fiestaturbo.com

[D9LSY]

Hi guys, i dont often post on this site, but do log on most days

ive been doing some work to my car over the winter months, and thought Id share some pics of the progress

I put the car into the garage late October to start working on it to improve the car , and repair some of the shell that was needing some welding to the inner sills , boot floor and some lightening of the shell

heres some pics, started with Fiesta Mk3.5 shell with ST170 engine, quaife gearbox , twin 45 delortos, LEDA suspension , etc.................





started stripping the car down and got carried away a little





started cutting out the rot on the car, inner sill and boot floor was the worst part

[D9LSY]

carried on reapiring the shell, and done some lightening of the shell too, but not going too mad







reapired the shell





I did some more welding to the car , but these where the main parts, after weling was done , prepeed the paintwork under the bonnet and inside, and got the sealer fitted to the repirs, and painted Polaris Grey

[EUFez]

Ford RS Accessory bumper... AthankU.

Looking good mate, love those bumpers. Work looks great, keep it up!

[D9LSY]

started putting the car back together











I had to overhaul the gearbox after putting the diff through the casing, output shaft bearing totally failed and destroyed the box, had to replace the quaife output shaft and pinion gear on the final drive

[EUFez]

In addition to my comment...

WOW! So much neater and looks fantastic. Great work mate...

[D9LSY]

I have a new engine for the car year, it will be ST170 engine with high comp pistons, steel rods, hardened and balanced crank, stage 3 st 170 head with VVT deleted to run black top Newman PH3 cams and vernier pulleys











done a lot of powder coating to the supsension parts , and fitted new uprated springs to the LEDA suspension, 350Ib springs on teh front and 450 Ib springs on teh back

[D9LSY]

bottom end and gearbox now fitted





dummy fitted the old ST170 head to get the radiator position, the new engine wont have the ST170 cam cover fitted so wont look like this





fitting new wheels OX racing 15 inch alloys and Compomotive MOs for this year





also fitting RST bonnet, and bumpers for this year to make the car look a little different, and car will be painted frozen white on the outside with new graphix design, hopefully car will be going for paint next week, when the roof vent is fitted to the shell, and aero catches to the bonnet

[Turboboy67]

Good work mate,

That suspension is awesome, over £2.5k when new , hopefully those spring will firm up the ride a bit,

are you having it corner weighted ?, probably worth doing.

New colours are going to look rather nice

[RS rob]

big fan of this!

bloody love polaris grey!

[FRSJON]

lovely work,really want to see the graphics...tempted on ours

[jonyb4]

looking great mate, cant say how many times ive seen this in Fast ford and performance ford mags

[jayrs]

[muz]

Did the gearbox give any signs it was about to let go? Or did the bearing just suddenly fail? Wouldn't like the bill for a new quaife input shaft if mine s**t itself!

[jayrs]

mainshaft bearings on these boxes is a common weak spot muz, had mine go on my rs years back, had no sign it was going, parked up, went to drive half hour later, sounds like a milk float on speed! then it started locking up in reverse, spripped it, and mainshaft chewed like his one, and i didnt find all the roler bearings parts but a lot of swarf on the magnet

[muz]

Yeah, I was told it's due to the gearbox casing itself twisting under big power kills the bearings? Mines just been rebuilt with IB5 bearings so hope it holds for now.

[jayrs]

never heard its due to case twisting, cant see how it would tbh.
the force that bearing is under has got to be intense, and its not a very big bearing really when you look at it, but if the shaft starts to move due to wear, its quickly going to go down hill, thats for sure, should of seen the end of my main shaft, jesus!

[D9LSY]

its very difficult to hear if there is anything wrong with the box, because of the whine from the quaife gearset, but it was a bit " chatery" on tickover and i thought the thrust bearing maybe needed changed

The bearing is a DU bearing and has no inner race, and the rollers run direct on the main shaft, and its quite small at 27.5 mm. I was very lucky to find another final drive quaife gearset second hand , and in Scotland too , and bought new bearings from Burton Power, and ill do a full strip down and inspect each winter now to protect the gearset, and the cars reliabilty

Thanks everyone who has commented on teh car , glad your liking it, ill update the thread as i go along

[RS rob]

Yeah, I was told it's due to the gearbox casing itself twisting under big power kills the bearings? Mines just been rebuilt with IB5 bearings so hope it holds for now.

that's correct about the case flex, been looking into it myself,

I take it your still using the bc box?
would be worth upgrading to an ib5
better gear shifts aswell

[muz]

Yeah, I was told it's due to the gearbox casing itself twisting under big power kills the bearings? Mines just been rebuilt with IB5 bearings so hope it holds for now.

that's correct about the case flex, been looking into it myself,

I take it your still using the bc box?
would be worth upgrading to an ib5
better gear shifts aswell

yeah I'm still using a BC, Rob. I'm also running a Quaife straight cut gearset though with a B&M shifter. The gear change is superb TBF. It's had the larger IB5 bearings fitted which should help.

