fiestaturbo.com

[AW0L]

Please note, this is a project log of work already done with the pics I had taken sorry if there are parts missing that make no sense, I am trying to put them into order so that its pretty much all there…

So here we go into what has so far been a very long journey for this car… here she is as of 2 weeks of buying it…



And under the bonnet



Just look at all that space…

This right here is a Fiesta Sapphire 1.1i MK3.5 and according to we buy any car, it’s a special edition… I.e., came with heated front screen, electric windows, central locking and dual airbags

In that time, I had done, alloys, spoiler, gave it a 2 tone paint job, KnN filter with 360 degree air flow mod to air box (kinda like American muscle cars have),a real cheap excuse as a oil catch can which I forgot to empty, mostly it filled up with condensation from the short runs to work I drove, M3 mirrors and Lexus lights (I know most people hate em, but then if that’s the case no one else will have them on their cars ha-ha) and fitted a 3” rolled exhaust…

I drove this then for 5 years as it was, putting up with the constant 1.1i engine issues that everyone seems to be having these days, constant cutting out etc… after a while of watching my Speedo drop from 80 on motorways to 50 whilst going up hill I was getting a bit fed up with it and thought of dropping in a 1.6 cvh, which a mate had, but he blew that up shortly after lol.

So I carried on with the gutless run around until it decided to start playing up again, destroyed a cat every year for MOT and was throwing oil everywhere… one look on eBay found me a Escort GTI Zetec engine for £60, bargin!!!

I removed my passenger seat and went to pick up this new engine, once I got there it was showing promise as it had all the extra bits that I wasn’t expecting to find, inlet, exhaust, pas pump, air con pump, only downer was the wiring loom was cut off and not unclipped.

So I got it home and left it in the car for the weekend, where on the following week I took it to my work and began to remove everything on it.

I haven’t got any tear down pics, but I guess all of you know what a dirty oily engine looks like… reason for tear down was, I didn’t know engines history and I wanted to clean it up and paint it.

So here is a long list of pics after clean up and painting and the beginning of rebuild.



I have fitted a CVH alternator bracket to this as I am not using the aircon and power steering so that mounting bracket went bye, bye, and I save a lot of weight using this mount.



AP Racing HD Clutch



The gold thing is holding the flywheel locked at TDC, I also have the timing pin in the front of the block



New water pump fitted, awaiting gen ford oil pump gasket



Fitted the alternator which came with the engine, I stripped it out and refurbished it with new bearings and new internals.



Another shot of the alternator

Had a massive delivery of new parts, gasket sets, new cam followers, plugs and leads, cam belt kit, aux belt, top section of cam belt cover as was missing when bought engine, fiesta zetec rear mount (lucky for me my car already had the mount holes already present), GTI IB5 gearbox, maf and banana pipe, air filter and HO inlet



Right side up again, the rocker cover sitting up like that as there is a timing bar across the cams holding it timed up for the cam belt



Cam pulleys painted up nice







All covered up, anyone know where I can get a clear cam cover???

Fitted the exhaust manifold and HO after again cleaning and painting, the exhaust manifold is temporary as I want to get a better tubular one.





Banana pipe, MAF and air filter fitted.

Now that the engine is pretty much finished to the point that I can’t do anymore till it’s in the car, I turned my attention to the gearbox. Again, a second hand part from a salvage yard, so was cleaned and cleaned again, old oil drained and flushed through with evaporating cleaner and again flushed with clean oil. Once that was all done I got trigger happy with the rattle cans and painted it…







Fitted to fiesta gearbox cradle

Took another delivery of intake pipe work and silicone hoses the same bore as the intake and MAF, measured up the spacing and made up my pipe, wasn’t keen on the banana pipe



(I later find out that the bonnet won’t close like this lol) anyways…

With engine and gearbox ready to go, its time to put the two together… dun, dun, duhhhhhh!!!



And so begins the “out with the old, in with the new” special thanks to Will and Kate for getting married giving me a long weekend to do the swap over





Out with old…

Ok right, the engine came out within 25 mins of starting, (after mackys breakfast of course) but that damn gearbox took over 3 hours of banging, pulling, cussing, cut hands, and 3 2l bottles of coke just to remove the bloody driveshafts… I resorted into removing the whole suspension on the passenger side and beating it into submission



VICTORY!!!!!



