fiestaturbo.com

[RS1800-Cookie]

Hi my names Matt Cook (Cookie), I have always been a bit of a ford boy where i started my love for fiestas in an Si 16v 3dr


this was my Si at trax in 2002

I then had various cars and in 2010 got myself a Focus estate 1.8 tdci that i heavily modified, sadly this was killed in Jan 13 due to being hit from another car on motorway







this pic was taken 4 days before it died


after loosing my drive i found myself driving a volvo and pondering what to do, its at that time i remembered my fiesta love and knew the flames had to be relit.

i bought an RS 1800 on a wing that it would be okay to do up, however the more i took apart the more i found the shell was rotten. I scoured the net to find a new shell and came up trumps....

Chippy_RS (trader on here who i reccommend) had a RS1800 he was trying to sell, after a little bit of negotiation we agreed to break the car so i could have the rolling shell.

finally the day came and the car was coming to my workshop


I started stripping the car down so as to start restoration, as with any old ford i found a few scabs, but these were cut out and replaced for clean metal.




excuse the bad welding, i was using flux cored wire and it was shocking! (now have a decent gas welder setup)







once all the scabs were removed and sorted i set about cleaning the engine bay area. i decided a lick of paint was needed. i sanded the engine bay and primed.



then painted



and started reassembling car and cleaning parts along the way.



I decided that i was going to make sure underside was as good as the rest, so i invested in a rollover jig





i applied 3 litres of shultz underneath once rust was treated and sorted. then painted the underside.



My plans to the car ment that the rear axle would need modifying as i wanted to build a escort Maxi rs2000 kit car style rear independant axle. so the conversion begun.... i must admit i was nervous when starting but the end result was worth it.





the original plan was to use the tank but wedge to fit under the axle, however my girlfriend nagged at me with a very true point..... size! .... at which point i decided a custom job was needed. i went about building a model to make templates and fabricate my own tank, i am mounting tank from axle fixings and front centre bolt.















the idea is to run the exhaust through the centre with heat matting on tank to disperse heat. this would mean the fuel sat lower down, helping centre of gravity and aero under car as its like a flat floor. oh and would see the capacity made much bigger

i started on the braking system whist designing the tank. my plans would see the car have 4 pots front and 2 pots rear, i opted for the following

300mm ST 170 front discs with MGF TF AP Racing calipers slightly modified to fit front hubs
278mm RS2000 rear disc brake assemblys from an escort.
No servo - brake bias twin cylinder

in order for me to run the wheels i wanted (rs2000 5 spokes 15") i would need to space the wheel from caliper, here is the final product.



note... the clearance is only 2mm!!!!







the rear setup (before cleaning)



calipers being painted.



I decided to paint the car while waiting on parts, i DA'd the complete car and painted in grey 2k high build primer.











i then wet sanded the whole car (tediously boring!) with 800 grit with a guide coat, then got paint on the go.













I have been buying bits..... to list atm i have a Bailey alloy header tank, B&M Quickshift, Alloy thermostat housing, Samco blue hose set (complete), magnecor 8.5mm HT Leads, Vibra Technics rear beam bushes and front mounts, Piper Vernier pulleys and other bits like chrome strut top caps and new badges.

so.... my vision.... well the original plan has changed over time, but the aim was to beef it up and retain the standard interior look. however.... like all projects my vison is changing....

plans so far :

Engine : 1.8 silvertop zetec to be different and as they rev harder, fully lightened and balanced bottom end, steel H rods, dished forged pistons, ARP bolts, Extensively modified head with larger valves, soild lifters and bespoke ground cams to flow data. vernier pulleys, AT Power 45mm oval throttle bodies, 330cc injectors, aftermarket ecu (not sure which.. Emerald, Megasquirt, Omex) 50-80bhp shot of NOS kit. est to get 230-240bhp+NOS

Transmission : IB5 gearbox casing with RS1800 gears, 0.76 5th gear from diesel escort, 3.** ratio crownwheel and pinion, Series 2 viscous LSD

Brakes : 300mm ST170 front discs with AP Racing 4 pot calipers, 278mm rear 2 pot setup from RS2000, Twin master cylinder Bias box with line residual pressure valves fitted. pedal modification to increase Ratio (needed as manual brakes not servo operated)

Suspension/steering : GAZ Gha Coilovers, rose jointed lower front arms, Maxi 2000 style rear independant axle with competiotion Vibra Technics mounts.

