My big ZT thread > 15.4.08 25bhp/20lbft extra and track prep

Post pics of your Fiesta here.

My big ZT thread > 15.4.08 25bhp/20lbft extra and track prep

Postby heeman10 on Tue Dec 28, 2004 11:17 pm

This thread contains almost all the work I've carried out on the car beginning from the 1.8 litre Zetec Turbo conversion, and continuing to the present day. Also included are some videos (below) and related links to my car.

Hosted videos (right-click, Save Target As...)

YouTube video "Montage", saves you downloading

Video: Launch control testing

Video: Headlight camcorder - the first video

Video: "Back out in the Fiesta" Part 1

Video: "Back out in the Fiesta" Part 2

Video: "ZT Montage", a look back over the best bits of 2006 and some late 2005, headlight cam/in-car/external combo

Video: "OTRagain" (on the road again) after a major dismantling/rebuilding of transmission, and more boost

Video: "Lost at Croft". Playing on the fun roads near Croft while lost!

Video: "New arm test". Testing the new shortened clutch lever arm with some more boost.

Video: An evening drive near Preston with a mate's Mk5 Zetec S, footage from both cars

Video: First summer blast of 2007 (Part 1)

Video: First summer blast of 2007 (Part 2)


Big thanks to "Smo" and "HawkeVIPER" for hosting these videos :) If they don't play properly, you may need to download a codec package from here If there are any problems with the sound playing, it often helps if you scroll forward about 5 seconds, then the sound should return.



Contents of this thread (click the subjects to skip to the relevant page)


Page 1: The beginning
Page 2: Fitting the ZT to the car
Page 3: Arrival of many parts and modifying the inlet arrangement a little
Page 4: Polishing aluminium parts, modifying charge carrier and more parts arriving
Page 5: Rear windows, fuel pump, wiring, exhaust, spare wheel carrier, arrival of brakes
Page 6: Modifying brakes to fit, new rear lights, metal polishing, charge carrier and Deflex gearbox mounts
Page 7: Modifying brake caliper brackets
Page 8: Oil presure sender, braided brake lines, radiator/intercooler/actuator bracket modifications at Fusion, fitting brakes, dash back in, dump valve
Page 9: Intercooler/radiator/bumper fitted, injector wiring, bumper modifications
Page 10: Exhaust modifications, engine wiring complete, Fusion air filter/coolant pipes arrived
Page 11: Everything bolted in, MOT rush, intercooler fans, broken Harvey Gibbs gearbox, new CTS gearbox, coolant temp sender mods
Page 12: Interior back in, new gearbox in, modifying gearbox mount washers, turbo heat wrap, car bolted together again
Page 13: Timing belt tension queries
Page 14: Uneven tickover, three sets of injectors, silver indicator bulbs
Page 15: MOT day, sill welding, all new inlet gaskets, idle problem solving attempts
Page 16: Modifying air filter pipe for fitment of recirculating dump valve
Page 17: Suspected (but not) leaking radiator, recirculating dump valve fitted
Page 18: New tyres, clutch pedal gave up with AP paddle clutch, coilover arrival/fitment
Page 19: Removal of stubborn locking wheel nut, fitment of final coilover unit, rebuilding gearlinkage with new selector rod, fitting FRST steering rack, breather pot modifications
Page 20: My guide to tracking your wheels, completed breather pot and random shots at home, Escort master cylinder/servo fitting, bumper repairs/smoothing
Page 21: Removing Fiesta rear brakes in preparation for the RS2000 rear disc conversion
Page 22: RS2000 brakes stripped/painted, more bumper smoothing work
Page 23: Final bumper repairs/sanding and in primer
Page 24: Fitting the RS2000 rear disc conversion to the car
Page 24: Manufacturing brake pipes, RS2000 rear disc conversion complete, front pad replacement and smoothed bumper sprayed and fitted
Page 25: MOT'd, Armtech rev limiter fitted, tidying up before Trax (including spraying underside of bonnet) and switch panel template
Page 26: Trax preparation complete, the weld on actuator pin fractured driving back from Trax
Page 27: Bolt sheared off in exhaust housing, turbo sent off for stud removal and actuator pin replacement including pics before/after and with T2 turbo
Page 28: Two videos of the car on the road using in-car and headlight-mounted camcorder, plus hi-res photo's after cosmetic detailling
Page 29: 1000 replies!
Page 30: Car passes 95,000 miles with an odometer shot. full car checkover before Santa Pod and SCC rolling road day, including ride height drop
Page 31: Turbo removal to remedy flexing actuator bracket, and gearbox removal to replace release bearing to help quicker gear changes, plus strip/inspection by CTS
Page 32: Gearbox returned fine after inspection, clutch removed and sent to AP Racing for inspection
Page 33: AP inspect the clutch, Fiesta/Escort quadrants are the same, much discussion
Page 34: Clutch back from AP with new pads, leisurely rebuild begins
Page 35: Almost rebuilt (with photo's), new header tank, waiting for new oil hoses, yet more discussion
Page 36: New Roose silicone oil hoses arrive, cut to length and fitted, car running again and adjusting boost and taken on a lonnng test drive!
Page 37: Measuring up and making a new, shorter clutch lever arm (inc. video of road test), photo's in Manchester under the arches
Page 38: Random photo's after a quick wash, new 4" straight cut tailpipe, photo's of the car frosted up at -7 C!
Page 39: The boring evolution of my tailpipe (LOL!!) and people babbling
Page 40: Couple of scenic shots, glowing turbo, detailling + de-swirling
Page 41: Agreed valuation 2007 pics, plus the rust bubble finally gets burst :cry:
Page 42: Rust bubble vanishes, courtesy of the bodyshop. First bit of bodywork I've had done!
Page 43: Smoothing rear bumper, cleaned up rear valance, primer and first coat of colour on bumper, video of tailgate popping
Page 44: Final coats of colour on rear bumper, new front window outer weather seals, LED gear knob resurrected for FITP!
Page 45: Two random photo's (including the ghey smiley :lol:) and it finally drops into the 5 second bracket in the 0-60 dash