Up she goes to fit the Zetec in, I have never lifted a car this high before, me and a mate from work laughed and was very worried about the cracking wood noises happening every so often…



Engine in and back in the ground



New rad fitted, this is the first time I have ever handled a new rad, I am not used to seeing straight fins and no bugs melted in



A pointless exercise, but I was waiting for my samco hoses and had nothing else to do and I hadn’t painted anything since the gearbox was done… so stripped and painted the rad fan, personally, I like the red fan blade, nicer than yellow



They’re here!!!! After 10 weeks of waiting I get to plug up all those holes in my engine… 10 weeks delivery, 10 mins fitting!!!



Around this time I had got hold of a RS1800 engine loom and added the wires for the oil pressure and water temp gauge into the large grey plug that connects the main car loom to the engine loom and extended the wires for the rad fan switch by around 30cm

*wiring wise, these are the only things you need to change, the oil pressure wire is in a 4 pin plug near the canister purge valve remove whole pin from here and fit into grey plug, water temp need chasing back as close to the grey plug as possible and solder a used crimp with a good enough length of wire and join the two together and put into the grey plug, rad switch wires are quite thick so I used parts of an old loom so I have the same colours and thickness and soldered together *

After wanting to take a break from wiring and mechanicals… I decided to make a better oil catch can taking more time and a bit more planning, here is the end result



If anyone wants to know how to make these, all it is, is a alloy sports drinks bottle, with a 3/4” to 3/8” reducing bush fitting, with a 3/8" hose tail fitting for 10mm id hose, breather filter, 1/4"hose tail for 10mm id hose and a couple pneumatic fittings and clear pipe.

I plumbed this into the crankcase breather thingy after I modified the PCV valve. By modified I cut the bottom off it so it no longer needs vacuum from the inlet to vent the crankcase pressure.



Here it is fitted in the car, and I made sure before hand that this one does not leak… lol

So with my list of things to do getting smaller I turned my attention to chassis strengthening and handling, these are in the form of these beauties…



ARB again, painted with new gen Ford brackets and bushes



Lower S Brace, Another eBay item at much cheapness £20



And fitted with new Catalyst

Now I have pretty much doubled the HP of my car, I am gonna need to stop the car pretty damn good and let’s be honest, the brakes on Fiesta’s are shockingly bad anyway… I mean just look how bad and under par these are…





Soo, I ran through my stash of Ford bits and happen to have Sierra XR4i Callipers sitting around going rusty (I was going to use these for my Cobra Kit Car… oh well)
After 2hours of stripping down, wire brushing and prepping I end up with this





And after a delivery from Bigg Red, I received new pistons, bleed valves, all new seals, covers and caps I got busy with the paint again; you can see all is already masked off for paint

If you are wondering how to get a old piston out… (I really enjoyed doing this), get a bike pump with a football attachment, pump air into the cut off brake line and have the piston face away from you… keep pumping and it fly’s out at some rate of knots… well funny!!!



Here they are with the first coat, used a brush to paint these, this made sure I could see the paint in all the gaps, rattle can paint didn’t really cover too well







All finished with all new parts, and braided hoses



Had to drill out the hubs to 12mm to fit these, here they are trial fitted with Sierra discs. (These are not the right discs for this conversion; they are too high on the hub and bind as it spins. I will get a set of RS2000 discs at a later date)



Making sure my badly scuffed alloys clear the calliper, can anyone recommend a referb place in Watford??

Next I move my attention to the last parts of the braking system, the servo… I went with the Mondeo conversion, but got me a Cougar servo instead, (same but different… lol)

As you can see the servos in Fiesta’s are small and just not good enough in my eyes



(Hello repeated picture… sorry, best one I got that you can focus on the servo)

I wanted to do something new and unseen (well by me anyway) so I bought myself a large sheet of 3d carbon vinyl wrap. This is what I ended up with after 1hour of pulling, shaping and cutting.





And then fitted to the car



Close up of the wrap and also shown is my new gen Ford fluid bottle and 2 new pipes I had to make as Ford decided that they would change the size of the fittings on 2 outputs. The green original pipe is the driver side front, just have to make up the passenger side but is being a bit of a fiddle to remove so I can make a new pipe.

Had a play around with some more wiring and found a small but probably serious problem with the MAF wires. When doing a “wiggle test”, the wires felt loose and gave fluctuations in resistance on my meter.

I always find this with every loom I buy from anywhere that says loom is uncut, Soo frustrating!!! Anyway this is what I find when stripping back the insulating tape.





Hmmm not quite the way I’d do it but each to their own, everyone has their own way to fix something…

After a few mins…



Here is a quick guide on how I join wires



And the finishing touch, braided sleeving



Not bad huh…

Ok moving on!!!

