who actually undercoat, none of the firms I've used in the past have done this and I learnt from experience that the less durable finishes like satin always chip and leave rust after a while. I will be going for undercoat this time as it saves me from getting suspension components hot dip galvanised first by a different firm! I'll be going for gloss black as I find it more durable.

[freak power]

Never thought about Borg Warner EFR Turbos? I wish I did a bit more research on turbos but the only thing that would put me off the EFR would be the price of them

[Excursion]

Never thought about Borg Warner EFR Turbos? I wish I did a bit more research on turbos but the only thing that would put me off the EFR would be the price of them

Agreed, very nice! Twin scroll is definitely the way to go! I'm using a WRC manifold on mine which isn't divided, so I'll stick to Garrett for now.

[RS rob]

looking great as usual,
engine really will be a beast
do you want to beat paul j's figure???

[Excursion]

looking great as usual,
engine really will be a beast
do you want to beat paul j's figure???

Thanks mate I'm not bothered about anyone else, magazines, Bruntingthorpe or any of that rubbish - it's all for me.

I'm bringing back your parts to London this weekend, so I'll hopefully see you pretty soon!

[RS rob]

looking great as usual,
engine really will be a beast
do you want to beat paul j's figure???

Thanks mate I'm not bothered about anyone else, magazines, Bruntingthorpe or any of that rubbish - it's all for me.

I'm bringing back your parts to London this weekend, so I'll hopefully see you pretty soon!

happy days mate!!
you got pm

[Excursion]

I've spent the last two Saturday's at different breakers and I've now managed to amass the parts I need for the entire project. It's been a while since I've been to a scrap yard, and it seems as time has moved on and now the majority of Mk5's in are now of a poor standard! It took me a while to find some decent parts from the Mk5's they had in.

Some more inspiration from the Mk5: bracing the bulkhead by joining the rear face of the front chassis legs to the scuttle panel. The brackets were fashioned from CDS and the mounts were pressed into 1.5mm sheet, then the high tensile bolts welded into the recess so they stuck through. Big thanks to my Dad who was helping me today!:


Location of chassis legs marked on the bulkhead. Note spot welds:


Mounts welded in and braces on. You may think 'that won't do anything!', but I've placed them so that the brackets are under compression when tightened, and it has actually done a great job of further reinforcing the scuttle area (which I already seam welded):


I discovered that non-deadlock lock barrels don't have the nessecary tab to actuate the barrel sensors, so I got a set of deadlock barrels from the breakers and rebuilt my existing ones to suit (note the extra tab):



In the car with new lock rods and sensor


Next up was the hydraulic clutch conversion, which involved some time consuming fabrication. Standard pedal box area:


New plate in to reinforce the pedal box area, cover up the original heater matrix outlet, and house the hydraulic clutch housing of the Ka pedal box:


And the same again on the servo bracket. I want to improve pedal feel as much as possible, so I reinforced the bulkhead knowing that it flexes under heavy breaking:


Primed:


Ka Pedal box in:


I've now got all the small clips and fastenings for the shell - I'm pretty fussy and don't like over spray on anything, even if it's not seen, so all of these will be fitted:


Finally I gave all front end chassis sections a good application of Dinitrol and I cannot recommend this product highly enough. I used to thin Wayoyl with paraffin, but if you go too far with that then you've lost all the protection. The Dinitrol comes out of the can like water but sets with a decent thickness - it's brilliant:

[jonyb4]

great work as expected mark, really like the scuttle panel braces, ive noticed alot of jap cars use these on the opposite side of the bulk head coming from the strut top towers, my mothers old celica comes to mind (twin headlamp shape)

[Excursion]

Thanks Jon, that’s interesting and it seems to be a feature of Japanese cars. The Evo’s have always used a bolt-on tubular brace between the A pillar and the inner wing (directly behind the side repeater on the Fiesta), and even the very new ones use this. If I had more time I would add one

[~nomad~]

I would like to do some minor fabrication on you. Sexy whore.

[dontpannic]

I would like to do some minor fabrication on you. Sexy whore.

I love this place

[Excursion]

In the back of Brians van?

[jimmyesh]

Great work mate. The lengths you go to make sure everything is completely perfect is mind-blowing Liking the idea of those bracing bars

[Captain Tightpants]

Made for an interesting lunchtimes reading that!



Looks good man.

