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by **garethhetherington** on Mon Mar 26, 2001 11:54 am

I have tuned my 1995 Fiesta 1.6Si to 153bhp, I now have problems stopping. I fancy fitting the disks and calipers off an Escort Cosworth to my car. I have come across conflicting reports of how easy this conversion is any advice would be gratefully recieved. thanks. Gaz

by **Robz_Fester** on Tue Mar 27, 2001 2:41 am

Aren't they 90 as standard? You've got an si to above standard FRST ponies? Well done mte. Just purchased an si myself. What you got? Mail me at : hyperd99@yahoo.com. Also send some pics if you want a feature on my site! <A HREF="http://www.forduk.f2s.com" TARGET=_blank>http://www.forduk.f2s.com</A> L8r, Rob.

by **Excursion** on Tue Mar 27, 2001 3:04 am

Congrats mate! Thats quite an achievement, Im proud of you. Id be jealous except Ive just fitted the thrust SSC engines to my XR2i. Not too bad a job like, no harder than getting over 150bhp out of an engine with 26mm vavles rar fookin rarrr

by **Andrew Malcolm** on Tue Mar 27, 2001 4:37 am

You will need 16" wheels to house the Massive Cossy Disks <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/eek.gif">, however this may upset the ABS <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/confused.gif"> but you will have to ask somone who knows a bit more about it Great Achivement getting 150bhp from a 1.6 Si, <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/biggrin.gif"> but I don't think Mark Belives you thou <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/lol.gif"> I think you should Apply for a Feature in Fast Ford, becuase not many people have achived what you have <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/smile.gif"> and havving 16"s and Cossy Brakes would get you a feature for sure!

by **Excursion** on Tue Mar 27, 2001 10:01 am

Magnex cat back and pipercross filter irrelevant, give bugger all power - the real power gains lie in manifold design and catalyst design. Filters on zetecs pointless due to stupid inlet manifold design. You will be lucky to see 5bhp from exhaust and filter ona 1.6 as the standard inlet/exhaust racts are fine for the engine. The standard inlet cam is fine, its only the exhaust that really lets it down but with 26mm valves its worthless anyway. Gasflowed head on zetec crap as the standard head flows quite well, even up to the 200bhp N/A mark. as cams gasflowing/porting on a 1600 is absolute diabolical waste of money. I doubt you have got any more than 105bhp with that lot.

by **garethhetherington** on Tue Mar 27, 2001 10:53 am

If you want 153bhp from a fiesta 1.6Si here is how to do it. Full Magnex system (cat back), Pipercross cone filter, Superchip which puts 4.9% extra fuel in, 2litre Zetec throttle body and air meter, Piper BP270A cams, Ported/Gasflowed head. Thinking about larger valves next and cat rep pipe. It actually produces slightly more but it seems to struggle gripping the rolling road. It was rolling road tuned at PowerZone by Rob Waddington. At the moment I am fitting a Sunny GTIR bonnet scoope and RS Turbo Arches/Skirts.

by **garethhetherington** on Tue Mar 27, 2001 11:22 am

I detect a touch of the green eyed monster? I can promise you that the power figures are correct, my Fiesta gives 153bhp at the flywheel this has been proved at Power Zone in Padiham in Lancashire. The exhaust manifold has been shaped to match the altered ports as has the inlet manifold and spacer plate. By the way do you know of anyone who does a performance manifold for my car?

by **Andy_XR2i** on Tue Mar 27, 2001 12:52 pm

Damn man! if you can get 153 bhp out of the 1.6 zetec, brakes are gonna be a walk in the park!! <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/wink.gif"> Seriously though dude, what you do to get 153??!

by **Excursion** on Wed Mar 28, 2001 10:21 am

The VTEC's intake tract is remarkably well designed, even the airbox dosent need repalcing for a cone - gives no more power. The exhausts are fantastic too - again no need to relace except headers for big power. The Zetecs just dont flow well enough, let alone the attempted "economy" 1.6!!

by **Andy_XR2i** on Wed Mar 28, 2001 10:37 am

he has a point you know, 153 is a little on the, cough*, optimistic side. Bearing in mind a 1.6cvh efi which has a reasonably flowing head to start with (about 105bhp worth) manages about 140 at a push with a full flow job cam valves etc... The only time I've seen n/a 1.6's go past 150bhp in a road car is from a vtec, and that peaks comfortably at something like 7500 rpm. (don't honda believe in turbo's or something?? 7500 rpm!!!!) As for the brakes, checkout Stewart's site at <A HREF="http://www.xrweb.co.uk/brakes.htm" TARGET=_blank>http://www.xrweb.co.uk/brakes.htm</A> Should enlighten you a tad.

by **Excursion** on Wed Mar 28, 2001 10:53 am

That guide is sound but DONT use stainless steel bolts unless you have a death wish

by **Excursion** on Wed Mar 28, 2001 12:13 pm

Im not jealous mate cos my car is way better than yours. Ive got a 4 branch and cat replacement kit for a Fiesta zetec, make me an offer innit

by **garethhetherington** on Thu Mar 29, 2001 11:18 am

Cheers I will avoid stainless bolts. Also where do I go next with the engine? Is it time to scrap the 1.6 and if so would the 1.8 or 2.0 be the best to use, I think the gearbox would bolt straight on the 1.8? What about the 2.0? How long did it take you to put the 2.0 in yours once you had all the correct parts?

by **garethhetherington** on Fri Mar 30, 2001 11:33 am

Cheers, might start thinking about a transplant in the next couple of months. Will now doubt have many questions for you then as its good to have someone who has done the work before to refer to. Gaz

by **Excursion** on Fri Mar 30, 2001 11:49 am

It will only take a week or so to get everything in. Id go for the 2 litre if its going to remain N/A, if its going 2 b turbocharged go for the 1800

by **Quantum** on Tue Apr 03, 2001 9:03 am

Just a quick note on the brake upgrade. Seeing that the callipers are likely to be around 10 years old it is probably a good idea to think about fitting new seals to them. I found that the only place I could get these, for the Cossie 4x4, was from uncle Henry at .... £26 each side <IMG SRC="http://www.v8fiesta.co.uk/ubb/smilies/eek.gif"> A complete rip off, but when it comes to brakes you can never be too safe. Regards, Stephen

by **garethhetherington** on Tue Apr 03, 2001 11:24 am

Cheers Stephen, was thinking of reconditioning them, bit steep for the seals isnt it. Got some great spares shops near me will give them a try they seem to be able to get anything.Gaz

by **zetec69** on Thu Apr 19, 2001 5:57 am

Gareth- Are you gonna be at USC this year? If so I wanna see your 153bhp Si up the strip! Then we'll see just how much bulls*** you are feeding everyone!

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