Related links to this build:

Photo's of the original damaged gearbox

Mapping updates

Gear linkage rebuild

Gear linkage rebuild..again!

Broken gearbox mount - punctured radiator

Repair work carried out by Pro Alloy on the punctured radiator

Fitment of Fiesta Frenzy rose jointed/camber adjustable arms

Insurance photo's

Manual adjust clutch pedal/guide

My guide to gift-wrapping your car (from the good old days before I had a car cover!)

Other links of interest

The evolution of my car in pictures

Mondeo TDI engine conversion

The original headlight camcorder!

Another batch of pics of the headlight camcorder in use

My Mk6 Zetec Climate TDCi thread



Rather than cluttering up the General forum I'll chuck any pics in here. It was a good day today. I spent a couple of hours yesterday and last night getting most bits off the car: bumper, radiator, intercooler, all hoses, header tank, bonnet, exhaust, wheels and put it up on axle stands. This afternoon I took off the rest - crossmember, brakes, suspension, ARB and a couple of bits left over like the speedo cable and exhaust/inlet manifolds, making sure there was absolutely nothing left connected to the car, and absolutely nothing that could foul against bodywork when the engine came out.

My dad was very helpful today and it speeds things up with two people to do things. So without an engine hoist to hand, we opted for a pallet truck (the two-pronged thing on wheels, can lift hydraulically by about 20cms) and our little excavator!

The pallet truck under the engine and box, chocked enough to lift equally on the engine and gearbox:

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Here it is, jacked up so it's just beginning to take the weight off the axle stands, allowing the engine and gearbox mounts to be undone:

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Mounts undone, and very, VERY smoothly with absolutely no problems at all, it dropped to the ground with no effort whatsoever, a huge shock!! :)

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Now you see the need for the heavy padding...don't want any of that paint scratched :D Lifting straps + digger = scary sight :aaah:

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The lift begins. This also went nice and smoothly, and because the engine and box were on the pallet truck, it was a case of lifting the car up, wheeling out the engine, then gently lowering the car back onto the axle stands and turning the excavator's engine off :D

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Et Voila:

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Hmm looks to me as though it wants a Zetec Turbo in there ;)

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There will be lots more pics to come, hopefully, of all the bits I intend to try to do before I have to go back to uni: fitting paddle clutch to the Zetec, the wiring nightmare that lies ahead, brake conversion, opening rear windows, custom rad and cooler, and maybe the oil cooler, though I can see myself doing that at a later date. I'm still short of parts, and they're taking a long time to get hold of, so some jobs will have to be put back.