Shell : battery relocated to rear, spare wheel carrier removed, jack cradle cut out, single wiper conversion, Euro lights (have spare set if anyones interested) Euro yellow fogs,

Interior : atm Standard zebra stripe wingback seats passenger airbag...... tho im starting to think of stripping it, cage, buckets and harnesses as its only ever going to be drove by me with a +1 (if there brave enough lol)

Comments, suggestions welcome

CheeRS Cookie

[Excursion]

Nice work. I love the tank mock up.

[RS1800-Cookie]

Hi thanks, it took a while but will look cool I'm hoping. Cardboards one thing..... welding and cutting metals another lol...

[Gus!!]

I love the rear beam idea!!

[Simon84uk]

Lovely build! Will keep an eye on this, very tidy!


Si

[RS1800-Cookie]

I love the rear beam idea!!

I'm hoping the rear beam will help with handling ... due to where the rose joints are positioned it's creates a positive and negative toe as suspension compresses. Eg right corner outer + (compressed coil) inner - (extended coil). Hopefully this will stop the wheel lifting off the ground.

Lovely build! Will keep an eye on this, very tidy!
Si

Cheers Si

[RS1800-Cookie]

Hi everyone, bit of an update.

Well.... i called about to find someone who would build my tank, however because it was rather complex nobody would take it on. Soooo i decided to have a go myself

To say it was a challenge would be an understatement however i did it. Its not the best looking piece of fabrication but once I seam seal welds with fuel resistant sealer and prep and paint it will be fine.

[Excursion]

I can imagine how long that took to make. You can smooth off the welds with a flap disc and I think it'll look even better. Little skim of filler too of you're really bothered

What are you doing about ensuring fuel is taken from both sides of the tank? I'm going to run two lift pumps so added a second flange:



I don't recommend the tank sealer because it degrades over time and blocks or even worse ruins your fuel system.

[RS1800-Cookie]

I have decided to run a bridge pipe at the bottom of the tanks. The idea being as fuel is drawn from main the secondary tank will drop at same level this means there's no need for secondary gauge, pump or even a switchover valve. Problem with two pumps is if one side goes dry n pump still runs then you will shag the pump.

Been looking into sealers. Best stuff I've found is U-POL grey stripe. It's a seam sealer which is resistant to fuel water grease etc. It's pretty awesome stuff. Or frost POR 15 it's only to guarantee no pinhole leaks.

[RS1800-Cookie]

The sealer is applied externally to tank. It only plugs the pinholes you won't see. So no real big risks of contamination or degrading. Mate used on his kit car 7 years ago... still holding well

[Excursion]

The sealer is applied externally to tank. It only plugs the pinholes you won't see. So no real big risks of contamination or degrading. Mate used on his kit car 7 years ago... still holding well

Ahh, external - sounds a lot better. I had in mind those epoxy based systems that pour inside the tank - you then shake the tank to coat it. It's used a lot in custom motorbike tanks.

[RS1800-Cookie]

hi everyone,

its been a while since i added any updates, truth is not a lot has happend due to lack of time and money,

the tank is now done, tho pic does not show it painted, i ditched the sealent idea..... was a disaster! had it all sandblasted and pressure tested tank, went over it with soapy water and found all leaks..... tedious but its done and DOES NOT LEAK !!!! lol .... its not as tidy as i hoped so maybe later on i shall invest in a tig, some ally and try again but for now this will be fine.



the latest development is i've finally given in to the 1.8 vs 2.0 saga...... its a project... and like most will change hehehe

the engine donor was a silvertop zetec 2.0
decided the engineering company im using for work is Scholar Engines

the spec after talking top scholar.....

* 2.0 block +86mm overbore
* wossner forged high compression pistons 12-1
*Forged H section steel rods
* Mahle end bearings
* steel race lightweight flywheel with 220mm pinto clutch (reccomended)
*lighted and balanced crank
*ARP bolts throughout
*Ported head, new exhaust guides, +1mm oversize valve seats
*+1mm 33mm inlet 29mm exhaust one piece stainless steel valves
*Hydraulic buckets converted to mechanical
*Custom scholar spec piper cams ground from blanks (good for 250-260bhp)
*AT Power 45mm oval neck throttle bodies injectors TBC
* emerald K3 management
* 4-2-1 manifold with a 2.5" system (decat)
* 2 stage Dry sump system


Too late to change now..... engines in scholar and paid up half of it lol





so.... for now next phase is getting the fuel lines, brake lines and car back on wheels

[MK4 Rick]

Nice work on the tank i bet that wasnt easy

[stevesoper87]

Looking good Cookie u couldn't do me a favour mate could u? have a look on the tensioner for the auxiliary belt on the 1800 motor and let me know the part number for it, unless u have decided u wanna sell it to me now went to my local Ford dealer, went through the parts catalogue and ordered what I needed but just the bloody pulley turned up they need to contact Ford direct now to try and track it down but if ive got the part number it may speed thing up and hep me out s**t loads. Cheers fella

[Excursion]

I can imagine how long the tank took in the end

[RS1800-Cookie]

Underside of car





Getting there .....

