fiestaturbo.com

[mies1974]

November 2008 I started my project, on a Radiant Red 1994 XR2i 1.8 16v (it's the 130 bhp version, in the UK I think it's called the RS1800).

I startded to remove the interior. My parents have a large and dry space next to their house.
Here ar some pictures...

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(I removed most of thuis foam, it was a bit damp... and because of the moist it started to fall apart...)




We found this. We'll see how we solve this later...






The plan is to keep it quite standard.

The alloys on wich it's standing on now, will not return on the finished car. I have some referbished 5-spoke 15" Ronal/Ford RS rims to replace them.

It started out as a search to find corrosion. I found some cracky bits under the carpets, so I removed it.

A previous owner, or a not so clever mechanic, probably placed a jack under the footwell of the backseat. It was jacked up anyway and the floor came up well before the rest of the car did. This cracked the underside and moist came in. In the years followed, this hole apeared:

I allready removed some rust. You can put your fist through here. Me and my father think about repair and weld it ourselves

The paintwork.. I put some Meguiars on it. That give's a nice red shine to it.

Engine-wise and mechanical ther is not much wrong with this Fezza. No stutter in the engine, I shift through the gears very nicely. No problems here.

This is.. (on this side of the North-Sea).. the driversside. We started the deconstruction here.


Behind the front arch ...


Same side some ventilation....

(those white rings are a mirror-image of two bicycle-wheels)

The floor on the driverside can be a bit drafty....




There! One sil gone...



... This is worse than I hoped is would be (isn't it always?)
After we took some bits out, we saw that what we thought was shallow rust, in fact was much much deeper..
Someone else would throw this car out, but we'll try to repair is bit by bit. Time is on our side.
First the inner sil (the grey bit) needs some attention. We have to restor some of the bottum and we have to weld on a new sil..
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The hole is whole again with bit of 'Fiesta floor'



Parts of the floor and the sill are restored.



To reach more bad spots, we removed the inner-sill.



I takes shape bit by bit.


Because we don't want to do this all again in a few years time, we will coat the inside of several bodyparts with 'INOX-spray' On the can it sayt is conducts electric current, but when we weld on it is spatters a bit.


For small bits we use some scrap-sheetmetal from a local bodyshop and some bits we don't use of the new sills...





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When this is ready we can built up the complete sill...






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Here we removed a bit of the inner-sill. It's been welded ans coated in INOX-spray... We leave some bits uncoated. This is where the spotweldes come.




The inner-sill welded on, and coated:





Outer sill put on and welded:



Whit filler on it and primed:



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No we can do the same on the otherside so we have to put it the other way around in our workspace...
Notice the nice carpentry of the racing-seat (exclusive bit of D.I.Y.)

(before we turn it)



... Outside ...






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We move on...


The other door went out. Also the other sill was cut out.




On this side the rust was not so bad as the passenger side.

The inner-part of the sill was removed to. It has been resored an welded back on the car.
All the parts are coated in INOX-spray. The new sill had been put on and it's been primed..



Here the rear of the little fiesta is up in the air.


The axle is removed now.
The Axle, the anti-rollbar, the brake-drums and the fueltank will be de-rusted and repainted
All teh bushes are replaced by PU bushes (FloFlex). At the local Forddealer we orderd a new handbrake cable,new rear brake shoes and some bits more.

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Some more....

Alle the axle parts are repainted. And the new orange bushes...



In the triangle-shaped axle we welded 3 steele plates, for more stability and less torsion.




I came across this scrapped Fiesta ST. I took te front brakes for a brake-conversion.

The old and the new...






Some fitting with the future alloy...

Succes is ours...!

The result


I can't wait to drive it and brake...!!!


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This summer my father shaped and welded a new piece for the fuel-line-hole in the rear mudguard.

Before:


.. and after:


Also the underside was in need of some care
I treated it with a grinding wheel with a wire brush. Then is was coated withe INOX-spray.





Then the bottom put in amber Tectyl ML (also the hollow beams, with the use of a spam tube). After this dried up a little I put Techtyl Bodysafe over the ML. next up is to put some undercoat 190 Black on it.