Nightmare: My trip down to FITP 05 isn't as certain as it was :( Have been invited to something I'd feel bad about if I didn't go...but FITP is FITP!!! Decisions decisions![/u][/b]
Last edited by heeman10 on Tue Apr 15, 2008 8:55 pm, edited 134 times in total.
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Postby Swanick on Tue Dec 28, 2004 11:23 pm

nice 1 :D has he got a ticket for that machine :P
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Postby Brycey on Tue Dec 28, 2004 11:25 pm

Great pics.

FITP is the Grand unveiling of this! You HAVE to be there!

No more chug chug jokes though :( :lol: :P
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Postby Richard_xr2i1800 on Tue Dec 28, 2004 11:29 pm

looking good, keep up the good work.

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Postby heeman10 on Tue Dec 28, 2004 11:41 pm

John - I sincerely hope he has...specially with those demon eyes he has in the photo :lol:
Brycey - You're damn right. All the hassle I've gone to to prepare for all this this holiday has been so I can make it to FITP, and I want to go more than anything...am just going to have to see what I can do. There's always the possibility the car won't even be ready :-?
Richard - Will do matey :D
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Postby andyhardy on Wed Dec 29, 2004 1:10 am

Good work mate :D

Can't wait to see it next year - just make sure you at least make it to one of the shows next year!

I'm already feeling doubtful about FITP myself! :lol:
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Postby Capri on Wed Dec 29, 2004 1:13 am

Jim mate, looking great, always good to see work in progress on something someone's been building up to for so long! Are you using the diesel gearbox?

Looking forward to continued updates... and to seeing the car at FITP... :P :wink: :lol:
My name is Alex. I used to have a Capri. I don't anymore. But I'm still called Capri.
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Postby RS_Rawli on Wed Dec 29, 2004 1:17 am

nice one jim ;)
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Postby wywywywy on Wed Dec 29, 2004 1:35 am

Jesus! That is a big workshop! And all that tools! And your dads in workwear too!

Where is the 2.0TDi engine going though?
Fiesta Mk3 The Complete FAQ
Have a look, and do a search, before you ask anything :)
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Postby Smo on Wed Dec 29, 2004 2:29 am

Looking good :D

Capri wrote:Are you using the diesel gearbox?

I don't usually like answering questions directed at other people, but I think he's using a Stage 2 CTS box remembering this topic:
http://www.fiestaturbo.com/phpBB/viewtopic.php?t=92764
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Re: heeman10's TDI to Zetec Turbo conversion *lots of pics*

Postby scarlet_pimp_mobile on Wed Dec 29, 2004 5:04 am

heeman10 wrote:Et Voila:

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what a colour match with those overalls :o

seems not that long ago seeing your post for sticking th tdi in! :-?

congrats on this stage :)
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Postby FezzR on Wed Dec 29, 2004 11:37 am

nice one fella,
get your ass to FITP, i might even return to show season this year :oooh:

dout ill be driving the fez tho :lol:
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Postby heeman10 on Wed Dec 29, 2004 2:44 pm

Cheers for the replies guys :)

Mandy - If I can't make FITP I'll certainly be making one or two other shows, can't do all this and not show it off and meet all the sound FT crew again!

Capri - As Smo said, I have a CTS box waiting to go on, but took the shafts out of the diesel box about half an hour ago to find they're nothing like the petrol shafts. Big screw up :rolleyes: I have no petrol shafts, so I'm totally schtuck.

wywywywywywywywywywy - My parents sell trees for a living (yes, it's a job!) and that place is where all the trees get stored when customers come to collect them, and where trees are parcelled up for postage (yes, they post trees too! ;) ). It helps to have a few tools when you want to do something like change an engine :p Sadly enough, my dad and I bought our overalls from the same place, so we both match the car :lol::lol::lol: The diesel is a 1.8 TDI, and is sold to an FT member who is collecting it tomorrow ;)

scarlet_pimp_mobile - You're damn right it doesn't seem long since the TDI went it, it was only April, and it died in August after maybe 1,500 miles in the Fiesta :rolleyes: Should've gone straight to petrol!

