fiestaturbo.com

[jimmyesh]

Cheers again for all the positive feedback!

I used standard focus st170 mounts. Basically I cut off all the relevant mounting points from a focus at the scrappy then dummy-fitted the engine and tack-welded them in, removed the engine again and welded them all in properly. Then the whole engine bay was re-sprayed.

This allowed me to fit the engine using standard st170 mounts so if/when they ever need changing it's just a case of ordering them up from ford, rather than having to remake one-off items again

It also allowed me to keep all the standard st alternator/starter/pas set-up too.

The loom was made up by taking the st loom(s) It's not just one! And going through the ford TIS cd rom (£2 on ebay) and removing all un-neccessary wiring/ connectors (there's about 1000 connector pictures!!) then re-covering the loom and wiring it all into the fezzer, As mentioned before I used the st170 ecu (allowed car to be bluefinned...) and also the G.E.M (Generic electronic module) which controls the anti-theft PATS sensor, the fuel pump driver module (the black box in my boot-see pic), also controls the speedo and instruments.

I also kept the focus relay box and fuse box as there's some nice modern features which I wanted in my "old" fezzer, also the variable inlet manifold is controlled by them too...

All the photos of the loom (+the box of wiring I REMOVED!), ecu, mounts, etc are all on my photobucket album if you need a further look for the time being. http://s119.photobucket.com/albums/o122/jimmyesh

I PROMISE TO DO A GUIDE ASAP! I'm just a really busy bloke that's all !

Sorry for the 'essay' but hopefully managed to explain some of the conversion

[jayrs]

love it mate

[jimmyesh]

Yours aint too bad either fella!

[jayrs]

cheers bud.

did you do all the work your self on yours?

[Captain Tightpants]

Love it!

Top work that man!

Steve

[Sphinx]

All your pictures are tiny! I need to see huge pics of the mounts etc......need to....for medical reasons

[jimmyesh]

To Jayrs:
yeah did it all myself ! was a big learning curve but at the same time was a lot simpler to do than you would think-things like the focus gearbox using selector/shift cables instead of linkages made the transplant easier regarding the physical differences between the fiesta and focus and like i said already it was just a case of dummy-fitting it all, lining the driveshafts up etc then welding in all the mounting points for engine/trans mounts.

I also had to make up some 1" alloy spacer blocks to lower the cross member that goes transversely under the car as the mt285 6 speeder is quite a chunky beast! also this allows this x-member to be used for a mounting point for the rear torque link from the gearbox, that all foci use.
photos to follow (BIGGER ONES! )

The driveshaft u/j splined ends fit EXACTLY(!) into the fiesta hubs, you just need the correct retaining nuts from ford.

The N/S focus driveshaft fits exactly to the o/s of the fiesta, the o/s focus shaft I had shortened proffesionally by RECOPROP in luton for the princely sum of £78 which included balancing too- bargain!

The hydraulic clutch was incorporated by making a hybrid fiesta./focus pedal box which houses the focus clutch master cylinder and a little bit of fabricating of the bulkhead to allow the inlet/outlet of the cylinder to be incorporated. (NO MORE SNAPPED CLUTCH CABLES in traffic YIPPEE! )

I promise i will post some BIG photos of all these tricky bits to help anyone else do this conversion, cheers again fellas

[jayrs]

cool.

i wonder if the 6 speed box could be married up to a cvh

[jimmyesh]

Yeah I'm 100% sure the 6 spd 'box would mate up to a cvh just fine as all the st170 "duratec" lump is, is just a black-top zetec engine (that has been tuned a bit by ford) and we all know that zetec and cvh engined cars share the same transmissions such as the b5 and mtx. so the bellhousing boltholes will line up with the cvh block bolt holes no probs.

The only sort of grey area I could think of would be the flywheel/clutch side of things as the st170 (and most other newer fords) run a dual mass flywheel, so if you wanted to use the cvh flywheel you will have to look into what clutch you can use.

