fiestaturbo.com

[pauldolman]

zetec manifold studs and nut kit, i'm going to use some stainless version of the nuts so they go blue the same as the stainless manifold i run

[pauldolman]

stainless aeroquip manifold nuts



INA tensioner and gates belt same as ford use





uprated road spec vibra-technics engine mount





oil pressure gauge


in line filter for turbo oil feed



few more bits









a cheeky mock up of the turbo oil feed



Some more stainless aeroquip nuts this time for the turbo manifold joint

[pauldolman]

STRIPDOWN BEGINS!!!!!!!!!!!!

few pics of the progress so far

dash and centre console out


bonnet and bumper off


intercooler, bonnet lock and support bar removed


rad, alternator removed


battery, turbo, loom drivers side completly removed and most of passenger side, most hoses, map sensor, ignition amps, WI setup, air injectors


bit more progress made today







engine and gearbox is out
a few pics





bit of a update, all welding is done, i'm not a welder by any means but gave it a go anyway, all seams solid enough,everything seam sealed and now onto filler and paint prep





















todays update









cleaned up the bottom pulley before it goes on the new engine



met up with jano today to drop my steel engine off and my big valve head and box of various bits i've collected for it and get everything bolted together and a new clutch fitted so when it comes back everything can just be dropped in the bay hopefully well that's the plan anyway





update on the bay

















new gearbox arrived today







in primer







first time i've ever sprayed with a proper compressor and come out well, it was well worth me paying out for a decent setup at home, it's highlighed a few bits that need a light skim of filler but concidering the amount of welding and grinding i've done so far so good

19 seperate bits have been dropped down to a local powdercoaters to be stripped and going satin black and a load of bolts removed and a few engine bay bits gone to a local eletroplaters to be zinc coated

bits back from the powdercoaters today







few bits back from the electroplaters



made up compensators on powercoated and zinc plated parts





engine bay painted today

[tin-ribs]

Fair play, engine bay looks cool
Didn't expect to see the engine out when I clicked on your update !

[pauldolman]

Fair play, engine bay looks cool
Didn't expect to see the engine out when I clicked on your update !

yes mate not hanging around, the rebuild well underway

[FRSJON]

love it paul you did the welding and the spraying?? a couple of questions... whats the hose thing coming out the top of your new gearbox? the crank pulley... in that little groove going round the outside did it have rubber in it?

[pauldolman]

love it paul you did the welding and the spraying?? a couple of questions... whats the hose thing coming out the top of your new gearbox? the crank pulley... in that little groove going round the outside did it have rubber in it?

the hose coming out the top of the new box it's just a vacume feed like you'd normally have on a b5 box on the end panel, just a different way of doing it

the pulley no it's always had that grove, it has both sides of the pulley, that grove holds the belt on, you wouldn't want it flush anyway, it does run a much widier belt on it than normal rs turbo's.

yes i done the paint and welding myself, don't be too hard on me i'm learning as i go, but i've been around more painters than most people so i have a good idea what i'm doing, i've designed a nice spray setup in my garage, it's just practice for me

[pauldolman]

New top spec head, top spec no expense spared, cnc machined, Newman cam, solid lifters, double valve springs, light weight spring caps,5 angle vavle sits and s/steel oversized valves, ported and polished, might be other bits too

[pauldolman]

few random bits arrived




new custom roose motorsort hoses complete set

random clips that are still avilable still missing some though

genuine escort cosworth top mounts

clean washer bottle tank

[pauldolman]

picked up my engine from Jano @ OKC, looks great, top job as usual Jano many thanks for your hard work

[tin-ribs]

Looking good mate
I've just bought a helix clutch for my build but not sure now if it's going to handle the power I am after.
Is yours a paddle ?

[pauldolman]

Looking good mate
I've just bought a helix clutch for my build but not sure now if it's going to handle the power I am after.
Is yours a paddle ?

yes mate, 6 paddle

[pauldolman]

had a good weekend on the rs, flattened and polished the engine bay, brake lines in, compensators in,bonnet stay with various clips and seals, header tank, chassis supports, lower arms, hubs, coilovers, front arb with bushes, wheels on and back on the floor, bolted in the s brace and gearbox cradle just to get them out of the way for the moment

plan is to get the engine and gearbox next weekend

[pauldolman]

