fiestaturbo.com

[Pez]

Try these, we deal with them at work and they're pretty good.

http://www.firstservetrade.co.uk/

[Project]

Only just revisited this thread for the first time in aaages, and all I can say is JESUS H. CHRIST!

Can't wait to see this baby finished! (That's a munki seal of approval, by the way, not that I'm sure it's worth bugger-all...! ).

/al

[heeman10]

Andy - You know what I'm like with my shiny stuff!!

Chris - Partco near me. It was 25 quid for the big box, then 2 or 3 quid for the smaller box of 60mm clips.

Al - It is worth bugger Al to me cheers matey

[heeman10]

Useful pics from today:



Anyone attempting a ZT conversion, suspension top breathers are de rigeur

[CRF]

Cheers Pez, will have a look.

Found some cheap at screwfix.com, not just as shiny as yours though James.

This is the mesh I was talking about............

[SantaHul]

any sound clips of the girl running?

[heeman10]

Chris - Do you have some pics taken from further away please? That looks pretty good, possibly sliiiiightly finer than I'd like, but yours looks good for the job. Whose car is that? It looks black

SantaHul - Not yet. I'll be ordering a video camera quite soon, so can get a video of it running probably. By that time though, it will *fingers crossed* be mapped and ready for REAL videos to be made I'll post them up as soon as I have anything!



Update:

I blitzed the coolant system later on this afternoon. I've collected a whole host of hoses and connectors and coolant-related parts from scrappies over the last couple of weeks, and boy did I need it all! I have now fully plumbed it all in bar the water pump to bottom radiator pipe. I have hoses which meet, but I have an angle and diameter change issue. I've designed a metal pipe which I emailed to Lee @ Fusion Fabrication just now, and hopefully I'll have it by Wednesday!

I also found a location for the air filter for now, so drew up the metal pipe I need to connect it to my turbo, and it will also incorporate a take-off for my recirculating dump valve. The air filter is pretty huge, and the throat is 82mm compared to the T3's 60mm neck, so there's another diameter change, and angle to design into the pipe. Hopefully he can also get that to me by Wednesday!

Things are looking fairly final now. Now the coolant system is sorted I can put the inlet manifold on for good, re-assemble the wiper mechanism, put the bulkhead panels and loom in place, and perhaps tidy the interior up a bit. The exhaust downpipe needs heat wrapping, and of course I can't assemble everything yet because I don't have the alternator. Getting closer each day though, and definitely not looking QUITE so desperate as long as I can book in for an MOT on Thursday afternoon/Friday morning. If I can, I'll be driving the car all day and night to rack up miles and bring out any problems.

[andyhardy]

[FezzR]

cool beans

[heeman10]

My eyes are funny

[Rodge]

I bet you feel like a kid waiting for christmas now that the end is near

[CRF]

My eyes are funny

Glad i'm not epileptic!

Do you have some pics taken from further away please?

Not at the moment, can get some for you tomorrow though when i get home from work.

Whose car is that?

Mine........

It looks black

????


Nice one with the pipes, seen the pipes he made for Matt, good work!

[heeman10]

Rodge - Surprisingly, I'm not actually! I was like that a few months back, but I've been focused on completing uni work and more recently assignments, and now when I work on the car it's very solid work, finishing job after job. In the earlier days it was more scattered work, but as time is so tight it has made me more organised and directional. That's not to say I'm not really looking forward to the finished result!!

Chris - The grey just looked a bit dark in the pics, that's all Yeah show me some pics from further away showing the ground up until the bottom of the windscreen, and the whole front of the car basically Lee is very very good. I'm forever singing his praises on here, as he's done quite a few things for me now and never lets me down

Update:

Not a lot to do until the alternator and my coolant pipes arrive. Was going to re-fit the wiper assembly and get the bulkhead panels on along with the inlet manifold, but I'm missing some wiper parts. Some nuts were corroded, so I ordered new ones from Ford...but they weren't in all the parts bags for some reason. Re-ordered those this avo. Thought I couldn't have it all bare without cleaning it, so gave it a quick polish and it came up pretty well The bits in the corners are hard to clean thoroughly as they're awkward to get to, and the folds in the weld sealant trap the dirt:



Then I re-wrapped 80% of the engine bay loom, as some of the black plastic wrapping was torn, and had random overspray on it from the previous owner (adamski ) etc, and it all looks spanking now:



Just going to swap the starter motor over again and then fit the inlet assembly. Bit stuck for things to do after that! I booked in for an MOT this Friday morning, madness perhaps, but a damn good way to make myself complete it!

[Captain Tightpants]

This thing not finished yet?! What you playing at eh?

Looking good mate!