Also the gearbox speedo drive will have to be converted to manual drive if you wanted to keep your original dash-unless you're minted and get a stack dash or something, otherwise you would need a focus dash (like mine) but then that is driven by the focus ecu and Generic electronic module so you would end up with loads of extra wiring

The good thing is the gearbox cable shift/selectors are much easier to fit/adjust.

You would need to trial-fit the focus driveshafts too as they are a thicker diameter than fiesta ones (fez ones wont fit the 6 speed box) and do as i said before and get the n/s one shortened to 328mm from 423mm by recoprop then bobs your uncle!

I reckon go for it mate, it'll be another first especially mounted to a more retro RS engine, nice strong gearbox too with meatier driveshafts.

[jayrs]

after all ive done now it wont happen yet

but its worth thinking about for sure mate,6 speed frst, on the small isle of wight
as ya say, would be a first

so this gear selector set up, im guessing its like the galaxy set up with the cables and what not, you got any pic's of yours at all?

also this 6 speed box, is it any longer than the normal 5 speed?

[heeman10]

Love it! What sort of exhaust system do you have on the car? I'd like to see a more distant shot of the clocks too, they look lovely Something that gets me is fitting an engine so tidily, making it look quite stock, then attacking every pipe and hose with blue silicone oversleeving and spiral wrap! Would you agree it would all look a bit more classy with brake pipes etc painted rather than sleeved? That must be a fantastic drive! Videos required!

P.S. What's that on the right hand side of the luggage compartment?

[jimmyesh]

Fair one fella, maybe I went a bit too far with the blue stuff lol! but hey variety is the spice of life and all that and it's not like it's irreversible or anything is it?! and at least the OUTSIDE of the car hasn't been hit with the "chive" stick eh?!

The small black box on the r/h/s of the boot area is the fuel pump logic unit which the focus uses to drive the fuel pump from the ecu as the st170 runs a returnless fuel system.

The car currently runs a 3" fiesta turbo magnex full system, no cat and a YKC sportscars stainless 4-2-1 manifold, a bit of a mongrel system I know but has a lovely note and was good enough for the previous 220bhp connaught n/a 2.1 that resided in this engine bay.

Yeah it's a lovely car to drive too, just seems to rev forever

Thanks for the kind words mate

[RS EDDIE]

F'CKING AWSOME MATE, YOU MUST BE ONE INTELIGENT FELLA. LOTS OF RESPECT MATE, AFTER THE TIME U SPENT WORKING OUT WHAT GOES WHERE, YOUVE REALLY HAD A RIGHT RESULT, LOOKS THE DOGS DANGLERS..

[jimmyesh]

Wow, cheers mate, I won't be able to fit my head through the door now ! I really am over the moon with all the positive feedback i've had about this project of mine.

I wouldn't say I'm any more intelligent than the average bloke though, I'm just lucky enough to have all the tools/welding facilities/workshop space etc at work to use when i like (+when the boss wasn't about!).

It was more just a case of being patient about it and just walking away from it all for a few days if it started to piss me off. plus taking time over things like dummy-fitting things and measuring/calculating. once you got a ford TIS cd for the wiring you're laughing mate.

I don't reckon it will be long 'till we see more older fords with the duratec lumps and six speeders as the st170 is getting older now and prices coming down so the bits and pieces will all be there for people to get cheaply and 'trial and error' fit stuff.

[~nomad~]

absolutly awesome, well done

[jonosi]

Wow, cheers mate, I won't be able to fit my head through the door now ! I really am over the moon with all the positive feedback i've had about this project of mine.

I wouldn't say I'm any more intelligent than the average bloke though, I'm just lucky enough to have all the tools/welding facilities/workshop space etc at work to use when i like (+when the boss wasn't about!).

It was more just a case of being patient about it and just walking away from it all for a few days if it started to piss me off. plus taking time over things like dummy-fitting things and measuring/calculating. once you got a ford TIS cd for the wiring you're laughing mate.

