Simon84uk's RS Turbo Project

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Simon84uk's RS Turbo Project

Postby Simon84uk on Wed May 07, 2008 4:51 pm

Well i'm back on the fiesta scene again, though this time will be a pig of a journey until I can actually drive it.

A few of you may remember my old blue XR2i 16v which ended up with a 2.0 conversion, recaro's and a super bright orange cam cover. Anyway I sold that last August (to a member on here called TimmyB) and I have regretted getting rid of it since. It was replaced with something f00king quick but it just isn't the same, doesn't have the fiddle factor the fiesta has.

Anyway I saw a sorry looking fiesta RS come up on Piston Heads that was too difficult to pass up, it has galactic mileage, rust, and head gasket had gone. But the body looked fairly straight and the owner was honest about everything, so I figured it was worth a shot. Only main problem was getting the car from Cambridge to Southampton as it has no Tax/MOT. I phoned a transporter guy and he came to pick it up that evening, and he dropped it at mine at 03:15 AM :o Luckily for me GTA IV had been released the prvious morning so I had something to do whilst I was waiting. :lol:

I decided I would make a topic for the project for anyone who may be interested and for anyone to see what happens underneath it all. I will appologise in advance for any bad grammer or spellings but I will try my best.

I will also try to keep this updated at things happen.


Anyway we'll start off with some pictures of the car before I stripped it down.

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So looks fairly tidy from the onset.

Seems as though spec is as follows:
- Escort GTi alloys
- Stainless exhuast system (haven't found manufacturer stamp yet)
- K&N
- Bailey dump valve
- Painted rocker cover (believed to be ERST one)
- Chrome EFi inlet
- Polished intake pipe
- Painted calipers & drums (bad job, brush strokes everywhere)

Now for the problems...

We'll start with the rust:
- Both sills have holes in
- Both door frames have gone under the seals
- Scattered patches in engine bay
- OSR arch has loose material behind it
- NSF wheel well has been started by previous owner but not finished
- Bonnet under front lip
- Brake cylinder has corroded
- Slam panel has patches by the welds above the lights

Engine/Transmission:
- Head gasket gone
- Battery was flat (possibly alternator)
- Dodgy looking wiring to central wiring connector
- Gear selector loose and floppy
- Missing oil filler cap
- 2nd hole in air filter not plugged
- Cam belt cover missing

Interior:
- It's the nasty grey interior (personal taste I suppose)
- Hole in dial surround (presumably from boost gauge pod or such like)
- No head unit or speakers apart from 6x9's in shelf
- Drivers seat piping has frayed and thigh bolster knackered
- Steering wheel has cracked leather

Other:
- No arch linings
- Crappy job of removing rear wiper
- Few bulbs out

Next up, strip the car down.


Simon.
Last edited by Simon84uk on Sun Jan 19, 2014 11:56 pm, edited 9 times in total.
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Wed May 07, 2008 5:14 pm

Now for the strip down...

First off a few pics:
- Inside

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- Outside

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Since this point I have started to take back the hard pack sound deadening on the floor pans and on the firewall. I have also taken the silicone and grip-fill off the arches.

The rust on the NSF arch and floor pan is a fair bit worse than I imagined, I also found pacthes on the firewall tucked behind the dash and there is some surface rust on the inside of the rear arches. I think tonights job will be to treat all the surface rust whilst it's saveable and keep plodding through the hardpack starting with the rear seats.

Next on the list, possibly the weekend is to start sorting out the major rust... looks like it's going to be a never ending task, but I got a mate who can weld so not all hope is lost.


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Re: Simon V's RS Turbo Project

Postby m3lee on Wed May 07, 2008 11:14 pm

im from cambridge, never seen that going about, mind you now i have a mk3 there popping up every where, allways the way lol
how much did you pay for this car, im guessing not alot

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Re: Simon V's RS Turbo Project

Postby bakewell001 on Thu May 08, 2008 9:15 am

Blimey, definately got a long project ahead of you there.

Hopefully you can save it though and bring it back looking good :)
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Re: Simon V's RS Turbo Project

Postby j7aoc on Thu May 08, 2008 9:16 am

Hi simon it look's a like you have your hands full if you need any help im just down the road :D with a shed full of parts :bonkers:
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Thu May 08, 2008 11:03 pm

She's been stood on grass for 2 years, so has started to rot most of the underneath. I feel it's saveable though.

