fiestaturbo.com

[Excursion]

Well the interior retrim is being handled by someone else, which leaves the following main chunks of work:

- Engine build
- Wiring
- Engine bay modifications (ABS, engine mounts, gearbox mounts)
- Engine bay paint
- General reassembly

I've decided to outsource the engine build to someone else because the reality is that this project would likely end up going into next year. I've just got too much going on now to really get this Si finished in a decent amount of time - which is a bit pointless in this case as it isn't a show car; I'm building it as something that can be used every day! I'm a bit dissapointed about this in one way, as it's something I'm more than capable of doing and I feel like I'm giving away part of my project to someone else - but I had to make a sensible decision here based on what I can realisitcally get done in a sensible timeframe.

I've been friends with Ian Howell for years now so he's going to take on my engine build to get away from the Wife and Kids for a bit What I'll get back is 400bhp ready to bolt in, which leaves me to sort out fabrication and rebuilding the car, so I may actually get it on the road for this summer.

Desired Spec
* I'd like to keep the rev ceiling at 7.5k for long term reliability.
* I'd like to do whatever possible to keep NVH to a minimum (if that's at all possible)
* 400bhp max

Long term reliability is also a consideration for me, I'd like it to be 'turn key' for years to come. The car won't be used for any kind of launches or sprinting, but I do like flat out high speed driving, so I'd like it to be able to withstand that. I hadn't added anything regads engine response, rev band etc as I doubt this is much of a consideration in something so light as a Fiesta!

Most important to me would be low speed tractability and good manners (I suspect this is down to the map) - I'd like to be able to take the car away for a weekend and use it for 'normal' activities and around town if I wanted.

[jonyb4]

more or less how i like to have my car (but obviously alot less powerful )

having soemone do the engine for you is alot of sence, but yea diown side is it makes you feel like your skipping on a part of the build, but if it allows you to have a easier stress free build and have it sooner, its a good decision

[Excursion]

Dropped off the engine today, spec is:

• Ported exhaust side (being a Black Top the inlet flows 20% more than a Sliver Top as standard)
• Ians exhaust cam and vernier pulleys on both cams
• Focus RS Pistons
• Ians rods to suit the 22mm pin pistons
• GT2871R and I'm going for a bigger exhaust housing to reduce back pressure - this will raise boost threshold by 250rpm but keep under bonnet temps lower
• TiAL stainless steel exhaust housing
• Pulsar inlet manifold
• Couple of thou honed from the standard bores to allow more expansion room for the pistons, because I want the engine to withstand my high speed driving (props to Ian for this as I wouldn't have known this tip!)
• WRC Inconel exhaust manifold

That's about it - there's really not much work involved to get 400, especially when starting with a brand new Black Top! I'm having it mapped on the Dyno with Pectel T2; I thought T2 was prehistoric but Ian assured me that the processor in it is still better than Autronic. I asked for 400 and Ian said I'll get a good 400 - so we'll have to wait and see what that means

I'm working on the car today and tomorrow. I hope to get the side skirts on, and the mk5 pedal box in.

[fiend]

Nice progress, where will it be mapped at? On an engine dyno?

[Excursion]

Nice progress, where will it be mapped at? On an engine dyno?

Yeah, Harvey Gibbs I think...

[jimmyesh]

Top work - That engine will be brilliant by the look of things

[Excursion]

Top work - That engine will be brilliant by the look of things

Cheers mate. I hope so It feels like a a cop out giving it away to someone else to do, but needs must.

[fiend]

Nice progress, where will it be mapped at? On an engine dyno?

Yeah, Harvey Gibbs I think...

I was going to say Harvey Gibbs. Won't go wrong there.

[- Danny Boy -]

Engine spec sounds good Should be lovely when its all done! Be nice to see this car back on the road too

[SEG1]

with the gt2871r off the car and as your waiting for the engine to be build, you might as well port the wastegate hole to reduce boost creep.
TD done mine and it does make a difference.
not expensive either.

take it you are going internally waste-gated. if not ignore me

[Excursion]

with the gt2871r off the car and as your waiting for the engine to be build, you might as well port the wastegate hole to reduce boost creep.
TD done mine and it does make a difference.
not expensive either.

take it you are going internally waste-gated. if not ignore me

Thanks for the tip mate but I will be going for a TiAL external gate

[~nomad~]

did you get to the bottom of pulsar inlet fitting then?

[Excursion]

did you get to the bottom of pulsar inlet fitting then?

Yes mate, I will upload pics when sorted.

[~nomad~]

was it a case of having a adapter plate made up or machining the inlet itself? very very interested in using same setup on mine, you think it would be good in a N/A?

