fiestaturbo.com

[Smo]

Some of you may have seen my poor little Popular Plus is pretty much on its last legs, so a suitable replacement was required to get my track day fix!

My main concern was rust, as that is basically my biggest issue with the old one, but initially I also wanted it to be pre 92 so that I could continue to run it without a cat and also being a MK3, I could use my existing suspension. Having missed out on a few early MK3s, and deciding against one that I actually viewed twice(!) because it had too much else wrong with it, I ended up settling for a 1995 1.1 Azura. I convinced myself the cat issue isn't a major problem, I can just fit a sports cat at some point, and with regards to the suspension I'll just swap the hub carriers, lower arms and turbo drive shafts over in order to use my Koni setup. Everything else should be pretty simple.

There's not a lot else to say at the min, and not a lot will be happening for about two weeks, but when it does there will be some proper updates.

Just a couple of photos for now:







Sadly, it's had a bit of a car park incident and the driver's side wing and a bit of the door are a little untidy:



... but at the end of the day, it's for track, and I can fix them at a later date if it really starts to bug me. The main thing with this is that it's solid absolutely everywhere

Just a shame it's red... The white ones will always be faster!

[hb69]

Haha, yep, white ones are faster

[Excursion]

I'll run a cat on mine, it doesn't really make any difference if you stick to a decent 200 cell

[Smo]

Would a 100 cell offer any advantage over a 200? 200 seem to be more commonly available and for better money.

[Christina]

Looks nice! Can't wait to see what you do with her

[knuckles]

What are you doing down potters bar ?
round the back of mini spares

[Smo]

It's where I bought it from

[Excursion]

Would a 100 cell offer any advantage over a 200? 200 seem to be more commonly available and for better money.

The performance difference is negligible but the 100 cell can give MOT issues and the cheaper ones don't last very long before becoming completely marginal.

Just seen the car now images aren't blocked by work proxy. I was looking for a Mk3.5 last week and thought you may have bought http://www.ebay.co.uk/itm/1995-FORD-FIE ... true&rt=nc

Yours looks good too!

[Smo]

I was watching that, as well as another in Norwich (which was sold for £500 on Gumtree and then immediately offered for £600 on eBay!), but the distance was a bit further than I was willing to travel if they turned out to not be what they were described as!

Mine's not perfect, but for what I saved in travelling and price, I can correct its issues as and when I feel.

I do wonder how long it'll be before the lack of rear wiper bothers me, though

And cheers, I shall take a look at the 200 cell options

[Christina]

If no rear wiper is annoying, try having one that doesn't work!

[russ-RST]

Glad to see you found a clean one don't go spraying it green now tho look forward to seeing this unravel ! If you need a hand with anything give me a shout buddy I'm about to lend a hand also as per the rear wiper il have a look at the weekend I should still have mine somewhere from when I took it off
Russ

[Smo]

If no rear wiper is annoying, try having one that doesn't work!

Oh, I've had years off that!

Cheers, Russ Probably not too bothered about the wiper in the long term, because I don't think I can be bothered messing about with the wiring!

I'll be swapping the engine in a couple of weeks time. Everything's planned, and I'll be giving myself about 12 hours to do it in. We'll see how it goes!

[hb69]

If no rear wiper is annoying, try having one that doesn't work!

Oh, I've had years of that!

Cheers, Russ Probably not too bothered about the wiper in the long term, because I don't think I can be bothered messing about with the wiring!

I'll be swapping the engine in a couple of weeks time. Everything's planned, and I'll be giving myself about 12 hours to do it in. We'll see how it goes!

[Smo]

Total typo.

Go remove some rust from your car.

[Smo]

So, this is the engine going in:



... completely standard 2.0.


Tony Law 4-2-1 will be coming over too:




Not sure about the cage at the min, bit undecided:






Zetec S rear beam will definitely be going over from the white one:




Also the Koni adjustables - they're looking a bit ropey now, though, so I may replace them soon. Poor photo:




Lastly, I have another gearbox, a CTS stage 2 - same longish ratios as my current Escort GTi box, but with the addition of a Quaife ATB differential. This is something I've wanted for ages (not the box particularly, but a decent diff), so I'm looking forward to seeing what it will do. The unfortunate thing is I'll be going back to a front start BC style box, just with an iB5 gear set. Long term, I'll swap the diff out into another rear starter iB5 casing as I've been much happier with this setup. No photo of this either, but it just looks like your average MK4 Escort gearbox!

