fiestaturbo.com

[285Andy]

its been a while coming but finally got spare time to get some hard work done in the old Bay. there's lots to do and new bits to buy. im rebuilding the original 1.6 cvh with polished crank, new bearings, pistons and steel rods. a nice flowed head, camshaft and followers and bought a auto specialist tubular exhaust manifold so will see how that goes. ideally would like to get it to Grove Garage for mapping once finished.
gearbox is being overhauled, turbo will be sent off soon.
all the front suspesion and engine bay brackets (everything thats black!) will be sent off for power coating.
all the zinc (silver and gold) will be redone
going to get some wrinkle finish done on the charge pipework, inlet manifold and cam cover

but first of all, a stripping session and a clean up and some rust removal

here's the pics





































































will do some notes on the photot later, ta

[Dave G fsi]

Excellent work there mate, looks like you are getting ontop of it all just in time

[285Andy]

thanks dave. you right about getting in there in time. there's not really much to do but once ive done it i cant rest easy knowing its all good some PITA bits to do in the strut corners where it meets the bulkhead as im probably going to have to take the dash and carpets out to get to it properly still,,, no problems

[- Danny Boy -]

Whats the rest of the car like condition wise? Lets hope pulling up the carpets doesnt give you a surprise!

[Smo]

At least you're the best man for the job, Andy!

I really like your car, just seems to get better and better each time you do a little something to it

[285Andy]

thanks smo cant ever see me getting rid of it somehow

hi Danny!, ive had this old banger some 11 odd years now and im happy to say that the shell although a little warped shall we say.... (had some roof repair in the past ) is very solid considering. it still has atleast 85 percent of its original sills and the offside has never been welded yet ( i feel like a proud dad when i say that ) coming years will see a rear wheel arch on the offside and sill end repair but ive been crafty with the waxoyl and canny with the sunroof drains and its really made it last. floor wise ive only ever had to repair the floor where the jacking points are at the front on both sides. the inner sills where both good and solid still and didnt need anything doing to them.
this is the first time ive really found any drama with it but as it seems in its infancy i can sort it out and keep it away

got some more pics from todays work. nearside front chassis rail has been rusty since ive had the car and every year the MOT advise it... not any more though!!

cut out and cleaned up


new piece made up and clamped into place


welded up and tidied


then finished off with zinc primer. this will all get loaded with waxoyl when finished



had to take the dash out to get to these area's where the strut turret meets the bulkhead.



passenger side, not too bad just a strip about 2 inches long



cut out and cleaned..



drivers side fared a little worse so looks like wiring out and pedal box.. dam it!



thats all for now! will be back next week for more

[knuckles]

looks like the rust has got yours in all the usual places for a mk3
i stripped my rs down to a bare shell to find it in all them places.

looking good so far with the rust removal. make sure you use loads of seam sealant and under body coatings inside them arches and engine bay.

[- Danny Boy -]

Awesome stuff Andy Will be nice when its all done

[285Andy]

i had the car booked in to the paint shop on monday as i had a "few bits" to sort out over the weekend should have known better really i still cant help but get exited about fresh paint though for some reason

[Dave G fsi]

Excellent progress

[285Andy]

ev'nin all. got a bit more done over the last couple of days so here's the piccys


rusty wing/slam panel area. always hated the way the wing didnt match the original nearside wing. and as it was getting crusty, it had to be dealt with

as a recap, how it first looked (sh**)



both wing and slam panel rust cut out



first off made a piece for the slam panel and tig welded it in. the grey "muck" is a heat absorbing paste. saved the paintwork then skurffed off flush



then made a piece to imitate the nearside, again tig welded in and skurffed off smooth. will need the tiniest bit of pudd to make good. although not noticable, each layer i treated with a anti rust zinc coat.



sorted out the neaside strut rust.



repaired the bulkhead layer



then made the top layer, welded in and cleaned up. will get a treating of zinc coating and 3M's finest seam sealer when ive finished all the other welding



got this in the post from Auto Specialist the other day



knarley piece of welding!!



smoothed off my front panel for nothing else other than looks as im hoping my engine bay will turn out custom but stil as OEM as i can





other than that, ive just started on the offstide strut tower so pics will follow

ttfn!

[RS EDDIE]

Wing tops look pucka mate!!!

[Excursion]

Great work Andy. I knew you'd do a good job

[Dave G fsi]

Brilliant workmanship

[jayrs]

nicely done mate

[Dave5300]

great work mate, and just look at that manifold!