I've been slowly removing the hardpack sound deadening and have scraped off all but an 8in sqaure patch on the boot (was getting late and neghbours are getting twitchy).

Other than that have taken back, treated and painted the inside of the rear qtr panels, luckily that rot hasn't gone through so don't think i'll need to re-spray them. But the roof, splash panel and boot lid will definately need spraying.

Plan for tomorow eve is to take off the remainder of the hardpack and start sorting the surface rust. I will start on the underneath at the weekend as will have lots more daylight. Then welding can start next week. My hands are red raw already, got blisters on 8/10 fingers and cuts of at least 3 per finger. :x

Need to sort the engine out at some point, but that will be the last thing on my mind for now. Does anyone in Southampton area have an engine crane? i'm considering buying one as it's £50 for 2 days to hire one and £130 for a new one delivered to my door.

Going to try and get the engine running first before I start on modifying it. Although general plan is ERST turbo & manifold, 2.0 ZVH with forged pistons, some cam, beige injectors, fuel pump, FMIC and then sort out some form of management.

Current parts list is as follows, if anyone has any of these lying about PM me with a price otherwise i'll be placing a mass burton order in the near future.

Parts (needed):
- Head gasket
- Cam belt
- Head bolts
- Inlet & exhaust gasket
- Rocker cover gasket
- Sump gasket
- Clock
- Front arch liners
- New lower front window seals inner and outer both windows
- Boot seal

Parts (at some point)
- Black dash, door cards, rear cards, shelf and the plastic trim bits
- Steering wheel & boss
- Head unit & 5.25in co-axials (got some 4in for the rear)
- Poly bush - full kit
- Coilovers

I'll try and sort out some pics of the rusty patches tomorow, theres a lot of rot, but nothing I can't handle! :lol:


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Re: Simon V's RS Turbo Project

Postby 260bhp_orion on Thu May 08, 2008 11:33 pm

sounds gd! loads of hard work to do there! think i may strip mine completely, may even start it tomorrow! want to see how good or bad the shell is before i start ploughing money into spary jobs etc! good luck mate
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Re: Simon V's RS Turbo Project

Postby j7aoc on Fri May 09, 2008 8:27 am

Ive got some part's in my shed like new head bolt's new rocker cover gasket Clock (& suround) and a brake reservoir top :wink:
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Fri May 09, 2008 9:35 am

Ah well spotted, I keep seeing it and keep meaning to write a reminder about the reservoir top, but always get distracted (usually with more rust).

Excellent news on parts, how much for the lot? also where abouts in southampton are you? i've asked you before I think, maybe a year or 2 back though.


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Re: Simon V's RS Turbo Project

Postby j7aoc on Fri May 09, 2008 11:22 am

Im from hounsdown i think your from hythe? I will pm you a prise i could drop them off
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Re: Simon V's RS Turbo Project

Postby RST-CRAZY on Fri May 09, 2008 7:54 pm

hey man looks like you got your work cut out there, i am hopeing to strip mine down too, i want to take out the rust and respray it and new wireing the whole lot and a new zetec turbo lump running 300+bhp droped in, but i do not have a clue but i hope to learn. :)
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Sun May 11, 2008 10:39 pm

Didn't get much of a chance to work on the project this weekend, spent a few hours finishing off a few loose ends on friday but the sole accomplishment for the rest of the weekend was meeting Jamie (j7aoc) and getting a few parts (and a lot of tips) from him. He's a genuine nice bloke and seems very helpful, cheers Jamie. His car is awesome, everything is tidy in the engine bay and it sounds like the heavens have opened when he takes it down the road... :Q

Anyway i've bought some steel to start making plates, and am starting to feel a bit better about the project now things are rolling, doesn't seem as much of a mammoth task as it did last weekend.

Will keep you posted when things happen next week.