Once it's on the road, I shall probably do the same as Henry (hb69) and polybush the lower arms using Powerflex's black series bushes - they've looked quite promising so far on Henry's car, so again, looking forward to seeing how they go on track.

[dontpannic]

Looking forward to seeing how it progresses!

[Smo]

So, bought these back in December...

Jenvey 45mm throttle bodies:



Firstly, in this state they're a major bodge. Poor throttle linkage, white silicon sealant everywhere, standard 2.0 Focus injectors (which actually flow less than 2.0 silver top side feds!), and to top it off, a standard Focus fuel rail - which means the injectors were actually sitting wonky in the bodies! The spacing is completely wrong.


So with all the dodgy stuff removed, I trial fitted them:




Space will be fine, should be enough for a decent foam filter; any longer and I'd have had issues. I'd ideally like to run longer trumpets, but I can do something with the back panel if and when the time comes.




So next up, I wanted a proper fuel rail. The usual one is the two piece Jenvey item which you join with a cut-to-length joiner, however Jenvey make a one piece item properly spaced for the Zetec E setup...

... such as this one on my desk at work:




I also wanted injectors that would happily flow enough for my current expected power (roughly 170bhp) and any potential increase in the future, so I went with VAG 1.8T items from an AUM lump:



AUM engines produce around 150bhp as standard, and easily cope with 220 to 230bhp on standard injectors, and more with an increase in fuel pressure. Basically, they're fine for what I want

The injectors are quite short, though, so some custom spacers were required...

... which I had made for me:




The next problem was brake servo. The manifold had no vacuum port, so I had one fabricated and welded on:




A part complete linkage was obtained:




And with the help of a chap at work, fabricated an additional bracket to use the standard throttle cable:





As you can see, it doesn't allow the cable to sit in the quadrant comfortably, so I will rethink this. However it does allow perfect throttle opening - when the pedal is at the stop, the butterflies are 100% open, without any part under stress. When I come round to fitting them properly, I'll probably use a universal cable to solve the quadrant situation, we'll see.

I've had them running briefly using the standard ECU to make sure they run and get a decent idle - that I'm happy with. What I'm not happy with is the brake vacuum. They're producing a vacuum, but not enough to operate the non return valve to the servo... Something to look at later down the line. I have Megasquirt (which works fine and I had mapped on my old 1.8 to some degree), but I'll probably replace it with something like Emerald when I come round to fitting the bodies properly later in the year. At the min, I'm going to get everything running as it is with the standard inlet and management to make sure all is good with the car, and do a few track days, then come back to these

[Excursion]

You need a common take off for vacuum, mate.

[russ-RST]

This was the update I as waiting for. ! I'm so looking forward to hearing this
What are you doing with the old gearbox (s) then I could do with one that doesn't leak oil everywhere
As mark has already said you need a vacuum that comes from all 4 I take runners , if your stuck for ideas look at bike throttle bodie installs , also my mate has a 306 on bike tb's you could nose at that if you like? It's not pretty tho!

Russ

[Smo]

Hmm, there seems to be mixed views on that, most saying that one is enough?

Some say a one way valve is required for each if you go that way, however I'll still have the same issue with not producing enough vacuum to operate them?

So do I ideally need a reservoir?

Or a one way valve that requires less vacuum to open?

Russ, my gearbox will be no good to you as it's a rear starter and would foul your rear crankcase breather. Plus it's knackered

[Excursion]

Hmm, there seems to be mixed views on that, most saying that one is enough?

Some say a one way valve is required for each if you go that way, however I'll still have the same issue with not producing enough vacuum to operate them?

So do I ideally need a reservoir?

Or a one way valve that requires less vacuum to open?

Russ, my gearbox will be no good to you as it's a rear starter and would foul your rear crankcase breather. Plus it's knackered

One is most definitely not enough; if you think about it you've at worst got a quarter of the available vacuum at one time. In reality and based on firing order and cam duration/timing it is more like half.

Why would you need a one way valve for each? Doesn't make any sense. You should have a take off on each port and a common line to the servo which is where the one way valve belongs - the ideal would be a vacuum rail with 15mm bore to act as a damper. The vacuum potential of your engine hasn't changed hence neither should the specification of the one way valve.

One of my other cars has ITB's fitted from the factory and is plumbed as I describe.

[russ-RST]

Iv only known people to join then myself, a one way valve with lesser pressure sounds a good alternative.
Ah fair do's buddy , well I'm on the look out for a rear starter ib5 for the zetec also what's on the 1.1? Engine ?
Russ

[Smo]

That's fair enough, Mark, I'll go that route!