[pauldolman]

alley clutch quadrante for my adjustable clutch conversion



vacume lines arrived, different colour than before



also picked up my dash and centre console from the flockers after a few minor touch ups

bit of a photo update of how things are progressing, still doing a lot of hours of it, think progress is still being made

loom run drivers side and re braided


starter/alternator feeds run through chassis rail and all braided


spot/fog light loom all run


bottom part of the inlet re painted with new gaskets


map sensor mounted


top harf of the inlet on, fuel rail on, coil pack, ignition leads on, brake bar and brake servo brackets on


first sign of life after the loom has been extended




Gearbox oil arrived



hi chaps

bit of a update

bung for the head sorted, turbo on with new fancy fitting and new stainless water feeds, downpipe on, wiper motor cover and heater cover painted in crackle black, wiper motor and heater all wired up and back in, bonnet on, most of management loom through into the engine bay, fuel lines through and plumbed into place, alternator heat shield in, new black vacume lines started on run from the inlet

[pauldolman]

water injection tank painted and new pipework


twins horns painted ready to be relocated in inner wing


new braided breather hose and end finishers


master cylinder in


water injection setup with new pipework


alternator in


radiator in


msd uprated fan loom and fan switch


fan loom in and braided


air injectors mounted


clutch pedal modified by jano for my clutch setup, many thanks matey












pedal box has been rebuilt with new pedal bushes and fitted new clutch cable too, got some more hoses back on now the heater has been bolted back in it's proper position, also fitted my inline filter in the turbo oil feed which is ready to go back on also

interoir removed vacumed, dash in, wiring tied up beheind the dash, centre console back in, gauges wired in

[pauldolman]

vid of the engine running


out and about now running everything in

[Excursion]

Looks really smart! What gearbox did you go for in the end?

[pauldolman]

Looks really smart! What gearbox did you go for in the end?

cheers mate

the box is a ib5 stage 3 box built from the ground up by G.E.A.R.S in southport rated for 300bhp

basic spec is

cryogenically treated gearset with custom gear ratios, 1,2,3,4 are s1 ratio's for better acceleration & 5th is s2 or frst ratio for better motorway cruising rpm

all new o.e. syncro rings & syncro hub tension springs & shifting plates

new bearings throughout with the diff bearing preload set accordingly

later spec self centralising gearshift

A quaife atb

a brand new gearbox case to ensure the bearing bores are spot on

new gaskets and seals throughout

millers competion gearbox oil

[pauldolman]

hi chaps, i got offered a set of mint morette twin headlight conversion some time ago but due to the winter rebuild they've just sat indoors collecting dust, the lenses are perfect not a mark on them that's super rare so the plan was to strip the surrounds paint them white and fit them and see what they are like, i wasn't to keen when i first put them in but they certinally do grow on you, i think they are the sort if thing that are retro cool, and works well with the low splitter

prep for primer








in plastic primer


2k primer


2k diamond white




assembled on lenses

[pauldolman]

rear end has been apart for powdercoating, rear beam, twin arb setup, and various brackets for the beam and arb bushes have all been done, the rear hubs and caliper brackets have been rust treated and painted, new rs2k handbrake cable & fuel tank has been out yet again which have been bare metaled rust treated and painted also trying to fit new fuel pump which needs some fabrication work to get it to fit, it's a bosch 040(group A escort cosworth one) it's about twice the size of what's in there at the moment, just waiting for some bits to return back to me to fit it

































everything back together and running, new bracket made for new group a cossie fuel pump(bosch 040) tank painted, polished bolts for everything rear end, rear beam, twin arb including various brackets all powdercoated satin black, new handbrake cable, hubs and calipers rust treated and re painted









few updates

rose joined drop links for the front antiroll bar with black annodised bodies


ht leads heat covers fitted to the RS not seen them on that many cars, but really like them, seem to work very well, looks good in white too





dash has come out once again, i really need to get to the bottom of this cold start issue that's caused me constant problems since the new engine was fitted, so i've planned to remove any additional wiring from the basic loom, lots has been added to it over the years, everything from hands free kits to alarms to additional gauges ect, i know it's a common thing we all do then re wire everything additional that's staying in there all brand new on top of that i have another ignition plug which looks practically brand new and running a new ignition live to the ecu, these two things were a suggestion by the mapper when the car was parchally mapped, if this doesn't solve the problem the i havent got a clue what it is

[tin-ribs]

Top job, looking really cool
Have you sorted the cold start issue ?

[pauldolman]

Top job, looking really cool
Have you sorted the cold start issue ?

no mate, no one can tell me what it is

sure it's something silly, but everything anyone suggested hasn't helped