A rear strut brace is placed (make: Wiecher Sports)




Today we put the rear axle back under the car. All necessary bolts have been cleaned.



All nuts and bolts are checked with the torque wrench. From the Haynes manual, we could take the torque.

Final result today is this:

[scouse-sambo]

Nice work

[SLEEMAN]

i like seeing projects like this, as there are some decent owners out there that can put money and hard work in restoring classic cars to keep them on the road!!! fantastic work mate keep it up can't wait to see the next update!

[mies1974]

Thank you, I'll try my best.

We (my father and I) do much of the work on saturday's and so it takes a lot of time to finish somthing. I dont'want to rush anything, either.

We hope this Fiesta will be on the road again in the summer of 2011. When there are updates wurth mentioning, I'll make some pictures.
Thanks again, guys!

[speedyxr2i]

great work nice one will keep my eye on this

[jonyb4]

i like seeing projects like this, as there are some decent owners out there that can put money and hard work in restoring classic cars to keep them on the road!!! fantastic work mate keep it up can't wait to see the next update!

could not have put it better myself

loving the work your doing there mate, real credit to you, im supprised you can ge5t floflex bushes over there

the rear end underside looks mint, bet it makes you not want to drive it now



interesting to see that the RS1800 over there is an XR2i 16v, over here, the xr2i is a 1.8 zetec engine, but its only 105ps, it lacks the cams, inlet maf and map the RS has, but its a simple upgrade, ive done it myself with my Si 16v, dropped a 1.8 in and done all the 120 bits liek cams etc

keep at it mate, it will be a nice motor once done,

ill keep tabs on this

[Excursion]

"The floor on the driverside can be a bit drafty...."

Great work.

[mies1974]

Another update today.

On the rear axle new drumbrakes are fitted. Also all the brakelines are fitted correctly under the car and tey're connected to the rear brakes.



Also a new handbrake cable is fitted and adjusted correctly.



As you can see, the old fueltank was painted and is reinstalled and connected.



The heat-shields are cleaned up and are back under the car.



Next up are the rest of the heat-shields, install the exhaust. Then we can put the Fiesta on some wheels and we can do some work on the front suspension and a little surface rust removal.

[jonyb4]

spot on mate, love the underside of the car, its almost like new

[mies1974]

All the heatshields are put under the car,



We cleaned the stainless exhaust and refitted the shiny pipe where it belongs...

[jonyb4]

the underside is gorgeous mate, reminds me i gotta get mine undersealed soon

[mies1974]

allright Jony, here it go's:

You gotta get yours undersealed soon!

[Excursion]

Excellent work, Michel! Did you find any cannabis in the glove box?

[mies1974]

Not everybody is high on drugs in Holland, Mr. Excursion....

Because it's previous owner was as football enthusiast I found an old football-ticket of Ajax-Amsterdam and on the parcel-shelf was an English flag

[jonyb4]

llama

[Excursion]

Not everybody is high on drugs in Holland, Mr. Excursion....

Because it's previous owner was as football enthusiast I found an old football-ticket of Ajax-Amsterdam and on the parcel-shelf was an English flag

I know, mate. Just "pulling your leg"

[EUFez]

Excellent work, Michel! Did you find any cannabis in the glove box?

Not even some Hash Brownies?

Nice work mate, keep it up! Looks mint...

[mies1974]

Not everybody is high on drugs in Holland, Mr. Excursion....

Because it's previous owner was as football enthusiast I found an old football-ticket of Ajax-Amsterdam and on the parcel-shelf was an English flag

I know, mate. Just "pulling your leg"

yeah, I know...

[mies1974]

Now. Today it was driving-time .. (it sounds very promissing)..

The car has to go the other way around into the garage, and so....
I went for a (small) drive with the Fiesta!

First, let's see if it starts after about 10 months of standing still.
Battery in place... Fuellpump does "zzzzzzzzz.." Ignition key I ... Ignition key II Startermotor turns... And!...



"Vrum-brum-brum-brum-brum-brum-brum-brum-brum-...." It starts in 1 go. And runs nicely.


On the driveway we got rid of the dust...