FezzR - If I ever pull this thing off for FITP, it'd be truly shameful if you didn't turn up in yours. Pull. Thumb. Out. :p

I've only got as far as getting the gearbox cradle off, removing all gearbox-engine bolts but two, and removed the driveshafts so far today. Had another look at the wiring, and walked away crying :lol::lol:
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Postby FezzR on Wed Dec 29, 2004 4:33 pm

the s**t thing is im more than happy to work on other peoples cars cos at the end of the day its not my ball ache, but when it comes to my own car :cry:

if i drive my fiesta to FITP i will so so shocked lol, unless our friend scort finishes it for me :lol:
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Postby FezzR on Wed Dec 29, 2004 4:36 pm

jim can you provide close up pics of the engine to loom connector 1 pic of Diesel interior side and zetec endgine :wink: side
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Postby heeman10 on Wed Dec 29, 2004 7:52 pm

Ian - I know exactly what you mean about helping people with their stuff and not getting on with your own, much easier for some reason :-? I'll get pics of the connectors when I carry on again tonight, but won't be posting them up till tomorrow due to my short bursts on t'internet, hope that's ok.

Today's pics

We carried the engine from one shed across to the main shed the car's in, using chains and a big log, which you can see on top of the engine:
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That is about a one metre step up, so of course...bring on the digger :D
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The diesel box and ERST CTS box side by side, for anyone interested. I will never live down my bungle with the driveshafts!! :lol: They are now out and, yes, they are the same as the petrol ones :rolleyes:
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The diesel clutch compared to the paddle clutch going on the Zetec:
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What a mess!
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And a scandalously random "arty" shot, which hardly merits it being posted:
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I looked at all the wiring once more, with yet again, no bright ideas :lol: I'm still not 100% about how to lower the engine the 10-12mm necessary for the charge carrier/inlet to clear the bonnet. The two gearbox mounts can be spaced with no problems, but the engine mount is another matter as far as I can see. Some phone calls/emails to be made/sent methinks.
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Postby Sphinx on Wed Dec 29, 2004 8:02 pm

Top work :D

I'v added you on msn so i can ask you lots and lots and lots of questions :D :lol:
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Postby mike_wall15 on Wed Dec 29, 2004 8:08 pm

You could have at least tidyed the hay away before starting! :rolleyes: :P

Good luck in getting it all in, well nice! :D
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Postby FezzR on Wed Dec 29, 2004 8:08 pm

clutch cover plate looks a bit discoloured. should be ok tho

as for wiring pics, whenever you like mate, its for your benifit (i hope :lol: ) :wink:
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Postby heeman10 on Wed Dec 29, 2004 8:19 pm

sphinx - No probs, will catch you on MSN when I'm back at uni, probably around Jan 10th.

mike - It's straw :p I swept and cleared it all away, it just keeps climbing all over everything!

Ian - TDI clutch and cover on the right, Zetec on the left.

I wanted to get the flywheel and clutch on by the end of today, but the guy at Ford didn't order the clutch cover locating dowels soon enough, so I'll have to wait another day or two. Every time I order a part they huff and sigh and whinge, makes the job that little bit more fun for me!
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Postby RS_Rawli on Wed Dec 29, 2004 8:55 pm

j j jimbob,

lookin good u hillbilly

fook lowering the engine, raise the bonnet :D
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Postby FezzR on Wed Dec 29, 2004 9:36 pm

i know which is which :P
was talking about the zetec one looking a bit blue/dark, which means it has got rather hot a few times
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Postby heeman10 on Thu Dec 30, 2004 1:52 am

Rawli - Am thinking lower the gearbox side of the engine 10mm, and if any probs...bonnet spacers :devil:

Ian - Please be quiet :) The Zetec clutch cover is a normal metally kind of colour, which I'm led to believe is quite normal...for metal things :) :p