I was going around everything and I was wondering do I really need the canister purge valve????



Can I just remove it and do this????



You can see I have joined the two pipes that go off to the purge tank on the driver side wing. As it acts as ventilation from the fuel tank I guess it’s kinda important. Can anyone shed any light on this??

After my successful try at vinyl wrapping the servo in carbon fibre, I thought I’d try a bit more this time on the roof… yes that’s right… I vinyl wrapped carbon on the roof cuz its £20 for 1.5m x 1m of vinyl and about £200 for a roof skin…

After 3 hours of cleaning the roof and fighting with the wind heres what I come out with



Just look at the sun reflecting off it, beautiful ain’t it????

And another view



Had a bit left over so done the spoiler too



I know it’s not everyone’s cup of tea but I like my spoiler, I bought another roll of vinyl, this time Police Blue… I used this on the spoiler ends so far





Such a nice blue… Plan is to do the sides and bumpers in the blue, and maybe the tailgate as well, bonnet in carbon but might do tailgate in carbon also. What do you think???

And now, mk5 clock wiring, I’m not gonna go into detail on how the wires go, but if you need a hand ask…



What I did here was destroy an old mk3 set of clocks and cut out the connector and part of the circuit membrane. After cleaning up the tracks on the membrane I soldered the wires from the mk5 plug onto the mk3 plug. This allows plug and play functionality so I can put the old clocks back in if I so wish.

And the clocks fitted into the dash, job done



I have the fuel gauge reading correctly and the only job left to do here is a mileage correction to bring the mileage to what the original clocks say, not for anything dodgy or to gain anything, I want everything to be right.

So, now we move on to more interior stuffs… in the last pic you can make out the centre vent area has some gauges in, well this is where they are staying now, before I fit them there, I had them in a pillar pod, which I didn’t like much, it didn’t fit properly and actually warped when it was a nice hot day.

Heres the pillar gauges…



As you can see, ERGGHH!!! And that’s why I moved them to the centre vent area.



and, just for gimmicks and completely useless and lazy, a start button that does work, but is mainly there to fill the hole that was in the dash from another button I had there.


and to finish off the interior for now, I removed the front seats and swapped with si seats, but I could only get seats from a 5 door, so I had to strip both my old seats and the new seats and swap everything over…

Before



And after



much better… pay no attention to the piles of stuff all over the place, it’s a lot worse now lol!!!

So on to more big and important stuff, I have always wanted to do a rear disc conversion and thought this would be as good a chance as any to do one, so here we go…

Started out with a MK5 fiesta beam that I bought on eBay. (ebay is great isn’t it? You can get everything you need easy and cheap ) it came complete with drums, abs wiring and HB cable, well, didn’t need any of that so that lot went in the bin, after I stripped it, I cleaned it and gave it 5 coats of hammerite black



And for the rear disc conversion, I used focus hubs, as they bolt straight onto the beam and was easy to get hold of. After a clean up and de rust, gave them a coat of paint

[Gus!!]

That was a beast of an update!!
Looks like its coming along well though!!

[jonyb4]

bloody love your workmanship, and the ideas you come up with, cant tell if your applying what you've seen off forums/from others or actually coming up with it on your own, but its sure working


sadly i cant say i like your exterior fashion, few will on here atleast, but atleast your not skimping on the technical side of this car

the engine build i found particually enjoyable


keep the updates coming

[heeman10]

I spy Foose

[AW0L]

thanks guys, i have got more updates to put up, but finding the time to write it up, upload pics and proof read it takes a while to do but what is coming up is fun!!!

jony, most of the stuff i have done has been frrom other forums but done my way, every mod i have done is totally reversable. the wiring on the mk5 dash is completely mine, i haven't seen or heard of anyone doing it that way. i know your not a fan of the lexus lights, and to be honest i am getting bored of them, might see about blue tinting the lenses when its in colour , as with anyones car, its all down to personal choice.

engine build was the most enjoyable part for me also, i have now fitted the Escort inlet and pipe cuz i was getting bad heat soak with the last set up.

Foose is the man!!!! lol

[Gus!!]

I could live with the lexus lights and stuff but that wing is a little ott?? I like the carbon roof!! What you doing about handling??