I don't reckon it will be long 'till we see more older fords with the duratec lumps and six speeders as the st170 is getting older now and prices coming down so the bits and pieces will all be there for people to get cheaply and 'trial and error' fit stuff.

this is the sort of thing i would love to do
but im not so lucky to have space etc...
everytime i look at this thread i think thats is fooking awesome

[heeman10]

Fair one fella, maybe I went a bit too far with the blue stuff lol! but hey variety is the spice of life and all that and it's not like it's irreversible or anything is it?! and at least the OUTSIDE of the car hasn't been hit with the "chive" stick eh?!

No, you most certainly do not have the taste of those who wander the streets in shell suits, black gloves and baseball caps whose peaks are parallel to most lamp posts! Quality car, and I didn't know that about the ST170's fuel supply, interesting

[scarlet_pimp_mobile]

I second heeman's motion, videos of this in action is a must!

Has Steve (Scort) seen this yet?? I wanna know if he'll be offering this conversion soon!

[jimmyesh]

Yeah will take the car for a thrash round the vehice park at work and get one of the lads to video it to hopefully show you all how nice the car sounds(especially at 8k rpm! ) and how nippy it is, after all you all deserve it for all the nice things you said about it lol! Will be posted by end of week i reckon, got athletics competition tomorrow so am away all day but after that I'll get it done.

As for anyone else offering this conversion or something similar, yeah i could see it but now everyone can know I DID IT FIRST lol! and part of me wishes i just got my credit card out and gave someone else all my hard-earnt to do it so I didn't have to devote so many hours of my valuable life to a little 12 yr old fez! only kidding by the way but some peope I know are like "why do you bother with it?-it's just a fiesta" or "its a ford for f***s sake" snobby gits all of them!

[Xr_Dub]

Let us know how it runs, and get a power run i want to knw the results

You should speak to Neil from Fastford about getting you a feature
its different hes on this fourm. thats his username = pornstar!

[jimmyesh]

Yeah will get a power run sorted mate, like i said before i reckon on a real 180 bhp at the crank as the st is 175ps (172bhp) as standard (these figures are the ones quoted on the ford TIS cd so if anyone disagrees then so be it!) and I think it's fair to assume about 8 bhp as a net gain from the k&n cone, the magnex full system, the de-cat and the manifold, and the bluefin combined. Gonna go for the piper exhaust cam and vernier next (after the "silly season" ...) Think i'll get the power run done at engine advantages in whitam as it's only just down the road from me.

On the other hand i could just be like some people i've seen in magazines and just suddenly "decide" it's got 210bhp from those mods!

I may decide to try and get a magazine feature although I think most people will be sick of seeing it by then!

Also want to get rid of the wilwoods/285 discs on front and replace with 300mm st170 complete front set-up as i want something a bit more road-friendly what with all the crap drivers that seem to have suddenly sprung up from somewhere!

[scarlet_pimp_mobile]

So what's it like with motorway cruising with 6 gears? I really hate the way my car is at 3.5 to 4k at motorway speeds with the ratio of 5th, as it is in most 5 gear boxes. I would like to be able to have a lazy cruising gear as I can't afford a 2nd big car to do motorway driving in. So where does yours rev at with those speeds in 6th? I know my dad's rests at just under 2k at 85mph!

[jimmyesh]

Yeah you're right there about needing a taller top cog! I've owned 5 mk3/mk3.5 fiestas (2x Xr2i 8 valve, 2x Rs Turbo, 2 x Rs1800) and I found the 5th gear in the early cvh n/a and turbo cars to be quite motorway-friendly and good for a decent top speed

With both the RS1800's however, they seemed to have a very short fifth cog that was very buzzy on the motorway- 4k rpm@ 80mph! and when that was mated up to my old connaught lump with 45mm jenveys it was horrendous!

Getting back to your question though, my RS now runs at about 2700 rpm in 6th @70mph whereas my old 5 speeder must've been about 3500 for the same speed so a definite improvement.

Whatever car your dad has must either have a big, torquey engine or a turbo diesel or something because a little 4 pot zetec/st170 lump would'nt really entertain pulling from under 2k at motorway speeds with any real guts.

So now it's just like my old gear ratios really but with a nice "overdrive" for the motorway and some nice close ratios for a good sporty little drive.