Illegally down the street (100 meters). Turned. And back again.. (much to cold without any doors )




...

[jonyb4]

lol bet that was a sign to see it going like that

good job

[Excursion]

[FlashXR2i]

XR2i superleggera


Nice work mate !

[mies1974]

Small update....

In short: The fezza's front is jacked up. The brackets of the airfilter-box are taken off. The gearbox is suspended (held up) on the battery-tray. The gearbox-cradle has come off. We took the front struts off and also the drive shafts.
The radiator and fan are out to...

thus the Fezza is now ....




In the wheel arches there was some rust here and there. This was basically not too bad, though. If I see the other XR2i donor car I have, this project car is not so bad after all. And these cars differ just about three and a half months.

Here in the rust is treated with FERTAN (anti-rust treatment). After cleaning that off, we can put Hamerite on it and eventually it Black 190.




Some parts are de-rusted and are treated with Hamerite...




I hope this summer the car is ready to go on the streets again, but we still have a lot to do, and we don't have much time.

[RSGeorge]

Another red fez getting saved thats what we like to see.

Liking the work so far mate, dont give up

[xr2imetalhead]

wow good progress there dude keep up the good work!!

[mies1974]

update:

The front suspension is refurbished and we gave it a hamerite treatment. The frontbeam, where the radiator stands on, had surface rust. that's gone and was also put in hamerite.

Both the lower suspension arms are put on the car. The front-anti roll bar is almost in place and the gearbox cradle is been put back in place



Some edges and holes are treated with Tectyl ML and wheel arches are put in Tectyl Bodysafe.



Here is a look at the other end of the support beam of the gearbox.
There is still a few things still to be finished.



Radiator has to go in. various hoses and wires to be connected. The Fiesta get's a strut brace under the hood. Obviously the struts itself are to be fitted.

Enough work, but the building does me good.

[jonyb4]

stone chipping the lower valance i presume?

[mies1974]

yees, that will be stonechipped

[jonyb4]

good stuff

if you dont mind, what do you drive daily then?

a ford?

[Turboboy67]

Top work

[mies1974]

In recent days we made some progress on de 16v.

Suspension .. nice and black


The driveshafts are back on tje car.


The large ST discs are mounted.


All brake lines are connected. The mastercylinder and the servo. Both are refurbished.


The heat shield is polished up. The waterpipe treated with a heat resistant finish.


As you can see the batterytray has a fresh finishn. The top strut-dishes (is that the right word for it?) are painted silver.


The radiator came from my donor-16v. The fan housing is refurbished.




maybe tomorrow I put the air filter housing back in place. now we are already comming along so nicely

[Russ FRST]

looking very good mate lots of heard work going on! keep it up..

[mies1974]

The thermostat 16v taken from the donor and also from the Project 16v taken and tested. Do both. One opens at 92 degrees Celciuis. The other at 88 degrees Celciuis ...(?)

The thermostat of 88 degrees was in it and is now again.

NGK spark plug wires to put the car.


As you can see the strut brace in place and cleaned tanks are in place.


The radiator in the car I had was a leak. This should be replaced with another leak proof radiator.

Also all the junk from the car. Edges should be sealed. Can be painted, inside ..



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some days later...
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Running!
http://youtu.be/o1WH0SPQ6eI

The leaky radiator is replaced by a different radiator. This has been refurbished (the slats are straightened and I threw some paint on it).
Everything is mounted again, and ... leak-free!

For the system to be flushed, the radiator first was filled with tap water only.
Starting the engine was not without problems. Starter motor would not "click". We took the old starter from the donor car and have it tested on the workbench to be sure which connector did what.

Same test on the car .... Nothing.

After a few blows with a hammer (Clarkson-style) and a few more tests (directly from the battery with jumper cables), the startermotor came alive.
Then start with the ignition key ... and the engine ran. (fortunately).


The tap water is removed from the system. And it is now filled with new coolant. We can continue with the built-off.

[mies1974]

Today, the sills are painted ... There is some color difference (of course with red). It wouldn't be hardly noticable, while the side-skirts are beeing mounted on the sills.

[jonyb4]

looks good, shame that red is so fussy