[AW0L]

the rear spoiler isn't that bad, it looks quite subtle and it makes a great place to put tools and cups of tea also again, personal choices etc

handling wise, i have the lower S brace, its sitting on GAS coilovers on a 60mm drop at the moment, front anti roll bar and on the rear it has the MK5 beam, i was going to put a strut brace on too but cant seem to find one that will fit with the mondeo servo mod fitted

[AW0L]

Ok, so as I mentioned in a post up there ↑, that I had changed the inlet set up from the HO to the GTI inlet, I have looked into it and both flow the same and have the same if not a slight size difference in the TB’s, and I am also getting cooler air into the engine as the pipe is not soaking in heat… heres how the engine looks today (for now at least )



ok so going back to the rear brake system, handbrake cable is next, you will see later, when I start work on the inside of the car that I have put in a MK5 handbrake lever, just cuz I could and its easier to do maintenance on the cable tension from inside the car. Put on with this is a custom made, hand brake cable. Those who have worked on MK3 fiestas will know that the brackets for the HB cable are offset on one side. I tried a focus cable which was clearly too long (came with the calipers so no loss there), even tried a racing puma one, still too long… (Still no loss there as Mark (Excursion) bought that from me) getting somewhat annoyed, I resorted to cutting the caliper end off a new focus HB cable and pulling the inner cable clean out. I then removed the end of the outer sheath cap on the bracket side, put the caliper end into the caliper bracket, run the cable around its correct path to the offset bracket, measured how much I needed to cut off and cut it to length. Obviously, you need to do that for both sides.

I then made a call to speedy cables who send me 2 caliper fittings to make up the inner cables, with this I put the cables back into the outer cable and hooked up the HB lever to the hook piece that joins the cables to the lever, making sure it stays perfectly straight, I measured the length I needed and cut the cable, pushed on the 2 ends and sent them to speedy cables to crimp them for me.

End result looks great, I just wish I took pics of that, but you get the idea from the essay lol.

Anyways… more rear end stuffs… been busy with more biggred deliveries, this time it’s a complete overhaul kit for the rear calipers, done the same as I did with the fronts and painted them blue. Went to my local ford dealership and got 2 new disc guards as the ones I got with the calipers where far past saving. Heres how they turned out.



And from above.



Ok, this is where it gets interesting. You can see in this one, the above said HB cable, looks standard yes? And of course the Goodridge braided brake lines, coupled with more braided brake lines… these braided lines go all the way to the front to the servo as seen here :0)



the reason I did this, is because I had to make 3 new pipes up and the flare tool I used seemed to give ok-ish flares but I didn’t trust them, and I kinda want to be able to slow down without the risk of the pipes not sealing properly, so I bought about 15 meters of braided hose and all new re useable fittings, and set about it should notice a serious increase in braking efficiency.

Moving on to the front again, egh, mechanics, its always back and forth and up and down… but hey its fun!!!

Bought a complete PAS setup from Phil (fiestasiphil) for an absolute bargin, thanks again mate this is the pic he had on the ad



set myself a whole weekend to swap everything over, old stuff came out pretty easy, new stuff, well lets just say, next time I do this I am doing it before the engine goes in… the hardest part was trying to get the column shaft to sit into the rack, every time I got close it moved and fell out, I fought with this for about 2 hours before it gave in.

I had a different cooler, I think it was from a CVH PAS set up, it has 3 or 4 rows, so used that instead of the 2 row cooler with the fins. (will try and get a pic here at some point)

Next turned my attention to the front mount bracket, lucky for me the holes were already there but no nuts to bolt onto, I have a rivnut tool, but only went up to M8, so I got some fittings from Ben (ben17southport), and made a rivnut tool that I found online using a M10 bolt, a washer and a nut with the thread drilled out. Heres the web page to show how it works

http://www.carolinarovers.info/croc-stu ... ivnut-tool

I was really impressed on how easy it was to fit these fittings with this method.

Heres the front mount fitted



Bit of a lame pic as doesn’t really show anything, but you can make out the front mount and some parts of the PAS system

And lastly, I am lucky to work next to a company who used to make all the displays for halfords CD players and speakers, but have now turned their focus to home entertainment systems. Anyway, I was given 2 sheets of Dynamat, plus, a boot kit and door kit all for free… WELL HELLO MEGA SAVINGS!!!!

So far I have used up the 2 sheets on the roof, and done the boot, heres the boot all matted up



And for you all to drool over, lol, something I have been working on, on my lunch breaks

[Gus!!]

That is gonna make a seriously cool noise!! What do the 15"s fit like with it lowered?? I admire this craftmanship!! You said about blue tinted lights, you want a set??

