fiestaturbo.com

[stevesoper87]

Well....... I am pretty much speechless to say the least, one at the attention to detail, two at the unbelievable bespoke mods and three the size of your bank balance I've just spent the last 2 hours, bearing in mind its now 1:40 in the morning reading this thread from start to finish and couldn't stop myself from reading to the end even though im shattered. Top work mate and a true inspiration, cant wait to see the finished result

[MK4 Rick]

Well....... I am pretty much speechless to say the least, one at the attention to detail, two at the unbelievable bespoke mods and three the size of your bank balance I've just spent the last 2 hours, bearing in mind its now 1:40 in the morning reading this thread from start to finish and couldn't stop myself from reading to the end even though im shattered. Top work mate and a true inspiration, cant wait to see the finished result

Defo top notch work.I wish I had the time and patients to do it

[Excursion]

Thanks guys

[Excursion]

Minor update.

I've been holding up the engine build; Ian was waiting for me to order a 95mm stroke billet EN40B crank from http://ikengineering.co.uk/cranks.html. I called IKE today to order the crank only to find they are closed until October 9th

In other news the head that Ian had modified for my build was donated to another customer who urgently needed an engine for an upcoming Motorsport event. The finished 2.0 engine made 560bhp on an engine Dyno! I don't have the graph, or boost figures to hand, but it does point to some interesting results in store for my 2.2 engine.

Ian has another brand new crate engine from which to start another head from scratch, and by way of a gesture for passing on my head (which really wasn't and inconvenience at all) he has for me a set of solid Inconel exhaust valves. The previous spec was solid stainless.

The car will be back from the bodyshop at the weekend. It's had a final buff now the paint is hard, and once back at the unit I can begin fit the bodykit and decals etc.

[hamps]

Sounds good

I love this car, your work is awesome keep it up

[Excursion]

I bought my G/F a new (to her) car so I've kept the old one for towing duties; it's the much criticised 2.0 'GTi' i.e. the variant that was probably responsible for ruining the image of the Golf GTi . It's pretty comfy and tows the Fiesta reasonably enough...


Anyway, the car has undergone a final mop to get rid of any marks I've added during the build so far, and it looks even better than before.






Next the bit I've been looking forward to: adding decals, badges, and mouldings.

[willowandmikey]

She's looking stunning good work mate. Was adding rear arch liners difficult ?

[Rhinopower]

You sure you weren't over the towing weight of your golf, and license with that combination?

[creator]

looks amazing mark

[Excursion]

She's looking stunning good work mate. Was adding rear arch liners difficult ?

Cheers. It's really easy! You can either screw them in, or drill holes and use the ford captive fittings (same type as the front arch liners).

You sure you weren't over the towing weight of your golf, and license with that combination?

I hadn't checked TBH, as knew it would be well under. I just checked: max braked weight for the Golf is 1500Kg. The fiesta is around 990 at the moment (no powertrain).

I can tow most (complete) cars with my license, as the combined weight is 3500KG.

looks amazing mark

Thanks mate.

[willowandmikey]

Sorry one more question arch liners off a mk4 or 5 ?

[Excursion]

Sorry one more question arch liners off a mk4 or 5 ?

They are both the same.

I call:

a Mk5.

[HCS PIMP]

Why does this car get sexier everytime i log back in after some time away .
Very good work as always

[mikeymikeyp]

Not tryin to be a knob but ,im sure when I looked in to towing The law states that the towing car can only tow 80% of its maximum weight ,,but hey if its a desent trailer the cops wont bother and ,iv only looked at the last page

Ill catch up next update lol iv not got 20 mins to read and slaver over it again

[mikeymikeyp]

When I had to take that gear off i heat it right up and it slipped right off
Then the box i was taking the LSD out of i had to get a stihl saw in to it ,,Hey im a cheapscate lol


YES I did have a look 2 pages back Its just so nice

[willowandmikey]

Thanks and as always I bow down

[Rhinopower]

Im guessing you have a B+E license then? The weight of the golf is 1100kg so your max towing weight would of been 1100kg otherwise! I still find it mad that i drive 26t lorries all day, but on a car i cant tow a trailer heavier than the car still...

The trailer i hired the other month was just under 500kg but that still left me 1200kg to play with, the passat is surprisingly heavy!


Out of interest are the incolnel valves sodium filled too or does the material negate the need for it?