Sorry not had it flat-out yet so dunno what it does yet but probably a real 135-140ish mph i reckon (and hope!)

[leeroy]

This is absolutely awesome, food for thought people. Boundaries have been pushed here, hats off to the guy, gives me a little thought................................

[scarlet_pimp_mobile]

Getting back to your question though, my RS now runs at about 2700 rpm in 6th @70mph whereas my old 5 speeder must've been about 3500 for the same speed so a definite improvement.

Whatever car your dad has must either have a big, torquey engine or a turbo diesel or something because a little 4 pot zetec/st170 lump would'nt really entertain pulling from under 2k at motorway speeds with any real guts.

So now it's just like my old gear ratios really but with a nice "overdrive" for the motorway and some nice close ratios for a good sporty little drive.

Aye, you hit the spot there, his is a Monaro, so the tourque carries everything forward at whatever speed. Your revs at cruising speed seem a lot more civilised to me, an overdrive gear is exactly what I'm after. I always feel like changing up once i've got to 70 in 5th!

So do you think that the ST 6 speed box could be matched up to a non-ST 2L zetec without too many problems?

[jimmyesh]

Hell yeah! dunno what clutch you'd run though as the st runs a dual mass flywheel, you'd need to do some fabricating too, like welding in the mounting place for the focus gearbox mount, lowering the x-member by about 1" and fitting the rear torque link mount to the back of the gearbox, You'd also have to convert the gearbox to have a manual speedo drive or elso run focus clocks(see my earlier posts for more details) i'll send you a pm soon. also you would need a hydraulic clutch pedal/master cylinder or convert the box back to manual operation.

[jayrs]

Hell yeah! dunno what clutch you'd run though as the st runs a dual mass flywheel, you'd need to do some fabricating too, like welding in the mounting place for the focus gearbox mount, lowering the x-member by about 1" and fitting the rear torque link mount to the back of the gearbox, You'd also have to convert the gearbox to have a manual speedo drive or elso run focus clocks(see my earlier posts for more details) i'll send you a pm soon. also you would need a hydraulic clutch pedal/master cylinder or convert the box back to manual operation.

you got any pics of the parts you mention above mate?

[jimmyesh]

Will take some next week and post them here

[Project_XR2i_Trackcar]

Jim

Nicely done mate, very impressive.

Judging by your location and the fact you've just been on exercise, are you forces by any chance? REME even?

[Project]

Awesome effort. I'd love to see this featured in a mag

[jimmyesh]

Yeah i suppose i should really immortilise the "MANJ" in a magazine after all the hard graft lol, As said before it was previously in fast ford about 2 years ago in the Jan 2005 issue for the rs1800 modifying guide.

Have been in touch with Dave from performance ford too, mainly to ask for advice about the brake set-up i'm using as he has the same bias pedal box on his mk2 xr2 track car, I'm not brave enough to go without servo assistance like him!

[jimmyesh]

My new brakes i got from Ebay last night, I won them ant 10pm and drove 40 miles straight away to collect them, now that's dedication!

Bought them for £90 for the whole lot too! Think they weren't listed in the correct categories or something - they only came up when you typed in "focus hubs" for some reason, not "focus rs rear brakes". still, I aint comlaining and he was a top bloke too, had a lovely Focus RS on his drive too (not the one i got the brakes off :lol)

These discs look pretty big too I reckon at least 280mm (glad i fitted bias pedal box now-gonna need it!) which makes a change from the little rear disc conversions I've done before...

Off to the workshop now to get them fitted, will post some pics of my handywork later on this aft/eve....

The only downside to this is i'm gonna need some even bigger front brakes now!

[ianFRST]

are you sure there rs items? if so, feck me. the normal 2L focus items go for more than that

[heeman10]

Bargain! llama at driving straight there! Will you be carrying out any other work on the car when you fit these? Maybe down the other end of the car?

[Excursion]

are you sure there rs items? if so, feck me. the normal 2L focus items go for more than that

Definitely mate, they've got the space between the disc hub and the start of the brakign surface