[Excursion]

Case flex is a big contributing factor to bearing failiure in BC boxes, I bought this to light. Get an iB5 casing, Dalsy. I'm not saying the iB5 is perfect or good for track use/more power - but it's a world away from what you have at the moment. Ford nailed it by the time the Fiesta ST came round (3rd revision of the iB5) - it's actually the main shaft that snaps in those rather than the bearing letting go, and the gearset is the same aside from the Synchros.

[D9LSY]

Yes the IB5 is a much better box, but for track days and very quick gearchanges the syncros dont like it and they regularly 5h!t themselves, done it twice with previous IB5 box in teh car

originally i was going to send the knackered BC box down to G.E.A.R.S and have them fit the quaife gearset into the IB5 box i have spare, they where also going to repair the quaife output shaft, but managed to get a brand new spare 4.5:1 final drive , so fitted that all to the BC box instead

I do prefer the gearchange of the IB5 box as its spring loaded and its soo much smoother, but Im using a B&M shifter too, so the gaerchange is also good with the BC box

I dont usually use the car for 1/4 mile or anything like taht, just the odd time if im wanting a day out at Crail , so i wont be doing anything mental with launches or such like, the car is for track days and wont have the same stresses on teh box as some high powered turbo charged cars with masses of torque, and with the box overhauled with new bearings , it hopefully will prove reliable with yearly maintenance and decent oil in it

[D9LSY]

Heres some footage from last years Durham and Debyshire RSOC day @ Croft, this is with the old engine , and the Nitros fitted, this has now been removed and sold on.

http://www.youtube.com/watch?v=wnLZrCWsrV8

[Excursion]

Yes the IB5 is a much better box, but for track days and very quick gearchanges the syncros dont like it and they regularly 5h!t themselves, done it twice with previous IB5 box in teh car

originally i was going to send the knackered BC box down to G.E.A.R.S and have them fit the quaife gearset into the IB5 box i have spare, they where also going to repair the quaife output shaft, but managed to get a brand new spare 4.5:1 final drive , so fitted that all to the BC box instead

That's strange because it should be the opposite - the BC synchros are useless and don't like quick changes (in my experience they crunch when you push them too hard). The iB5 synchros were improved to cure that and suit the short shift linkage in the Puma and Zetec-S...

[D9LSY]

Trust me, its the other way around, the IB5 box doent like very quick gearchanges , it knackers the syncros

[Wittmann]

This is getting interesting...

[Stuartcarvell]

Hello,
Sorry to hijack, but do you have a paint code for your bright blue colour on your cam cover?
Thanks
Stuart

[DALSY]

thought id do a wee minute update

see yous guys on track next year, almost finished now

[Rhinopower]

Looks good, what sort of money are the cams?

[Turboboy67]

Aaaaaaaaaaah, love it mate

Did you get my PM about the rear springs the other week ?

Have you had it RR'd yet ?

[FRSJON]

coming along nicely

[DALSY]

Shuan dont worry about the springs, ive sorted it out mate, thats them all fitted and set up now

Car was rolling roaded, but had soem issues on the day which didnt allow it to get mapped properly, but did still see 178 bhp @ the wheels at 7000 rpm, its gona rev to 7800 rpm when the ecu gets sent down to webcon, so ill see what it will do after thats ammended

thats the car all running now, and ive done an event at Knockhill and Crail raceway, and its going well,








now booked on for Angelesy RSOC show on track, so lookin forward to driving round there in anger for the first time

[Turboboy67]

That looks so much fun mate,

I'm having thoughts about doing another track Fiesta

178 at the wheels isn't shy either

Are you at Croft ?

If so I'll bring my helmet

[Ratspeed]

That looks great, awesome build too!

[jonyb4]

like shaun said it looks liek such a good enjoyable toy, i can only dream mate, it might even be more exciting than the RS on track?

such a good line up of cars you got, like a paragon of ford ownership

hats off to you

[DALSY]

cheers guys , yes she is a proper laugh, going really well, so very pleased with it

Shaun , yep im booked on for Croft on the Sinday mate, theres a few cars from the group going down, bring your helmet, and we will see about getting you in the car