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Re: Simon V's RS Turbo Project

Postby Simon84uk on Sun May 11, 2008 10:46 pm

RST-CRAZY wrote:hey man looks like you got your work cut out there, i am hopeing to strip mine down too, i want to take out the rust and respray it and new wireing the whole lot and a new zetec turbo lump running 300+bhp droped in, but i do not have a clue but i hope to learn. :)


It's not as bad as it seems, the sole hardest thing for you will probably be the management. Once the car's in peices everything just slots into place. Although if you get stuck there's a world of knowledge on this site for you to use (or exploit at your leisure). I've found that these are by far the best forums for fiesta's i've ever come across, and reading them again has even convinced me to buy another one. I just couldn't keep away.

I've now got it into my head that FITP is waaaaay out of all possibility, but still maybe there will be a RR day coming up in not too distant future. My absolute deadline is the Saturday Night special at santa pod at end of August, maybe organise a ft.com outing? hopefully it wont snow this time, was awfully cold at the last one.


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Re: Simon V's RS Turbo Project

Postby Simon84uk on Tue May 27, 2008 2:00 pm

Haven't had much of a chance in the last 2 weeks to do much until the bank holiday weekend, but we have got loads done.

Rust update (areas known about):

NS footwell (3 patches) - Done :)
OS footwell - Done :)
Small pin hole by windscreen - Done :)
Hole on firewall - Done :)
Section under splash panel - Done :D
Engine bay - Done :D

Both Door shuts - Not done :(
NS Sill - Not done :(
OS Sill - Not done :(
OSR Above exhaust - Barely looked at yet :(
Sun-roof - Not even touched it yet :-?


Rust update (newly found):

NS A-pillar - Rusted through & filler everywhere - Treated the area behind it need to source new part. :(
Firewall to left corner - Rusted through to wheel arch - Has been plated, just needs painting. :D
Most of the underside has surface rust - Started to explore but nothing serious - Needs treating and painting. :(

Once all rust is cut out, plated/replaced and treated can start thinking about a lick of paint. Pics of rust progress:

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More bad news cam when removing the head, thinking it would be a simple gasket problem... turns out one of the inlet valve seats is pitted and the #2 cylinder is scored. I think the head and valves can be sorted but as for the block could be sorted but might aswell go ZVH, after all what's a project without an engine change. So a new plan is in order for the engine.

As much as i'd love to do a zetec-turbo conversion, just seems a bit OTT. So i'll plump for a 2.0 ZVH setup instead. I have sourced a block and internals, so just need a few bits from fiesta/escort zetec and we're half way there.

I think whilst i'm going to all that trouble may be worth considering a few more things...

T3 and manifold,
-31 actuator,
701 injectors,
Cossie fuel pump,
OFAB loom, map sensor & ecu,
Chip or such-like,
Front mount intercooler.

If i'm going to run this set-up then definately need to run bigger and better brakes and suspension. Got to be close to 190bhp with all that (after a good setup session), so needs to be able to handle the extra oomph safely.

Here's a few pics of the engine removal and showing the problem areas:


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To-do list:

Weld sills, OSR section and A-pillars,
Address the sunroof situation,
Sort out the shabby bootlid,
Painting inside,
Organise re-spray for roof, A-pillars, splash panel, and boot,
Build and install engine,
Arch liners,
Brakes & suspension,
Escort RS lsd gearbox,
Re-furb wheels.

A good few months of work left, already missed being ready for FITP and now gonna miss Classic ford show at Santa Pod :( . The next occasion is the Saturday night special at end of August at Santa Pod. Other than that going to nurburg in september, not with XROC anymore as it's apparently been cancelled but a few of the guys are organising their own trip. My mate who's been helping (welding & advising mainly) has been inpired to start another project of his own, thinking either Series one RS Turbo or MK1 escort so I imagine i'll repay his hard work on that one. He's also going on the Nurburg trip (if he ever gets his car back from the bodyshop).

Still not given up all hope yet, but OMG it's starting to get crazy!!! rust pretty much everywhere, shagged engine and having to work around the w@nk British climate. But will make the final product that much sweeter!!