Steve

[- Danny Boy -]

Good progress Mark! Whats next on the list of jobs to do?

[Excursion]

Cheers guys!

Next up is to weld in the front top mounts and remove the front crossmember. I'm then going to strip underseal away from the seams underneath (to let them breathe) then wax the whole lot. Add some rear arch liners, strip off the tank and rear beam and send a load of stuff for powder coat. It's all a bit mundane for the next couple of months

[Rhinopower]

I have to read this thread while sitting on my laptop in the bathroom, it gives me a semi and then I have to take a cold shower.

[jonyb4]

I have to read this thread while sitting on my laptop in the bathroom, it gives me a semi and then I have to take a cold shower.

after i seen bathroom i figured you'd say whilst taking a s**t

[Rhinopower]

I have to read this thread while sitting on my laptop in the bathroom, it gives me a semi and then I have to take a cold shower.

after i seen bathroom i figured you'd say whilst taking a s**t

No, i save that for when i read your thread

[jonyb4]

[~nomad~]

I have to read this thread while sitting on my laptop in the bathroom, it gives me a semi and then I have to take a cold shower.

good, repeat daily please, and not with the dog piss shower gel please!

[Excursion]

Wiring update. The loom I've used is from a later Fiesta, and it is split into a main/interior loom and an engine loom. I've now nearly finished the interior wiring changes.
All wire colours are OEM, exterior sections are insulation taped, interior are a mix of felt tape and cloth tape in order to maintain OEM quality.

Additional wires to the engine bay side.
Blue: Outside temp sensor
Re: Heated washer jets +ve
Green: Traction control on/off
The Fiesta never had switchable Traction Control, but luckily there are spare pins in the green & white connectors which join interio loom to engine loom. I have a spare loom from which I will take spare pins and wire up the switchable T/C wire as if it was standard (I have been using Ford OEM colours throughout).


There are some spare pins in the door loom plugs, so I've run an illumination feed through for puddle lights.


In the roof area.
Green: Reverse light and illumination feeds ready for a compass equipped auto-dim mirror.
Blue: Existing interior light
Red: New rear interior light
Yellow: New sun visor lights


Centre console area.
Red: New OEM Focus Heated seat connectors
Green: New rear seat area 12v socket
Yellow: New OEM Focus Traction control connector
Blue: Tailgate release switch


I've added an OEM 4 pin connector behind the instrument cluster area, for ground, +ve and illumination. This is for whatever engine monitoring systems I decide to fit.


I try to keep the soldered joints as neat as possible, and barely larger than the original wire


OEM plug in modules
1) Heated Front Screen -new


2) Passenger Airbag and Seatbelt pre-tensioners -new (there is a seat airbag version I'm currently looking for)


3) Screenwash low level sensor -used


I have a spares pile of OEM looms, so I can utilise any OEM connectors, pins, wire colours etc. Our house is a renovation project so I don't feel guilty about leaving this lot in the spare room...

[- Danny Boy -]

Awesome stuff Mark, as usual!

Something made me laugh...

I have a spares pile of OEM looms, so I can utilise any OEM connectors, pins, wire colours etc. Our house is a renovation project so I don't feel guilty about leaving this lot in the spare room...

... Then I looked at the wiring, and thought, thats not too bad, kept scrolling and saw the box and I was like.. OH! Thats LOTS! lol

[dontpannic]

Very, very impressive Mark. This is going to be one very well thought out car!

[RS rob]

so many top notch mods here,
will be brilliant to see all done!!!

[jonyb4]

impressive stuff mark

liking some of the idea's

your setting benchmarks here, im already wanting to fit a rear light and 12v socket

[Excursion]

Cheers guys.

I collected the new wheels today, only I got them home and they turned out to be 4x114 and not 4x108! I returned them and got a refund. Very annoying given that they were a custom order made to my spec!

[andymac]

Loving the properly finished looms, it's one of those things I find really annoying - seeing a loom that's been butchered by an auto-electrician (or barely evolved simian at the local garage). The one in the rover has been stripped back, repaired in places and rewrapped throughout while the golf will get an entire a 95% new engine loom this year too - it's an easy thing to do, just time consuming.

[heeman10]

You're kidding?! Great, custom order wheels that don't fit! They must be overwhelmed with mildly angry one-time former customers!

This car is missing just two things:

My front bumper.