[Excursion]

Im guessing you have a B+E license then? The weight of the golf is 1100kg so your max towing weight would of been 1100kg otherwise! I still find it mad that i drive 26t lorries all day, but on a car i cant tow a trailer heavier than the car still...

The trailer i hired the other month was just under 500kg but that still left me 1200kg to play with, the passat is surprisingly heavy!


Out of interest are the incolnel valves sodium filled too or does the material negate the need for it?

Yes, B+E. I was just before the cut-off date. I also have G+H but I cannot find a reference to it anywhere.

Passat is a decent tow car

The valves are not sodium filled because of what you suggest: the material negates the need for it. Stainless valves are softer and their dimensions grow/change with heat, whereas Inconel is extremely hard and remains dimensionally stable even at extreme temps.

I didn't know this previously but according to Ian the exhaust valve stems in high power Zetecs have a very hard life, but Inconel keeps the wear characteristics similar to a standard engine.

[Rhinopower]

Showing your age having those extra letters!

Are the valves an off the shelf part, it something adapted from another purpose. Do the valve guides need updating to suit?

[Excursion]

Showing your age having those extra letters!

Are the valves an off the shelf part, it something adapted from another purpose. Do the valve guides need updating to suit?

No idea, mate, to be honest. I'm having another head made up from scratch (crate engine head). I'll ask Ian...

[fiestarsturboblack]

When are we going to see engine bein installed with rest oslf ancillaries mark???? An shes looking good

[willowandmikey]

Secondary Door Seals
I've always planned to improve on the aperture seals fitted to the Mk3. They are a basic single seal which leaves the entire shut area exposed to the elements meaning undue corrosion often occurs on the hinges and seams. The exposed panel gaps also contribute greatly to interior NVH, so there would be little point soundproofing the car to the extent I have if the outer body fittings are left in standard form.

When I was last in the scrap yard I had a brief look around a few of the saloons and purchased some seals which were of a roughly suitable size to work with and modify. I chose some upper and lower seals, the upper covers the A pillar and the lower attaches along the sills (I may revisit the upper seals in the future if I can find a more complete secondary seal which attaches to the door itself).

Here are the seals and the upper mounting brackets which I removed by drilling out their spot welds. The brackets are from a car that was roughly the same colour as mine so I could save time when painting.


Secondary Door Seals - Upper
Photo to show the standard Fiesta aperture - upper.


Here's the new seal shortened, reshaped, and fitted.


Detail showing seal modifications to suit Fiesta aperture, rear.


Door closed demonstrating a perfect seal which will hopefully create a tangible reduction in wind noise.


Passenger side in place. Note: the main door seal isn't yet fitted.


Secondary Door Seals - Lower
Photo to show the standard Fiesta aperture - lower.


The fixings for the lower seals comprise a captive plastic fitting in the sills, and a removable plastic stud that pushes into a stainless steel channel on the seal itself. I drilled the Fiesta sills for five fittings spaced equidistantly, then etch primed and painted the edges of the holes. I smeared silicon grease over the captive fittings before pushing them home.



Modified lower seal fitted.


Here's a test fit of the stainless steel scuff plates I have to go on once the car is completely finished (blue protective film still attached).


Door closed demonstrating a perfect seal.


Again the passenger side was completed.

Can I ask what you used for the secondary door seals in the end I.e which vehicle they were from and how you secured them. Once again I bow down

[GRP16V]

The Fezz trailer pics above,

i have to say: " This is fu*u*king awesome " , Fhrit-shop

[muz]

I haven't checked this for a while, but once again, sterling work, Mark. Please tell me, though, that the ghastly blue anodised bells will be changed for something more, how shall I say, aesthetically pleasing?

[Excursion]

Thanks guys.

Muz, yes Golf anodised like the rears.

New Ford decal and badge applied to the tailgate.


I'm using polished stainless scuff plates from a 'Ghia' model; we were limited to a 5 door model in the UK but I found the part number for 3 door version sold on the continent and used that to order from a UK dealer.
I had to make some notches along the lower edge of each plate in order to accommodate the captive fittings I previously installed to secure the lower secondary door seal.


In place.

[tompeteRS]

I believe those scuff plates were found in the UK on Fiesta 'Black' models only - I'll remember to take my anorak on the way out!

[Excursion]

I believe those scuff plates were found in the UK on Fiesta 'Black' models only - I'll remember to take my anorak on the way out!