Simon

Running receipt list:
Car: £1000
Paint, Kurust, brushes: £30
Cam cover, head bolts, dash surround, brake res cover: £20 (bargain)


Running shoppig list:
2.0 Zetec short engine
Pistons
Head skim/re-furb
Belts, gaskets, pumps
T3 & manifold
Actuator
Fuel pump
Injectors
Oil filler cap
OFAB loom, ecu & MAP sensor
Chip
Mirrors
Black interior
Arch liners
Last edited by Simon84uk on Mon Jun 23, 2008 11:33 am, edited 1 time in total.
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Re: Simon V's RS Turbo Project

Postby Matt_fez on Tue May 27, 2008 3:32 pm

Should keep you busy for a while mate, quite deceiving from the first pics it looks "quite tidy" amazing what you find on closer inspection.
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Re: Simon V's RS Turbo Project

Postby j7aoc on Tue May 27, 2008 5:52 pm

Good to see the hard work is paying off Si. If you get stuck for any thing give me a ring i do have a LSD it's still in the gearbox which was mint but after it came out my mates frst and going in mine i couldn't get all the gears it was for a guy up the road but he's not got back to me yet. You willl have to get the car mapped after as the 195 chip wouldn't be any good
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Re: Simon V's RS Turbo Project

Postby m3matt on Tue May 27, 2008 7:27 pm

hi mate, good luck with it all. this is gna sound weird lol, but, i live in essex and go to uni in winchester so im back and forth from essex to southampton basicly all the time, so, if you want anythn collected in the essex/london to winchester area for ya car dont hesitate to ask! might save a few ££ on postage.

look forward to seeing this finished!
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Tue May 27, 2008 10:17 pm

j7aoc wrote:Good to see the hard work is paying off Si. If you get stuck for any thing give me a ring i do have a LSD it's still in the gearbox which was mint but after it came out my mates frst and going in mine i couldn't get all the gears it was for a guy up the road but he's not got back to me yet. You willl have to get the car mapped after as the 195 chip wouldn't be any good


Cool, should I get a proper ecu to map or can the chip be re-flashed to suit?


m3matt wrote:hi mate, good luck with it all. this is gna sound weird lol, but, i live in essex and go to uni in winchester so im back and forth from essex to southampton basicly all the time, so, if you want anythn collected in the essex/london to winchester area for ya car dont hesitate to ask! might save a few ££ on postage.

look forward to seeing this finished!


Cheers for the offer i'll bear it in mind when it comes to the mad eBay rush for engine bits :lol: .

Matt_fez wrote:Should keep you busy for a while mate, quite deceiving from the first pics it looks "quite tidy" amazing what you find on closer inspection.


Yeah it's slightly disheartening really, I thought "yeah this will be a doddle" originally, but seems everywhere I look there's another patch magiacally appeared. Like the late Mr H. Houdini had his "special" blanket over the rust the whole time, the cheeky bar-steward. :x

Anyway, i'll update when more to report.


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Re: Simon V's RS Turbo Project

Postby j7aoc on Tue May 27, 2008 10:23 pm

They will just mapp a chip to plug into your standard ecu
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Thu May 29, 2008 12:01 am

Cool, would tremona (sp) garage do this? or would I need to go to power engineering or suchlike? also do I supply the chip to be flashed?

Management is not my strong suit, give me a shagged engine and i'll put it right, but i'm not to up together on ecu's.


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Re: Simon V's RS Turbo Project

Postby j7aoc on Thu May 29, 2008 6:07 pm

No mate they can't and there not keen on ZT or ZVH's But these might for-tune-pve-rolling-road-business-goes-live-vt158552/

and power engineering don't map chips
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Sat Jun 14, 2008 1:20 pm

Just a small update, haven't been doing much to the car as getting ready for holiday tomorow. Going to Tunisia for a week. But have been organising and collecting parts for the car, got a fair amount of it sorted now. Still well within budget.

Now got an aboslute deadline of 11 September by midnight!! Booked myself up for the Holland trip to the European Ford Show in Landgraaf (with a nice trip to the 'ring on the way back). Should be awesome.

Anyway see updated parts list(s) below.


