MWSTEWART | 500+ BHP Project | 28/01/2019

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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby Pudnpepsi on Mon Apr 02, 2012 9:27 pm

Awesome. just Awesome, how a Mk3 should have been. love the colour combo too. one thing.. how do you get the watermarks on your photos... photoshop?

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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby AndyKam on Mon Apr 02, 2012 11:18 pm

Truely amazing mate. Love the seats. Aldridge are just down the road from me. My retrim will be done by them too.
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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby Excursion on Tue Apr 03, 2012 10:57 am

Pudnpepsi wrote:Awesome. just Awesome, how a Mk3 should have been. love the colour combo too. one thing.. how do you get the watermarks on your photos... photoshop?

Pud.



Cheers! I wrote a PHP script for my website that automates the process, so I just upload the original and the script resizes, adds the watermark and then generates forum code.

You can use Photoshop too, in fact before I wrote the web script I used to set up a macro/batch to automate the process within PS.
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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby Excursion on Tue Apr 03, 2012 10:58 am

AndyKam wrote:Truely amazing mate. Love the seats. Aldridge are just down the road from me. My retrim will be done by them too.


Thanks Andy! You definitely won't be disappointed :D
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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby Pudnpepsi on Tue Apr 03, 2012 12:41 pm

so not only are you a clever cookie around a car, your good on the old commodore 64! hats off to you mate! :)

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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby mrorange2 on Tue Apr 03, 2012 12:59 pm

WOW i love them very nice work!!
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Re: MWSTEWART | 500+ BHP Project | Interior Trimmed! 27/03

Postby Excursion on Sat Apr 07, 2012 8:59 pm

Thanks guys!

I've finally finished the interior wiring loom, which took a lot longer than I expected it to. The result to the untrained eye is something that looks like a factory loom; I followed the factory colour schema and used factory connectors to extend or add functionality. I've added 25 new features but to cover each would make for pretty dull reading, so I'll cover just one as an example:

Here's the standard set of multi plugs to join the interior loom to the engine bay loom. The four thicker red cables feed power from the engine bay fuse/relay box to the in car fuse/relay box...
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As I'm moving the battery to the boot it would mean these wires unnecessarily feed into to the engine bay then back to the battery in the boot, so I stripped them out and ran them back to the boot instead.
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I also removed the fuses and terminals from the engine bay fuse box so it's obvious that nothing should plug there. I've actually created a document which details all changes made to the loom so it's easy to maintain the car going forward.
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Here's the finished result. The new black multiplug is from an earlier Fiesta and all its wires are for new functions. I created twisted pairs for any data lines in order to minimize RFI.
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Wiring for four fuel pumps. I've used the existing grommet under the seat and run the new cables through and split them into two sets and covered with PVC sheath. There will be two lift pumps in tank, and two Bosch 044s mounted to the side of the tank, fed from an internal swirl pot. I don't need two 044's - the second is just for resilience. The looped wires to the right of the photo will be run to a dedicated fuse & relay board in the boot.
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The wiring in place behind the dashboard. The thick red cable runs from the engine bay, across the dash, and down the right hand side of the car. I've used this route so that there aren't any 12v lines on the left hand side of the car that could possibly induce interference in the audio RCA cables that will be run on that side.
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Here's the dashboard in place. I've now got to retrofit a passenger airbag and fit the HVAC controls.
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There's now a layer of Luxury Liner Pro on all of the lower panels. Thanks to my Dad again for that!
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The first new components for the rear suspension arrived and these new adjustable alloy arms replace two of the three standard arms on each side. They are currently fitted with spherical joints but I'm having them modified to accept Focus RS bushes, which are still a considerable upgrade for a Fiesta. The third arm on each side will be replaced with a billet 7075 pieces made to my specification, and I'm also having the rear hubs copied in billet 7075 together with some disc bells, and brackets specifically for the AP calipers. Everything will be anodised in Gold.
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby heeman10 on Sat Apr 07, 2012 10:12 pm

Good update :)

Are those rod ends fitted with push-on rubber covers?
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby - Danny Boy - on Sat Apr 07, 2012 11:35 pm

Good progress Mark!

Any reason for mk5 dash over mk3?

Rear arms looks LUSH!
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby RS EDDIE on Sat Apr 07, 2012 11:45 pm

Mark.....its beyond words mate!!!! Pure amazing work!!!!

Cant wait to see it!!!!! :Q
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby andymac on Sun Apr 08, 2012 1:12 am

heeman10 wrote:Good update :)

Are those rod ends fitted with push-on rubber covers?


Looking at the photo with the exposed bush I think it's safe to assume so.