UPDATE

I test-fitted the brakes for the hell of it at about 10:30 tonight, and they appear to go straight on as a few of us thought in the first place! Standard bolts from the Mk3, no spacers etc. The outer pad cleared by about 2mm, and the inner pad was pushed right back against the piston anyway. All looked funky dory to me :)

I put my new bumper on briefly to measure up for a cooler, and I think I quite liked it really :D Will put some pics up tomorrow anyway, as usual.
Last edited by heeman10 on Mon Mar 07, 2005 7:44 pm, edited 1 time in total.
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Postby FezzR on Thu Dec 30, 2004 12:27 pm

fine if you dont want my opinion, just stating what the picture clearly shows :Q
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Postby heeman10 on Fri Dec 31, 2004 3:43 pm

Ok I got those pics of the three plugs, though I forgot to bring the top view of the 2i plug over:

Bottom view of 2i cabin-bay plug:
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Bottom view of diesel cabin-bay plug followed by top view:
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Bottom view of FRST plug next to injectors, followed by top view:
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Uprated Bosch Cosworth pump arrived from Holland at last, and my Mondeo starter motor came this morning too:
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And a couple of pics of my bumper. Doesn't look too great with nothing behind and no lights, but you get the idea!
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Postby Max M4X WW on Fri Dec 31, 2004 3:49 pm

What cooler are you having?
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Postby FezzR on Fri Dec 31, 2004 3:53 pm

how come the engine aint in?
your hand are far too clean you havent been working :rolleyes:
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Postby heeman10 on Fri Dec 31, 2004 4:16 pm

Max - Because it was all getting a bit rushed, I was going to settle for one of GRS' twin pass coolers like Gav's, but now I'm giving it more time I'll start thinking about changing things around for a single pass again. Whatever it is, it'll be fitting in such a way that the bumper won't need cutting :)

Ian - Latex gloves my main man!
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Postby FezzR on Fri Dec 31, 2004 4:29 pm

coolant temp
oil pressure
reverse light
charge warning
ignition live (red and black)
earth (brown)
and one from where the speedo cable exists the G/box
rev counter (from edis)

get your multimeter out and compare diesel enginge loom and frst engine loom
Last edited by FezzR on Fri Dec 31, 2004 4:47 pm, edited 2 times in total.
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Postby heeman10 on Fri Dec 31, 2004 4:33 pm

Ah coolio. Well, I'm going to pull everything out and put a FRST loom in anyway, now I've got time. Make it all beautiful and neat and everything, much more satisfying :D Thanks for than Ian, and I'll race you to the finish!!! :lol:
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Postby Max M4X WW on Fri Dec 31, 2004 4:37 pm

The bumpers allready cut! :lol: Pro-Alloy?
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Postby FezzR on Fri Dec 31, 2004 4:43 pm

put the engine in first like i said, much better imo

also means there is naff all in the way when the engine is lowered raised

EDIT TO LIST ABOVE

worked out how to lover engine mount yet?
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Postby heeman10 on Fri Dec 31, 2004 11:13 pm

Max - I mean the top face of the bumper will remain standard...ie the bumper won't protrude above, it'll all be contained behind the cutout. Not Pro Alloy, no, I was really disappointed by their end result :( Probably going to stick with Radtec or GRS.

Ian - Yeah I am putting the engine and box in first, just so the car can be towed back to its shed. Purely whipping it all back together for now so it can go back there, and work will continue at easter. I'm leaving the engine mount, as most people (bar one notorious person!) have said they lowered the gearbox side alone, which gave enough clearance. I'll make some spacers up when I get back to uni.
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Postby Max M4X WW on Sat Jan 01, 2005 12:30 pm

heeman10 wrote:Not Pro Alloy, no, I was really disappointed by their end result :(

You mean from the thing in PF?
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Postby FezzR on Sat Jan 01, 2005 2:17 pm

pro alloy seem to have very good flow, hense the very little boost losses and lag.
This is not ideal for reducing temps tho
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To celebrate https://t.co/wXVkvJipaS being 20 years old this year, I've written a series of articles detailing the… https://t.co/B0vE0Y3KvP

17:42, 4th December 2021 Twitter Web App

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