Simon

Running receipt list:
Car: £1000
Paint, Kurust, brushes: £30
Cam cover, head bolts, dash surround, brake res cover: £20 (bargain)
Injectors, Oil filler cap, OFAB loom, ecu & MAP sensor, Chip, Mirrors, Arch liners: £??? (uber bargain, will not reveal price! cheers mate)
T3 & manifold: £65 (another bargain)
Downpipe: £30 (needs to be chopped and welded)
Fiesta Si sump, water pump, oil pump, oil pickup, dipstick tube: £30 (still need flywheel)

TOTAL: £1175 + undisclosed bargain
Budget: £2500-3000

Running shoppig list:
2.0 Zetec short engine
FMIC
Pistons
Head skim/re-furb
Belts, gaskets, pumps
Actuator
Fuel pump
Black interior
Zetec flywheel
Clutch
Coilovers
Setup once complete
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Mon Jun 30, 2008 3:55 pm

Made a start again to the car at the weekend. I now got the car in my garage so it's out of the elements.

Have welded up the NS sill (need a bit more when the rear beam comes off), NS door shuts and the big hole by the tail pipe. I have removed the bootlid so I can sort out the dodgy attempt at fillering the wiper hole (which I pushed on and my finger fell through and gave me a nasty rusty cut :x ).

Other than spending the day welding and cleaning I have sourced some more bits during the week, like coilovers, heated screen, actuator, oil feed and polybushes. Might have missed some things but only been back in the country 6 days and most of them i've spent with a stomach bug (and we all know what that entails :rolleyes: ).

So only rust remaining is:
- NS A-Pillar
- OS door shuts
- OS sill
- NS Sill small section (once rear beam removed)
- Sunroof

Then it's a case of a lick of paint inside car and engine bay, organise what need's a re-spray (maybe a full one is on the cards :D ) and finally bung an engine in.

Update made to lists below.

Running receipt list:
Car
Paint, Kurust, brushes
Cam cover, head bolts, dash surround, brake res cover
Injectors, Oil filler cap, OFAB loom, ecu & MAP sensor, Chip, Mirrors, Arch liners
T3 & manifold
Downpipe
Fiesta Si sump, water pump, oil pump, oil pickup, dipstick tube
AVO Coilovers, Heated front screen and loom
T3 Oil feed
Paddle clutch and cover
-31 Actuator
Poly bushes

TOTAL SPENT: £1877
Budget: £2500-3000

Running shoppig list:
Rear boot seal
2.0 Zetec short engine
FMIC
Pistons
Head skim/re-furb
Belts, gaskets, pumps
Fuel pump
Black interior
Zetec flywheel
Setup once complete
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Re: Simon V's RS Turbo Project

Postby rsonblackwheels on Mon Jun 30, 2008 5:17 pm

what a gr8 project,

will be awsome whem finished ,

well done for saving it from almost certan doom :D
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Tue Jul 01, 2008 11:36 am

Cheers mate, I couldn't sit by and watch it rot-in-peace.


It's starting to come along much quicker now can almost taste the end of the project but still at least 4 weeks work left at 3 evenings (2-3 hours each) and a weekend day (10 hours) each week. I've put in about 100 hours so far with an estimated 100 or so more yet to go. So at about 19h per week should see me done in maybe 5 weeks (which is around Ford Fair time). But that's time my friend and I spend on it, still need to add on time for spraying (est. 2-3 days labour once i do prep work) and setting up (possibly another day or 2).

All I can do for time being is keep on going, once the welding is done then the rest should pick up pretty quick. I'd like to see the welding complete either this week or next then I can start on the chassis components, painting and prep work.

The sprayer is about a mile from my house so going to tow it there/push it late one night (not sure how illegal that is, technically could go on the path as no engine :wink: ). But he did a friends car, including bodywork and the finish is mirror smooth with no visible soft edges and he also did the rear arch on my blue one that had rusted through. But as i'll be giving him a prepped bare shell there shouldn't be any need for soft edges and should (fingers crossed) be as good/better than it came off the production line.

Once the car's in the spray shop I can start on the engine and get it assembled, ready to put back in when I get the car back.

Time management was never my strong suit so having to learn pretty quick, especially as a tight deadline (Sep 12th) and a load of work left to do. Also i've never done a ZVH before so this is a first for me :o , but can't be that bad it's only a few extra holes.

I need to draw up a timeline of tasks, maybe i'll do that today just to keep me on track. I've already booked the time off from the girlfriend anyway :lol:.