Ahh, didn't know that

[Dave G fsi]

Not looked at this thread for a while, looking amazing! Great work

[Excursion]

Thanks Dave

This is potentially the most anal modification so far! For Christmas I bought my Dad a new interior for his A4 Cabriolet, and today whilst helping him to fit it I noticed late door card courtesy lights have colour matched connectors - red for marker, and white for puddle - and a shroud over the back of the lights to prevent stray light coming through other areas of the door cards.


I gave in to the temptation and removed the surplus lights and connectors from Dad's old door cards, and swapped them with those on the Fiesta. Here are my old lights and connectors from a C5 A6:


Here are the new lights and colour coded connectors.


Next up was the interior cruise control wiring. The Ford retrofit instructions are beautifully illustrated but the supporting text is no where near comprehensive enough, so I had to resort TIS to cross-check original wiring diagrams.


I got as far as modifying the retrofit loom to perfectly suit the layout of the Fiesta. The loom provides fused live and switched lives from the clutch and brake pedal switches, amongst other things.

[Excursion]

Recaro equipped Fiesta's were supplied new with two pads that could be added to the front seats to increase lumbar support. The pads are sandwiched between the seat frame and the backrest foam; it's quite a crude system really, but it works. I've added one pad to the drivers seat.


I have decided against using the Mk3 Mondeo instrument cluster due to how it looked in the confines of the Fiesta dashboard. There was too much of a gap between the two dials compared to the space between the dials and the dashboard. For now I am going with a Mk5 Fiesta Ghia cluster which has a rev counter and black dial faces. The Puma/sport series clusters of the same era have white dials and red needles, and look very cheap.


I finished the cruise control wiring this afternoon. I have integrated the Focus retrofit loom by using genuine Ford multi-plugs from the same era as the Fiesta loom, which not only look correct but will also enable me to remove the CC system should I ever need to. It's not really worth taking photos of this work but suffice to say it is quite time consuming! A couple of examples are below.

1) Black two pin plug added to integrate the cruise control loom with the instrument cluster: indicator lamp and VSS (Vehicle Speed Signal).


2) Single pin plug added to the ignition switch for a 12v supply (original pin to be reinserted).


I also added a two pin plug to the previously modified column stalks, for Xenon flash and variable sensitivity auto wipers.

[jayrs]

It's coming in great mark

[freak power]

Im so glad your using black dials rather than white ones, The inside of this car screams class and style and by adding white dials is like the queen wearing sovereign rings.

[Excursion]

Cheers Jay.

Im so glad your using black dials rather than white ones, The inside of this car screams class and style and by adding white dials is like the queen wearing sovereign rings.

Haha, sarcasm? Thanks if not

The wing mirrors on each side of a Fiesta are slightly different, so being a champ I decided to buy a set that appeared to match, not realising that the difference was in fact due to them being LHD and RHD; the offside mirror is longer to help with visibility in the blind spot. The net result was that I had to get another o/s mirror sprayed, only this time a RHD version

Today I rebuilt the o/s mirror with the - correct - RHD parts.


I attempted to show the difference in mirrors here.


Rebuilt.


New internal mirror trims, to suit electric mirrors.


I applied Absorber 15 to any contact areas.



Trim and switch fitted. When this car was built a small hatchback equipped with electric mirrors was still quite something - hard to imagine!


I'm not completely happy with the seating position in the car. The seats are from a Mk3 (89-93) whereas my car is a Mk3.5 (94-96), and the 'anti-submarine' seat mounts make the front of the seat too high - especially given the Recaro's have a degree of this built in. I shall return to the seat mounts at a later date and modify them.


These sections of foam push in at the rear of the wheelarches and prevent dirt/grime etc. passing behind the front wings into the door reveal. They just help keep the hinge area a bit cleaner.


Fitted. It's a bit messy in here as I had the car machine polished and some of the polish has run behind each panel.


The only thing preventing installation of the steering wheel is the clock spring. As I previously mentioned, I need to convert the standard two conductor clock spring to four conductors, to support cruise control. I had a mock up this afternoon to evaluate some ideas and see what approach would be safest and most reliable.


This doesn't look like much but it's the first successful prototype. It is a four conductor clock spring that provides 3.5 safe turns of steering with 0.75 turns of contingency. My steering rack is 2.75 turns lock-to-lock.


Now I can move on and modify the new clock spring I bought from Ford.

[hamps]

Top work as always mate, I love the updates

[Dave G fsi]

Looking great Mark, I managed to get some of those back supports for mine (when it is back in one piece) in the original bags with the instructions. Took ages to find!

I did already have a pair, but they started growing fungus out of the foam, so had t be binned