Your going to have to take me for a ride in it once its completed you realise!

Steve

[heeman10]

Dr Dowell - Shat it Course I'll be taking you out on it!

Update:

I thought I'd better check some MOT-related things last night, as it's due in three days Indicators, headlights, brake lights, reverse light and fog lights all work as intended. What's even better is that my bumper lights can now just plug into the standard Ford connectors on my 2i loom instead of using my own wiring and bullet connectors



I put the inlet assembly back on again today, hopefully for good, and had a fire up to (a) make sure after playing with and modifying the injector loom, all was still well, and (b) see if swapping the E-DIS module had solved the problem of the rev counter standing still. It fired up a treat yet again, effortlessly, and idled nice and low and smooth as a greasy banana Sounded great too, even though the centre section wasn't clamped up Still no revs showing on the clocks though. Had it up to 20mph ticking along in second gear on the axle stands, so at least the gearbox does actually turn!!

Random shot of the exhaust:



My alternator will be refurbed by 2pm today, which is GREAT news. That means I can fit that, then fit the exhaust, turbo and manifold, actuator etc for the "last" time. I swapped the starter motor back to the FRST starter (bought a 2i starter thinking it might be the problem when it was the alternator all along) and fitted the starter heat shield. Going to scrappy today to get the wiper bits I need (Ford are taking too long) then I can get the bulkhead panels and MAP sensor plate etc in and have the bay looking half-complete

[CRF]

Here you go mate.........









CheeRS
Chris

[heeman10]

Ah cool, nice one, looks good! I picked up some agricultural mesh today for less than 4 quid, might do the trick. It's silver and metal, but all I've found, apart from the 600 x 300mm black plastic mesh in Halfords....for 22 quid!! Not paying that!! If tomorrow goes as well as I hope, I will be out on the roads pintling around and doing systems checks Lee@Fusion has guaranteed three pipes to be with me tomorrow, which means everything can be hosed up and put back together The time is finally here!

[Rhinopower]

northen tart, still not finished???

[heeman10]

It's quite surprising how much there has been to do, even though it may look as though I just need to throw the rad, cooler and bumper in and it'll be finished. I'm closing in on that stage now, so as I say, I'll hopefully be out on the roads tomorrow evening putting miles on everything. The only thing I was expecting to give me problems was the top radiator hose which I cobbled together, but now I have the silicone hose and custom T-piece coming, all should...SHOULD be well. Fingers crossed!

[heeman10]

Bad day for project heeman

Today's going to be a frustrating one. The reconditioned alternator's now on, and didn't send sparks showering from the battery terminal, which is nice! I've decided the exhaust simply cannot stay as it is. It's hard up again the front of the car, hard against the sump, and I still only have about an inch between the downpipe and the alternator. I've found a local guy who's going to lend me his trailer to take the car to him. We'll work out the best way to clear all three things (slam panel, alternator and sump) and then weld on a mount under the car to tuck the exhaust RIGHT up inside the sump, and up under the car nice and tight for maximum ground clearance. I should've done this a week ago, but was going to wait till I could drive it somewhere. So exhaust sorted tomorrow, MOT Friday morning, and everything needs fitting to the car somewhere between tomorrow and Friday!

Also, just came to start it to see if the rev counter on my other clocks will work, and the engine's refusing to start The time pressure's immense, so a non-starting engine is not really what I needed. Another bad point - I've discovered I have an oil leak from the oil temp sender in the sump. This means I'll have to drain all the oil again and see what's what. You've got to expect these issues, but they're cropping up at a very, very bad time!

[MAD_Adamski]

oh dear mate you'll sort it good work tho and glad the 2i loom came in useful in the end you are still usung the immobiliser aint you???? that may be why it ain't turning over if its still wired up you gotta use the immobiliser first then try to start it.... know it sounds silly just dn't know if u forgot that??

[andyhardy]

James - check all the wiring around where you've been playing about with the car - you've probably disconnected something!

If anybody can get it fixed and running between now and that time it's you mate - you've basically made your own Fiesta kit-car!

What time on Friday is the MOT?

Cheers,

Andy

[heeman10]

I re-soldered the multiplug with 15A wire, and only THEN did I see that I'd left the ACT sender out of the throttle body, leaving about a 9mm hole. That was enough to stop it running, so of course that's now sorted. No revs on the other clocks too, so it's an E-DIS related issue. I can live with no tacho for now though.

Bulkhead is all in now. MOT is now pushed back to 3pm to give me the best possible chance of making it. The engine is now bone dry so I can tackle the temp sender leak issue. Also found the brakes were leaking a little at the caliper end...I THINK that's now cured

If I manage to pull this off....MOT'd and mapped next week, I want to hear chants of "James is a legend! James is a legend!" up and down the country from FT members!!! Can it be done?