Mark, are the pumps mounted either side of the tank to ensure that there's an adequate fuel supply under hard cornering ? I assume of course, that that would be a secondary consideration - honest... :D :lol:
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby RS rob on Sun Apr 08, 2012 11:46 am

hey mark, not been on here for a while
looks like you've been mega busy with this
looking epic!! :D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby jonyb4 on Sun Apr 08, 2012 1:34 pm

like eddie said, i cant even comment!


id love to know these 24 other changes to the loom though!!


my mind has been blown :oooh:
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby 285Andy on Sun Apr 08, 2012 5:44 pm

mind boggling Mark :D i havnt seen this thread for a while and back then i thought f**k me thats so well thought out and inovative. then i take a catch up look and youve kicked it up a gear!! :lol: just stop it!!!! :lol: actually i kid, keep it up man! i love it :D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Dave G fsi on Sun Apr 08, 2012 8:16 pm

Excellent work mark :Q

The only difference I would have made would be a mk3 dash rather than mk4/5
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby AndyKam on Sun Apr 08, 2012 10:01 pm

Dave G fsi wrote:

The only difference I would have made would be a mk3 dash rather than mk4/5


I prefer the MK3 dash too, but I suppose fitting the aircon behind a MK4/5 dash will be a lot easier as these came with aircon as an option.
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Excursion on Mon Apr 09, 2012 11:49 am

Thanks everyone! Feedback is always appreciated :D Questions answered below.

heeman10 wrote:Are those rod ends fitted with push-on rubber covers?

They are mate.

- Danny Boy - wrote:Any reason for mk5 dash over mk3?

I like the Mk3 dash but I've grown to like the Mk4/5 dash. The main reasons are here:

1 - Mk5 dash is actually structural, and when fitted as intended it stiffens the A Pillar and scuttle area and makes for a quieter ride. I find the Mk3 dash is prone to rattles/noise.
2 - I wouldn't be able to wire up the car with a Mk3 dash as there's not enough room behind it for the loom. The high line Mk5 loom is a fair amount thicker than even a deadlock equipped mk3.5 loom, and that's without the features I added.
3 - Mk5 dash has more area for a larger heater box. Mk5 matrix and A/C Evap are much larger than Mk3 so offer better heating/cooling. Matrix and Evaporator can also be removed from the engine bay.
4 - I wanted dark grey trim, OEM 'wood', OEM glove box lighting and glove box A/C.
5- The Mk5 dash protects the driver from being crushed by the steering column, and allows fitment of a three piece column which also helps in that respect. Not a deciding factor for me but is nice to have.

andymac wrote:Mark, are the pumps mounted either side of the tank to ensure that there's an adequate fuel supply under hard cornering ? I assume of course, that that would be a secondary consideration - honest... :D :lol:


Hopefully the following image explains (blue is exhaust):
Untitled.jpg


It's mainly due to the new exhaust route which will create a well in each end of the tank.

jonyb4 wrote:id love to know these 24 other changes to the loom though!!

I will upload the document when finished :D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Pudnpepsi on Mon Apr 09, 2012 2:01 pm

One Clever, clever Cookie...
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby jonyb4 on Mon Apr 09, 2012 3:05 pm

:D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby andymac on Mon Apr 09, 2012 11:57 pm

Excursion wrote:It's mainly due to the new exhaust route which will create a well in each end of the tank.


Ahh, fair. Happy coincidence re fuel scavenging then.

Think you'll have her ready before winter ?
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Dave5300 on Tue Apr 10, 2012 6:08 pm

theres so much done to this mk3 it baffles me :aaah: pure awesome :Q
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby - Danny Boy - on Wed Apr 11, 2012 10:39 am

With regards to that reply Mark, it answers my question perfectly!

I never knew it helps with structually. Learn something new everday!

Does this mean the mk5 is a flimsy car? :lol:
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Capri on Tue Apr 17, 2012 12:53 pm

I think I've run out of superlatives to use on this car. :D
My name is Alex. I used to have a Capri. I don't anymore. But I'm still called Capri.
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Max M4X WW on Wed Apr 18, 2012 6:13 pm

Excursion wrote:OEM 'wood'

[Cant find a photo!]

Really :-?
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Excursion on Wed Apr 18, 2012 8:13 pm

Max M4X WW wrote:
Excursion wrote:OEM 'wood'

[Cant find a photo!]

Really :-?


Absolutely :)
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby fiestarsturboblack on Wed Apr 18, 2012 8:44 pm

mate thats an aswum fezz ur buildin, cnt wait to see it complete
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby FRS_Steve on Wed Apr 18, 2012 9:39 pm

Max M4X WW wrote:
Excursion wrote:OEM 'wood'

[Cant find a photo!]

Really :-?


Image

???
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby jonyb4 on Wed Apr 18, 2012 9:41 pm

wheres the "sick" emote smile then i need it?! :P
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Excursion on Thu Apr 19, 2012 9:00 am

FRS_Steve wrote:
Max M4X WW wrote:
Excursion wrote:OEM 'wood'

[Cant find a photo!]

Really :-?


Image

???