Simon.
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Mon Jul 07, 2008 11:09 am

Spent another weekend skinning my knuckles! but with nearly all welding complete it was a worthwhile sacrifice.

Have finished the OS door shut, OS sill and the NS sill. So only major section left to tackle is the A-pillar, had to get a genuine ford panel for this and OMFG was the price a shock... £100 inc VAT for a flipping piece of pressed metal. But suppose it's one of those areas where only the best will do as it takes a lot of strain. There are a few small bits to do like patches on the boot to re-do the de-wiper attempt and de-lock it, and to sort out the rusty sunroof. :( With a small bit of luck the bodyshop guy I know, who'll be doing the spraying, is going to give us a hand with the A-pillar so will be done with at least a little professional assistance.

We took the rear beam off aswell which I scrubbed down and gave a lick of paint. Looks much better now especially with the bright orange rear poly bushes fitted. Was a right pig of a job to remove the old bushes but with a bit of brute force and ignorance they were released. :lol: When re-fitting the beam I put the rear coilovers back on, and as I hadn't set the height or anything the car sat really stupidly low.

I have now had the rear strut brace delivered so that will go on soon and have collected the LSD gearbox. I am awaiting delivery of T3, Cam & pulley and a steering wheel & boss kit.

I'll take some pictures this week of the progress made if the rain holds back long enough for me to roll it out the garage.


Simon
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Re: Simon V's RS Turbo Project

Postby rsonblackwheels on Mon Jul 07, 2008 11:34 am

nice progress dude

get them pics up

:aviator:
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Mon Jul 21, 2008 2:23 pm

Going to sort out some pics today, i've taken them just need to crop and upload to photobucket...

Been busy all weekend and pretty much every spare hour I had. We've got the A-pillar done just needs fillering, sills all welded and fillered and have started to strip the zetec down to get worked on. The spot of rust on the roof I thought would be simple is another gaping hole but should be sorted this week, we've had the professional assistance of a local bodyshop guy who owes us a few favours come down to advise on a-pillar and roof.

I've bought some forged pistons, a zetec engine and a few zvh required bits. We've started painting the inside in a first coat of matt white, looks super-sweet! But the bodyshop guy brought along a paint sample of something he want's to use i'll put pics of it up in a mo aswell... it's cosworth blue with a copper flake in it. I have to admit I like it, after all blue has always been my colour of choice, but i'm worried it's going to look out of place on the RS. Partly because it would take it far away from the original, and partly as it's one of those personal taste things. So when it comes to sell it a few years down the line (lets hope it's a long way off yet) will it make it worth less in the end. I accept i'm going to lose money on it whatever anyway but the main plan is to keep it for when house deposit time comes around and the more it's worth the better. I'm open to suggestions on paint so let me know you're opinions.

Anyway pics to follow in a little bit...


Simon
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Mon Jul 21, 2008 2:55 pm

Rear beam has been painted blue, also shows the bottom of the rear coil-overs.
Before:
Image
Ater:
Image

Coilovers stripped down
Front:
Image
Rear:
Image

Paint colour
Blue:
Image
Transition:
Image
Copper flake:
Image

General pics of car in/out of garage. We made a makeshift tent when it absolutely wee'd down on saturday only as soon as last rope was tied it stopped and never rained again :x .... was not amused!
In garage:
Image
Makeshift shelter:
Image

Few pics of the shell, not all up-to-date pictures but give a glimse of what's happening.
Image
Image
Image
Image

Gonna scrap the receipts and list what I have/haven't got...
Parts sourced:
2.0 zetec engine, fiesta zetec bits, Forged Pistons, T3, -31 Actuator, FMIC, Kent Cam & Pulley, OFAB + chip
Random engine bits,
Few chrome/stainless dress up items,
Stage 3 paddle clutch, Re-con series 2 LSD box,
Polybushes, AVO coilovers, rear strut brace,
Heated front screen with loom, MK3.5 mirrors, Steering wheel & boss
Paint, materials, panels
Sump gasket, ZVH conversion parts, power cable (for battery to boot)
Engine mount and head (to be collected)