[jonyb4]

i think its safe bet you have a thing for JDM? the spoiler and HKS style filter point to such

[AW0L]

That is gonna make a seriously cool noise!! What do the 15"s fit like with it lowered?? I admire this craftmanship!! You said about blue tinted lights, you want a set??

i can't wait to finish them and get my ecu finished up, the 15" fit fine the rub a little on the fronts on full lock but other than that no problems. as for the lights, pm me a pic of em and a price please

@jony spoiler yes, filter, well it was the only one i could find that didnt rub on the battery

[jonyb4]

any more info on that throttle body set up?

[AW0L]

i followed this guide, http://www.sportingfords.com/forums/vie ... 60attached

[Gus!!]

Picture of them blue lights when they were on my car (was a while ago) i know 1 of them has a bit missing off the corner i'll get a picture of it later!!

[Rs Adz]

fantastic build not 100% on your styling but your workmanship is top rate

[AW0L]

Picture of them blue lights when they were on my car (was a while ago) i know 1 of them has a bit missing off the corner i'll get a picture of it later!!

ah yea i seen those, i will let you know :0)

fantastic build not 100% on your styling but your workmanship is top rate

exterior i haven't really done a lot with yet,, ok, the spoiler not many people like, but i'm not gonna go all out and get a massive fibreglass body kit which makes all cars look pants, as they normally end up cracked/broken etc

[jonyb4]

think the point with the spoiler is itas may suit a japansse drifter, but never will suit a small hatchback let alone a European ford

[Michael!]

i like the spolier hahahaha, dare to be different!

fancy a set of standard lights though? those lexus ones are fudgekin awful

what engine mount did you use?

[Excursion]

Superb post, I've just caught up with it all. Your standard of work is excellent.

Just one thing - it's probably worth upgrading to a Zetec gearbox cradle and brackets, and also fitting the ib5-to-block strengthening bracket.

[AW0L]

i like the spolier hahahaha, dare to be different!

fancy a set of standard lights though? those lexus ones are fudgekin awful

what engine mount did you use?

cheers mate, i got some standard lights, might play with them or get some blue tinted ones at a later date, i used an SI front and rear engine mount

Superb post, I've just caught up with it all. Your standard of work is excellent.

Just one thing - it's probably worth upgrading to a Zetec gearbox cradle and brackets, and also fitting the ib5-to-block strengthening bracket.

Thanks Mark, i can't say that its up to your level of work, i would love to do what you have done. i am quite proud of what i have achieved, just wish i have the dry storage to work on it more.

i will upgrade the cradle at some point, the brackets are ib5 ones, i just lost the strengthening one, its seen in a couple shots but i took it off for some reason and now i cant find it

[jonyb4]

i am quite proud of what i have achieved

You should be, certain people on here inspire me to work better, dispite my fathers half arsed efforts that try to tempt me into a quicker fix (aka bodge)


if i were you, id either go for standards, MHW smoked, or RS accessory rear lamps, for me these are the only options (clears work on certain cars/body colour)

[AW0L]

if i were you, id either go for standards, MHW smoked, or RS accessory rear lamps, for me these are the only options (clears work on certain cars/body colour)

yea i will wait until its in colour to decide fully...

this is the colour i am now going for

[THE GIT]

i did the same as you yonks back andy lol

[AW0L]

lol yea mines been on there 5 years now, and i had it on my old fiesta before that for 3 years

[THE GIT]

the black cars long gone but i am building another budget track day car lol

[jonyb4]

for that colour id go for the MHW's personally, but yet again i already did

its a similar colour to java, tweek used clears on his, suited it, but he had a whole white theme going on

[AW0L]

for that colour id go for the MHW's personally

yea, any idea where i can get some ???

[jonyb4]

ebay or keep an eye in the for sale sections on the site

MAY be selling mine once i get the RS accessories next week, not sure yet though im quite attached to them

[AW0L]

ebay or keep an eye in the for sale sections on the site

MAY be selling mine once i get the RS accessories next week, not sure yet though im quite attached to them

dibs if you do!!!!

i found a set on ebay for £85

[jonyb4]

ouch, id pay no more than £60 for them

mine however are slightly damaged, a chip tot he very bottom of n/s, and i put a spider crack into the n/s while detango'ing it, doesnt bother me but its noticeable

[AW0L]

thats what i thought, but then again they are rare for mk3's now and sort after, these sellers are not stupid when it comes to things like that, and they are new... maybe they will be a xmas pressent...

[Gus!!]

Jony if awol doesnt have them i might?? Depending on what you are asking and postage i guess??

[jonyb4]

ill keep it in mind mate