[jonyb4]

wow!

your an excellent welder mate!

very inspiring

[285Andy]

thanks for your kind words all!

got some more done, here's the piccys


all on the offside now as the nearside is all done.

all the crap cut out from strut and bulkhead



chassis leg is in great condition and will just need a underseal and wax coating



rust had spread into the inner wing re-inforcer and this isnt repaired as well as id have liked. to do correctly would have meant removing the wing and the car isnt in a bad enough state to warrent doing that at this moment in time. i will add though that all the rust was cut out and there is a wheel arch liner so is only incorrect if you can see it if you know what i mean





repaired first layer (wraps over strut) which is the bulkhead



then repaired the top layer which is the panel the heater sits on and painted up



also painted up under wing



its now down the paint shop and im expecting it back on monday or teusday so i can start the refit

got most of the gold zinc done! looks awsome! also got a bucket full of bits i want done in zinc silver ready and waiting to be done



trying to be a bit diffenert, i want a larger throttle body and so went donw to my local scrappy and went through his parts bin and found this GM one. same outer diameter but just over 1/4" larger throttle plate





the engineer next door is going to bore this out to match. (blue line is just to give you an idea of how much bigger the hole needs to be.) and the hole on the throttle body need to be elonggated about 2mm each one apart from the top left hand one.



top left hand bolt hole is an odd one for the standard frst body so built the area up with weld





will takcle the throttle cable operation next but will be a while yet. may even dump this if i find something more suitable. i have a few spare inlet manifolds to play with lol!

thats it for now , cheers!

[Excursion]

Great work, Andy. FYI the TB flows enough for well over 400bhp,s o stepping up in size won't necessarily add anything but may harm response. It's the manifold that's poor

[Dave G fsi]

Looking really good mate, good progress there

[285Andy]

Great work, Andy. FYI the TB flows enough for well over 400bhp,s o stepping up in size won't necessarily add anything but may harm response. It's the manifold that's poor

thats usefull to know! thanks mark like i say if its too much like hard work i'll drop it quick

thanks fella's!

[rob pace]

good work mate, i bet there is no other road with 2x FRST'S in it

[285Andy]

must be the only one in England i reckon Rob

got the car back today. here's some pics.












will get stuck in over the next few days re-fitting it

[Dave G fsi]

Absolutely stunning mate, bet your well pleased!

[Ratspeed]

That looks brilliant! I do like a nice fresh bay

[jayrs]

looking good mate

[jonyb4]

aww thats gorgeous man! very fresh, dont damage it on the rebuild

[Excursion]

It takes me longer to get around to installing a dashboard The joys of living 200 miles from your project

Great job Andy!

[Dave5300]

now that is fresh! cant put an unpainted engine back in there!

[285Andy]

hehe! thanks for your kind words all! i also hope i dont scratch it on fitting it up jony i cant see me not making a mark on it somewhere though

got a little bit more done on the car over the last couple of days

here's some pics

starting out, i stripped off all the old insulation tape from the main loom and re-taped it. it took ages because if its too slack, it looks whack and you got to get all the branches looking right or it'll again look toot













yes, your right, thats is a lambda sensor plug. ive fitted a lambda sensor in the exhaust so may help with mapping but if not ive fitted a air/fuel meter to plug it into. white plug next to it is for nitrous solonoids



next im going to tackle the engine managment loom. proper scruffy





and lastly, got some more gold zinc done




cheers all!!

[Dave G fsi]

Looking stunning mate, keep up the good work

[MircoJ]

Looks great! Will you also add some new underbonnet decal?

[crazycage]

nice fabrication/welding mate

[285Andy]

MicroJ, im not sure on decals yet. they can sometimes be a bit pricey and i dont think they would add to the bay anyway

cheers for all your comments people

more piccys time! fitted up some more parts as they arrived back from powdercoating.

i had a bit of a problem with the wiper motor. i gave it to the platers with the alloy ends still in as they are pressed in and pinched. they kinda shrunk in the wash so to speak and the outer spindle nuts didnt fit anymore so i had to buy another one. this time though i just glass bead blasted it and clear laquered it. the inner spindles and linkage rods where zinced ok though so still used them.





fitted all the rear bay panels. soo glad i got them done in matt finish as they turned out great! all the rest of the black so far is all in satin black including the sensor panel.





fitted lots of new parts like steering rack, universal joint, heater matrix, track rod ends, top mounts, antiroll bar bushes, brake pipes. still need to get fuel filter, servo and master cylinder, gearbox mounts, header tank cap, wiper blades and clutch cable to name a few off the top of my head...

here's the rest of the pics anyway















thats all for now. got a second round of powder coating going on atm. also still waiting to hear about pistons which is now holding me up for rebuilding the bottom end gearbox is done and ready to pick up and havnt sent the turbo away yet either.

cheers for now!!

[mrorange2]

Great work looks lovely wish i could have done this to mine.