That's it :) I wanted to have the parts redone in Maple veneer but it wasn't possible for the heater panel sadly.
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby mrorange2 on Thu Apr 19, 2012 9:39 am

Awesome i honestly cant believe some of the things you have done to this car very very clever! :Q :D :Q
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby dontpannic on Thu Apr 19, 2012 10:16 am

I actually bought that kit from eBay for my MK5. I love de wood! :lol:
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby FRS_Steve on Thu Apr 19, 2012 1:24 pm

I think the wood will be a nice touch, and should go well with your seats and door trim. I've said it before and I'll say it again, I'm amazed at the amount of thought and attention to detail that has gone into this car, it is going to be something really special. I've never seen so many wires in a Fiesta! Hours of work gone into that wiring alone. Keep up the good work man :D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby :: blade :: on Thu Apr 19, 2012 2:15 pm

Not been on this site much lately but just gone through this whole thread :O omg so much work gone into this, its sooo good cant wait to see it finished :D
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby dontpannic on Thu Apr 19, 2012 3:50 pm

:: blade :: wrote:Not been on this site much lately but just gone through this whole thread :O omg so much work gone into this, its sooo good cant wait to see it finished :D


No, you haven't you fudgekin traitor.
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Re: MWSTEWART | 500+ BHP Project | Dashboard in 07/04

Postby Excursion on Thu Apr 19, 2012 6:56 pm

Thanks guys :D

The sound deadening and vibration damping is now complete. There were some voids between the roof skin and headlining so they have been covered with a layer of Silent Coat Sound Absorber 15 over Silent Coat Noise Isolator 8. The base is RAAMmat BXT II which covers the entire roof skin.
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Rear section complete.
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I've used Silent Coat Noise Isolator 4 on edges of any apertures in order to protect against chaffing.
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I removed the dashboard again in order to apply Silent Coat Sound Absorber 15 to any surfaces which were in close proximity. The material is great for preventing any squeaks or groans, not that there are many from the very solid Mk5 dashboard.
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Next I moved onto the roof furniture. I was originally going to spray the original accessories to match the new headlining, but as time went on I decided that they weren't special enough.
Image
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So, I went out and purchased some accessories from an Audi B5 A4 Facelift 'Sport' model which included new interior lights and a section of the surrounding headlining, then using some spare Fiesta headlinings, I figured out how to modify and mount the parts.
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The position of the fixed mount on the Astra sun visors is different to where it was on the Fiesta, which wouldn't have been an issue except one of the screw holes in the new position fell over a recess and punched hole in the overhead chassis box. I made a couple of removable brackets up to get around this as I wasn't happy securing something with only one screw when it should have two. The connectors in focus are for the auto dim mirror and rain/light sensor.
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I have fitted the re trimmed headlining and A pillar trims. I used pads of Silent Coat Sound Absorber 15 behind all trim to prevent any minor squeaks etc.
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A4 roof handles modified to fit. They are silicone damped.
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A4 Sun Visor clips fitted.
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Re-trimmed Astra VXR Sun visors fitted.
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A4 Rear interior light fitted.
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I had to tweak the A Pillars slightly to get the Mk4/5 trims on. I'm pleased with the fit.
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Here's the cut-out ready for the Audi front light which I shall cover later in this post. I haven't fitted the door seals yet which is why exterior paint is visible. I have a set of new original door seals but before they go on I'm going to investigate if any of the velour finished door seals from Audi/BMW/Mercedes etc. will fit.
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I've purchased a set of door looms from an Audi A6 that was equipped with the 'interior light pack'; the clear objects in the front of the photo are lenses to direct LED light into the interior door handle reveals. I will incorporate these looms into my doors together with the A6 puddle lights and door marker lights. I had already got Peugeot courtesy/puddle lights but the quality and design is, as to be expected, not a match for the Audi parts.
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Here's the new front interior light which is actually more of a multifunction console than a light; it is from a well specified model so has LED based submarine lighting, map lights, and provision for a Telephone Microphone. The on/off switch is dual pole so has dedicated control of the rear light i.e. the rear light comes on with the front light in position 1 (that isn't as straight forward to achieve as sounds). The unit mounts by two screws through the lugs outlined in the photo:
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I enlarged the original Fiesta light recess and fabricated the two Top Hat shaped brackets to secure the new light.
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The first test fit in a scrap headlining.
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I carefully cut the original Audi headlining and mounted it to the Fiesta attached to the light. I got the sides to fit perfectly but the front and rear edges were a problem, particularly the front as highlighted in the second photo.
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I fabricated a metal part to fill the gap.
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Next I welded the infill piece to the light mount frame, and then used Epoxy to reshape the outer edges of the headlining.
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It doesn't look like much, but I've used a combination epoxy, adhesive foam and finally fabric tape to reshape the Audi headlining to fit perfectly against the Fiesta headlining. The next step is to cover it in Alcantara.
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