[Excursion]

Looking really good.

[rsturbojames]

what a project mate..... great work

[RS1800-Cookie]

Hi everyone its been a while so I thought I best do an update
I finally have finished the underside and as a result the car is OFF the jig although this did happen at 2am in the morning! #dedication






Whilst doing tiny bits towards the braking assembly I have been buying all sorts of goodies for the engine! To list a few:
* Crower I-beam forged billet rods
~ standard rod versus Crower rod
[img]img%20src="https://farm3.staticflickr.com/2933/14236550526_6611e05010.jpg[/img] full set + one standard as a comparison
[img]img%20src="https://farm3.staticflickr.com/2931/14259296914_074e4e594e.jpg[/img]

* Wossner High Compression Pistons



* Mahle motorsport main end and con rod bearing shells
* ARP head studs, main bearing studs, flywheel bolts + lube
* Fuel pressure regulator


The beauty is all the parts are now with Scholar Engines who are doing the machining work required! The block is being bored to 86mm +1.2mm oversize increasing the capactity to 2048cc or 2.1 as is known from Burton Power.

The crankshaft is being polished, balanced and where needed re-honed. The con rods are being machined on the small end from 19mm to 20.65mm to accept the Wossner gudgeon pins. Hopefully if all goes well these shall be ready in 10 days and then I can start building my bottom end!!!

I have finally decided that I will be using a 2 stage dry sump system with a Mocal oil cooler.

After reading the horror stories people have experienced with compbrake bias boxes I decided to research why, I have found that most cases were where people had replaced the servo for the box but not taken into consideration the PEDAL RATIO... I shall try to explain..

braking systems with servos on cars usually have a pedal ratio of 3.5-1 this is multiplied by the servo to 7-1 ish.
the braking systems on old master cylinder setups has a pedal ratio of 6 or 7-1 to begin with.

the fiesta brake pedal was 3.5-1 if i used this with the pedal box i would have had a really crap pedal. you would of had to really push hard to achieve a nice bit of braking.

so..... me being me i decided to calculate and modify the braking pedal and transfer bar to achieve the correct ratio. i went for 7-1 although after making the adjustments its actually 8.3-1 !











After copious hours of "faffing" around I finally cracked it full pedal travel equates to full master cylinder compression on the bias box ("great success!")


I've decided to run the brake fluid pots on top of the master cylinders purely as I will not have the space in the engine bay to run on lines as the dry sump tank will be situated under the engine bay!

Hope you like the pictures of my progress cheers for looking!

Cookie

[Smo]

Like what you've done with the pedal/master cylinder setup. Could do with something similar but don't have the patience!

Some really interesting work you've been doing here. Definitely keen to see the outcome of the engine when it's done.

You'll have to come along to one of the Action Days at Combe when you're done and get it out on track

[RS1800-Cookie]

Like what you've done with the pedal/master cylinder setup. Could do with something similar but don't have the patience!

Thanks, tho it wasn't a question of patience it was a question of doing the job right.

Some really interesting work you've been doing here. Definitely keen to see the outcome of the engine when it's done.

I can't wait either I saw what the zetec btcc project engine specs were from scholar.... Over 250bhp. The guy who is assisting me from scholar reckons we will easily get this poss more but til it's built, dyno'd we are both in the unknown.

You'll have to come along to one of the Action Days at Combe when you're done and get it out on track

For sure you will I know combe well for my step brother races formula fords there and I have been round several times

[RS1800-Cookie]

Hi everyone, well.... its been bloomin tough going recently. I had a bit of a moment where i nearly jacked it all in and gave up.

Im glad to say, my girlfriend has made me consider my position. The project is still on.. i quote " its a family pet, you are never selling that!"

Anyway, stuff been done. Well the calipers are now fully refurbished with new seals and EBC pads.