[Excursion]

was it a case of having a adapter plate made up or machining the inlet itself? very very interested in using same setup on mine, you think it would be good in a N/A?

Ports 1&4 need some welding inside the port and some adjustment with a die grinder. Quite a few breather take offs welding up, and an adapter plate welding on.

I'm ditching the ITB 'cos they are a pain to map, and don't make a massive difference in a turbo car. For N/A i'd leave them but balance them up with an airflow meter used for setting carbs.

[SEG1]

with the gt2871r off the car and as your waiting for the engine to be build, you might as well port the wastegate hole to reduce boost creep.
TD done mine and it does make a difference.
not expensive either.

take it you are going internally waste-gated. if not ignore me

Thanks for the tip mate but I will be going for a TiAL external gate

the way forward

[Excursion]

I fabricated some brackets to hold the edge of the RS skirts firmly against the sill - I rolled a step into some 1mm sheet which will trap the return lip on the inside edge of the skirts. No they're not perfectly straight, I rough cut them with an angle grinder


Mk8 Fiesta front panel clips for the bottom of the skirts (up into the sill) - these weren't long enough in the end, I think they were over £1 each and I over ordered in a big way


I will try something like this:

Drilling holes for the brackets and trim clips - I pumped a load more wax into each hole until it was dripping out of the sill join. I then painted each sill with semi-set Waxoyl.


Brackets fitted and a skirt fitted to show the good fit



Windows are in, new side mouldings, new weather seals etc (had to wait an age for the Mk5 aperture seals as they were on back order!) and new genuine lights all round - although I have changed my mind about the lights and will fit some smoked side repeaters and my UK RS accessory rear lamps. Here's the car with the skirts and new brakes fitted. I'm going for silver calipers with blue AP Racing decals.


I'm still waiting for a Mk5 aerial which is on back order, when it arrives the car will be water tight and I can give it a good clean. I will take some pics with a decent camera when that's done!

[- Danny Boy -]

Awesome stuff as usual!

[EUFez]

Awesome work! I've fallen in love with this colour.

[jonyb4]

looking fantastic mark, i love this colour so much

cant really see whats going on witht hat plate you've made, where is it?


the brakes look stunning, id honestly say leave them red, ive not read your going for a sleeper look, they shoud be shown proudly

[knuckles]

Mk5 aerial on backorder ? WTF

are you talking about the base or the rod ?

[tompeteRS]

Looking good

Did you manage to sort all the mouldings out Mark?

[Excursion]

Cheers all

Mk5 aerial on backorder ? WTF

are you talking about the base or the rod ?

Both mate, the strikers, door seals and a few other bits were also. I ordered in the first week of Jan and they only arrived at the end of last week

Looking good

Did you manage to sort all the mouldings out Mark?

Not yet mate, I will take the rear quarter one from you: please drop me an email with your price and payment details.

[jimmyesh]

Looking good

[Excursion]

I've changed my mind again with regards wheel choice Another set to sell!

I've now decided on some Team Dynamics Pro Race 1.2 in Anthracite


I have an additional 44mm rear track - 22mm either side thanks to a combination of Ka hub spacers and ST170 brakes, so I know 205 profile will work there, but what about the front? Can 205/40/16 work?

[Max M4X WW]

Same wheels as I've got for mine, look forward to seeing them on

No idea about tyre size, I was going to use 195/45/15 to start with

[RS rob]

how wide are the wheels mark? 7j???

[Excursion]

how wide are the wheels mark? 7j???

Yes mate

[RS rob]

two options the way i see it
- 195/40/16 (would be too harsh for a refined gentleman as yourself) but would be the easiest for fitment and lack of rubbing
- 195/45/16 would be the best compromise

the 205 width tyre is envolving the archwork needed for 17's basically
i remember all the arch trimming i did years ago

[jonyb4]

couldn't agree more with the choice of wheels, the colour will be interesting to see how it works with the aubergine

can i ask where the Ka spacers were sourced from?


I'm in two minds whether the pro race 1.2's or 3's would suit my car best

[SEG1]

i run 205 with no issues ,but they are 15s
205/50/15

[leighk2010]

coming on very well mark!

love the td 1.2s would really like a set for mine..

also how hard were the brakes to fit in the end? just bolt on as you thought they would be?

[Excursion]

coming on very well mark!

love the td 1.2s would really like a set for mine..

also how hard were the brakes to fit in the end? just bolt on as you thought they would be?

They weren't in the end.

[Excursion]

Going for double valve springs and a bigger Turbo now - may as well

[jonyb4]

oh dear

i can see this being the next most powerful zetec engine with pictures of harvey and iain standing aorund the engine in Fast ford like they did with theyre last