Ad - I'm afraid the immobiliser came off, to remove any possible complications.

Andy - Cheers matey Vote of confidence is nice every now and then

[heeman10]

Pics from today

Lee @ Fusion has come up with outstanding goods yet again. This big pipe gives me a 60mm-82mm diameter change, including a 45-degree bend, allowing me to fit my big air filter to a hose I have that fits onto the compressor. Lee said he had to "bodge it together quickly to get it to me on time" If I could produce things that look this good when I'm hurrying and bodging, I'd bodge everything!!







The left of the two pipes below goes from the reducer hose on the water pump to a 90-degree hose I have that fits onto the bottom rad pipe. Diameter change from 34mm to 38mm I think, with a 45-degree bend. The right hand pipe will fit the hose from Roose Motorsport, and incorporate my fan switch:




Not what I wanted to be doing two days before my MOT



The bulkhead mess is all in now. I think I like the look of the chrome, though I must admit it looks neater with the soundproofing in place, as it hides all the wiring. I'll leave it as it is for now anyway, feel free to comment, I expect a mixed bag





Tomorrow morning will hopefully see the exhaust modified, and then EVERYTHING can be bolted back on/in. Fingers crossed, as usual!

[Rhinopower]

heeman, no offence intended here but the welding looks like pidgeon s**t on the fan switch bit, personally i'd ask for a replacement. If you need anything else made we've got the best kart chassis welder in the country!!!

[heeman10]

Lee rang me at around 11:45 yesterday morning to say he'd received the drawings just then, confirmed the dimensions, and got them off with his courier the same day (early afternoon) and I received them this morning. He didn't even have time to put on the 25mm stub on the air filter pipe (for my dump valve) he was in such a hurry. The weld is fine. I'm sure if he'd had time he could've prettyfied it, but given the miniscule amount of time he had to make all three pipes, I think he did a damn fine job. I wouldn't get my metalwork done by anyone else, as far as I'm concerned he's the best man for the job.

[Rhinopower]

fair enough, fooking quick turn around!!!

[andyhardy]

Wicked mate - I really have got my finger's crossed for ya!

Cheers,

Andy

[heeman10]

Just put the wheels on properly for the first time. With my spacers on (THINK they're 3mm not 5mm) the spokes clear the calipers by about 2.5mm Just need to put the bonnet on in the morning then it's off to sort the exhaust. The guy who's doing it used to be big in rallying...RS200s, 6R4s etc, and his workshop's a mess, and dark and dingy. Going to stay right by the car, as I don't think he's used to working on cars that people really care about Cheers Andy

[Sphinx]

Looking great!! Respect for taking on such a huge task! seems like your either learning a lot on your way or your pretty good anyway!

I know what ya mean about taking your car to people that dont really care, always worries me to!

[krsi]

I haven't been on here for a while so I've just been reading over what i've been missing.

Nearly there mate, hope everthing comes together for your MOT and getting it on the road. I can't wait to see the car in action

[Max M4X WW]

What can i say. Everything looks amazing!!

[andyhardy]

How's it all looking for the MOT tomorrow James? By the lack of posts today I'd imagine you're pretty busy with it all!

Keep on truckin'

Andy

[heeman10]

Cheers ppl

Only just got back from having the exhaust sorted. It is now absolutely spot on. I have more alternator clearance, 10mm+ clearance of the front panel, 5mm+ clearance of the sump, and it sits lovely and tight up under the car. The backbox had shifted a little afterwards, so we heated the pipe at the back of the box and shaped it to fit the bumper cutout properly. It was about an inch to the left, and we'd just finished the job.

Me: "The backbox isn't in the centre, we'll have to sort that"
Him: "Ah that's fine like that, it's not touching anything"
Me: "Oh, you don't know me do you?
Him: " "

Pics

Fiesta ready for its fun day out. First time it's been on its wheels for a while, and almost 9 months since it left the house!



Some may remember I made up a temporary mount for the centre section, which gave me no more than about 5" ground clearance all the way along the underside. This new mount holds the exhaust absolutely spot on perfectly under the car:



The re-re-modified system, I couldn't have asked for a better fit



Back home, centralised backbox, and it's now sitting outside in the sun waiting for me to bolt everything back onto it. May the insane rush begin!!



Stu@MSD said if I give good enough notice they can take me a couple of days later, which gives me till Monday to have it ready for mapping if I need it Ok, time to go crazy!

[andyhardy]

Excellent news mate - great stuff with the exhaust and the extra bracket that you made up!

You need to get rid of that TDI badge now the car's using the correct level of distillation from oil!

Cheers,

Andy