The engine parts are now all with scholar engines and being machined. All the parts to build the bottom end are being collected next friday, to list

* 2.1 ltr silvertop zetec block rebored to 86mm
* polished, shot peened and balanced crankshaft
* mahle motorsport end and main bearings
* wossner high comp forged pistons with ring gaps done.
* crower I-beam forged billet rods ( small end matched to gudgeon pin)
* steel one piece lightweight race flywheel 220mm clutch
* 2 stage dry sump system
* ARP bolts / studs

I originally painted the car in 2k acrylic. however there was an unforeseen error with moisture in line. I had fish eyes all over the paintwork. I had no choice but to attack it with the DA sander and prep to start again.... however... as i dont want to go through the hassle of repainting or removing glass again i have decided to do the rollcage now.

The plan before was to do in stages due to costs. I think its fair to say those plans are gone. I am investing in a custom cages multipoint rollcage in CDS. do it once, do it proper!
http://www.customcages.co.uk/Rollcage/LoadRollCage.castle?manufacturer=Ford&model=Fiesta%20Mk3&type=Multipoint


the car atm after i dusted it off from sanding

[FRSJON]

bad news about the paint but will be awesome once finished

[RS1800-Cookie]

Cheers jon

Was gutted , tho in some ways it's a blessing in disguise. See as I don't want to make a mess of the floor I have decided to lob the roof off and buy a raj autoflock carbon special!

Speaking of which need 3 more peeps for a multi buy, anyone interested? ?? PM me if so

[RS1800-Cookie]

So.... After a stern talking too from the girlfriend we set about gutting the interior today to remove the soundproofing tar.

Even had her muck in! #achievement!






Bring on the cage now!

[FRSJON]

good effort from the missus! mine wont go near mine lol oh,i might have another for a carbon roof

[RS1800-Cookie]

Sounds good to me pal, send them my way so I can get a list of names for raj. £420.00 group buy price instead of £540.00

As for the missus, it's great the involvement and not stepping aside. In fact she wants to build a car for herself now lol. Looking at a sport ka possibly with some hefty ponies.

Went to ford fair, got inspired by lukes and robs fiestas.... my plans have changed hehehe

Missus comes back from ford fair with the blue oval bug! Great success! !!!

[Excursion]

What are your new plans? Turbo?

[RS1800-Cookie]

Turbo.... never! Not in this build anyway.

No just I originally planned to do stages.

Stage 1 was to do underneath engine and box but keep standard interior.

Stage 2 was to strip interior and convert to track

Stage 3 is to go on a massive weight reduction programme. Trimming off all unwanted matter. Replacing Wings, bonnet, doors, roof, tailgate and rear quarters all in carbon but painted so it looked standard.

I'm skipping stage 1 as makes sense to fit cage before paint etc.

[Excursion]

Ahh. OK. This soudns good! Have you spoken to 'Freak Power' WRT a Zetec NA engine?

[RS1800-Cookie]

Ahh. OK. This soudns good! Have you spoken to 'Freak Power' WRT a Zetec NA engine?

No, but i did take a look at the thread. very interesting stuff.

[RS1800-Cookie]

Theres been lots of swearing and shouting in my workshop tonight..... I started building the engine.....

So I bought some crower rods off evil bay under the influence they were silvertop....

I fitted the crank, hung a piston on rod and put in a bore. At which point I was F-in n blinding! The bloody rods were blacktop! Pistons were sticking out bore by 4mm. Silvertop being 136mm rod with 32mm from crown to gudgeon pin and blacktop 140mm rod length and 28mm crown to gudgeon pin.

Solution..... need to swap pistons for blacktop ones not silvertop.

...... at which pint I picked up a scraper, angle grinder with wire wheel and hacked the crap out of removing the seam rubbish ready for the cage which has now been ordered

[RS1800-Cookie]

My girlfriend took some pics of the engine being built and of the seam sealer removed.











The sealer stripping venting period! Lol

[RS1800-Cookie]

Today i started to fit the rollcage. not gonna lie its a manly jigsaw !

went for a custom cages full multipont.

lobbed roof off ready to fit a carbon one


Had one issue, difference between mk3 and 3.5!






roof is now cut off ready for the carbon replacement

[RS1800-Cookie]

Had a manic productive day yesterday. Got the cage fully tacked into place so as my brother in law can weld in. Must say.... it looks the nuts!








Ordered new harnesses. Sabelt 3" FIA 4 point blue (adding 6 point crotch strap later on)

Got my new pistons.... to which my silvertop wossner high comp 86mm ones are now for sale

Started reupholstering my 2nd hand bucket seats