Parts Required:
Re-spray
Setup
Cam belt
Aux belt (s)
Head Gasket
Manifold Gaskets
Block work
Flexi for exhaust
Tensioner
Service items
150A ANL Fuse & Holder
Cossie fuel pump & filter
Intercooler Pipework

Spent so far: £2838.48 (£1000+ Est. Remaining)(£161.52 original budget remaining)
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Re: Simon V's RS Turbo Project

Postby j7aoc on Mon Jul 21, 2008 11:08 pm

looks cool mate you will need a large fan too :rolleyes: :lol: Pop over and say hi if your free the week end
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Tue Jul 22, 2008 9:41 am

Excellent, yeah i'll probably need all the cooling I can get. Would be good to see your new motor, can run a few ideas past you aswell. I'll see what I can do at the weekend, it's me and the gf's 4 years so probably have to do something special :( :lol:

But i'll try and spare a half hour or so...


Simon
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Wed Aug 06, 2008 3:03 pm

We decided that as the rest of the work the previous owners did was sh@t we'd inspect their work of the filler panel and.... OMFG I could have done better using my feet and some bent scissors.

I mean how difficult is it to cut out the rot, treat it and fit the panel... obviously too much for the monkeys who owned the white warrior in the past. They just slapped the filler panel over the rust and though jobs a good 'un :x

So anyway we've cut the rot out and done it properly just need a little bit more welding to it then all welding is complete. I have started to sand and filler where needed to get it ready for bodyshop in a week or so. I invested in an orbital sander :D - that has saved me a lot of time, effort and grief. Also the interior has had its first coat of paint and looks 10 times better already.

The block is currently being bored, blocked and tapped for my ZVH conversion. I could have blocked off and tapped it myself but as it was getting bored by pro's mught aswell get them to do the rest to save me a lot of hassle.

I bought some RS2000 wheels to use on the car (haven't decided on colour yet, probably dark) and have bought cossie brakes for front and rear-disc setup. I'll try it with standard servo first but if really bad (which I imagine it will be) then i'll switch to an RS2000 or mondeo one.

Other than that I have removed the heater matrix and half the dash to save weight. As i'm running heated screen don't need the heater for clearing the screen and I can just wear a coat in winter. Bought some stuff off autospecialists at Ford Fair just to tidy a few bits up, I know it adds weight but at least it looks good.

I'll post up some more pics when the weather is better so you can see how close things are.


Simon
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Fri Oct 10, 2008 11:27 am

Thought i'd post a quick update....

Project starting to drag like my old man in tights... having problems finding time to do anything amongst the rain and bitter wind (and having to fit in time with the woman and work).

Anyway it's close to being able to start it for the first time, I have the remote oil filter stuff now and all I need now is a fuel pump and some oil spray blanks.

Very nearly had a fuel pump but parcelforce managed to destroy the package and lose it in transit, not amused :x and may have sourced some blanks (thanks xrsi :D , hopefully)

Engine is in and plumbed in, electrics are pretty much there, intercooler mounted and new wheels & tyres now on. So nearly there mechanically, can almost taste the fumes.


Simon
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Re: Simon V's RS Turbo Project

Postby Simon84uk on Wed Mar 11, 2009 3:29 pm

Fook! Have I really not updated since October? :lol:

I will post up a massive update tomorrow with some pics, but for now a brief overview.

Basically as of this point in time it is pretty much there, all welding done, body-kit on, needs some filler-work finishing but on the whole is ready to roll... apart from one small problem. I can't get the ECU to see the crank position signal, :lol: :x

I almost had it ready for 19th Feb, if the ECU had worked then I would be driving her by now. Had MOT, Mapping and RR session booked ready, but nothing :(

Anyway current focus is on getting the ECU working and to be honest I've lost a lot of motivation with that as spent hours checking wiring and testing pieces, even bought a new sensor. I'm going to try and update the firmware and apply a new basemap but I don't know whether it will work.

Will add proper update tomorrow (EDIT NOW UPDATED ON NEXT PAGE :D)


Simon
Last edited by Simon84uk on Sat Mar 14, 2009 12:36 am, edited 1 time in total.
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Re: Simon V's RS Turbo Project

Postby ace1001ace on Wed Mar 11, 2009 5:17 pm

Sounds sweet, look forward to the post!!!
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