There is so much conflicting information about this out there!

Russ, you can pick up GTi boxes so cheap, just keep an eye out. You'll need a custom bracket for one half of the front mount as it's different where the starter motor isn't there. I modified the other half as one of the holes was in a different place if I remember rightly. The rear mounts the same. You need a rear starter from something like a late Zetec Escort as the mounting holes are different, and probably some of the wiring too. You'll also need to modify the 1.8 block to allow the starter room to fit. Lastly, you'll need the gearbox register from a rear starter Escort too.

Nothing from the 1.1 is available for the time being, sorry!

[hb69]

If I got coilovers would you be interested in my current suspension?

[Rhinopower]

I had 1 vacuum on my throttle bodies and it worked perfect.

[Smo]

I had 1 vacuum on my throttle bodies and it worked perfect.

This is what a lot are saying. What one way valve did you use? The standard one?

[Minstral]

posting to simply keep updated with this in my posts

[Gus!!]

Looks nice and tidy, a mk3.5 would have a slightly stiffer chassis anyways??

[Smo]

Indeed it does!

I remember the first time I went out in a Fiesta Si and being amazed how tight everything felt. Driving this new one of mine home wasn't far from that. I'm really looking forward to seeing how different the car will be from the Popular Plus (and its floppy floor) with the suspension and power. That said, the cage definitely made things better in the previous car!

[hb69]

Over the weekend, the Fiesta underwent some major surgery. As I had a camera with me, ill update this thread with photos of the events that took place

The setup for the work was pretty substantial, seeing as we were used to lying on the floor in the rain this was quite amazing

The new, the old, and the middle aged



As it was a two day event, myself and smo started by doing the jobs that needed doing at the back of the car, these were fuel pump and rear beam/suspension

Tank coming off the white one



Where it used to reside



Photo through the inspection hole, just because I could



Tank off the red one



Having a gander at the pump



New tank/pump in the red one and fuel line fitted



Then we moved onto the rear beams

Standard 1.1 beam



Removed it



Then the polybushed zs beam and konis off the white one, disconnected the brakes first



Undid the top shock bolts



And on the floor



On the red one, fitting handbrake cable



Steels on, and on the floor



That concluded the antics from the first day.

Next day was the majority of the work due to take place. We started at about 8am

Me and Steve started with the front suspension on the white one. It all needed to be moved across, carriers, lower arms, arb, hubs, track rod ends, and shocks





While Nick and Eddy started dismantling the red one



Eddy had a split glove situation



With the suspension removed, the work started on removing the 1.1



Eddy gave it mouth to mouth



5 minutes later it was sitting on a table on wheels



Table modelled by Burman here



Miniature Simon was happy with this



Burman had conquered it



And Eddy took it away



Where it sat in the naughty corner, and had some time to think about how slow it was



We had a look at the empty engine bay



It was red and empty



Then we started on removing the zetec from the white one



This made Steve happy



And me



Out it came, onto the table with wheels again





Lowered down, ready to have the new clutch and lsd gearbox fitted





Lunchtime!



Then into its new home





Some jiggling to get the cradle lined up



Started to refit the front suspension

Steve with his favourite tool



Me and Toby did the other side



Empty engine bay on the white one



But a garden hose was needed from it



Mark wanted to be in the engine bay, so got in



Then we put the bonnet down



Some sort of leak occurred on the red one



Engine in its new home



Bleeding the brakes



The man in the cabin



Pointing at something?



A commotion



On to starting it for the first time, there was an earth that hadn't been connected so the battery light stayed on



Connected the earth. Started up fine.

Happy days



Back on all its wheels







Old engine in the back of the white one





Slammed



Something in the bin?



White one ready to roll out into the open



With Burman at the helm



Fuel for the journey home





Tired



Time to leave



The car left and im reliably informed it successfully completed its maiden journey. Top banana.

[bakewell001]

Nice write up, Butler.

I'm looking forward to our "beer and burger" reward for such an eventful day!

[Smo]

Cheers, Henry, an update and a half!

Thanks to everyone that helped; I only had the ramps for the weekend and was a little stressed out at the thought of not being off the ramps by the end of Sunday!

Pretty boring video, but its first drive:

[dontpannic]

and it's first start:

[Excursion]

Nice quick turnaround there. The red car sure is a contrast to the old white one!

[dontpannic]

Nice quick turnaround there. The red car sure is a contrast to the old white one!

We don't f**k about Mark!