fiestaturbo.com

[PUREtom]

Right, this is to let you all know the problems I encountered fitting the ZS rear beam, focus brake set up and how i solved these problems.

ZS rear beam :- No real problems involved with fitting this. Just a direct replacement for the original. 4 screws each side, wheel off, handbrake cable off all clips.
The only problem I found with this was if you have RS2000 side skirts like me! I had to break the last rivet so that i could lower the beam down. As the skirts fit directly below the attachment of the beam to the body. Not a problem, just re-rivet it after.

Focus rear brake set up :- This is where the problems start. But they do fit perfectly to the beam!

Brake hose:- the existing brake hose of the Si is too short to reach the focus calipers. You can see this in this picture. Note the black hose is the new one, explained later:

okay this end


This is too short now:


So...i had to pop down to the local motor shop, they directed us to a helpful chap who has loads in Basildon. The fiesta Si hoses are 13 inchs, we need about 16 inches. So went to have a look in Basildon, and they had some 17 inch, Mk 3 escort 1980-83 front brake hoses that fit pretty much perfectly, as you can see from the pics above and below (black hose)

Please note that we moved the brake hose the other side of the strut after we tried the wheel!!


Hand brake cable :- after looking on FT.com for a while, XR3i handbrake cable was the cable that everyone said should work and that fit. But this wasn't the case.
We had to take the yoke off the fiesta handbrake and use that, as the yoke would not fit under the floor pan.
The outer cable is too short, but shortcuts can be taken, this is ok.
The inside cable was too long, and this was a problem. As you can see from the pic below, the cable is too long!



SO my dad had to make up some sought of spacers on the lathe.

This is what he came up with:



Now this fits here:

This is what it was like before:


After all these problems, the handbrake cable was cable tied into position (with shortcuts taken). The cable needed to be adjusted so that it was an MOT pass.

Now the brakes were bled, and the wheels were put back on. Notice the wheels stick out with the zetec s rear beam.
Here are pics of the final result:



Tom

[PUREtom]

Moderators- if you feel this is worthy of being a guide, then please re-title and put in guide section.

Thank you

Tom

[Faith]

Looking Good Fella, Notice the difference wen ur driving?? i used to have a zetec s so i kinda know how it should feel altho it is a diff car.

All that extra stopping power you now got!! bet it makes u feel safer! Can really put ur foot down now...lol

You seem like you know your stuff, think i mite be coming up to urs wen i get round to putting a zetec s beam on mine! $$$$$$$!!!

Cheers

Adi

[PUREtom]

beam is piece of piss, its the focus setup thats a chore!

I only went down the road. But as soon as I got off the drive and the rear went off the kerb, i could feel the stiffness! but braking, is a little better, just need to get the fronts then ready for 'the lump'!

[EvilFranky]

Excellent guide mate.

Should defo be made a sticky

[SPo0n]

has the handling improved with the new rear beam?

[MAD_Adamski]

looks good tom well done i painted my beam and calipers but still a good job unpainted, i think you'll find the wheels stick out around 20mm+ each side and many people will have to be careful how much they have lowered their cars as this conversion makes arch rubbing a big prob......

i personally used a mk5 handbrake lever, and a ford puma racing cables and these fit spot on with no spacer so worth people thinking bout...

but nice guide should help many others

[Cellze]

If this does become a Guide it looks like your dad will making a lot more of those spacers

What setup are you having up the front?

Great guide.

[Jays_si]

arent your wheels sticking out past the arches there mate?

[MAD_Adamski]

his wheels are yes which is good for handleing there is a big BUT,

some MOT places can but v funny bout wheels sticking out past the arch just gotta have a mate in the right place

[pollocks]

could get wheels with a higher et say if he had 35 to start with get 55 to sort of offset the new gained width something i would think about tbh as u can always get your wheels with one offset front n diff rear D:

[andyhardy]

Could the RS2000 rear disc setup be used on a Zetec-S rear beam?

[fiesta_fras]

if ur only in basildon u should come see us in Grays,

it is a fiesta house, three of us live here and own:-

1. Turbo Diesel Fiesta
2. Soon to be zetec turboed fiesta (mine)
3. 1.6s being scrapped soon because bits going into...
4. brand new engined FRST build
5. XR2i 1800 16v runabout
6. One soon to be started Rs1800i

and Andys girlfriend has a mk4 one, thats makes 7

thats gotta be a record for fiestas registered at one house, technically number 7 is not registered. but she stays over loads

[rich_frst]

wicked guide tom!!! you finally got a beam then!! where did you get it in the end!?? did you try nevedon?!

nice to know the puma handbrake cable works well with it-cheers ad!!!!! i had a xr3i cable lined up for mine, nevermind

[rich_frst]

i personally used a mk5 handbrake lever, and a ford puma racing cables and these fit spot on with no spacer so worth people thinking bout...

how did the fitting of the hand brake lever go mate!??!?! any trouble?!?!? i might try a focus one!!!!

[PUREtom]

has the handling improved with the new rear beam?

Defo mate, works a treat, sticks to roundabouts!

[PUREtom]

arent your wheels sticking out past the arches there mate?

One side is a bit more than the other. Maybe cuz all the bits are from breakers and bin in crashes!

[PUREtom]

mine is lowered on 35mm Gmax (mk3) on mk3.5 struts. This makes it sit a bit higher. I don't get any rubbing with it, but if it was lowered more then it would def rub more.

wicked guide tom!!! you finally got a beam then!! where did you get it in the end!?? did you try nevedon?!

nice to know the puma handbrake cable works well with it-cheers ad!!!!! i had a xr3i cable lined up for mine, nevermind

I got it from that place in rainham called FLP or something. Nevendon only had a puma one when i rang them

[andyhardy]

Anyone know if the RS2000 rear disc setup will work with the Zetec-S/Puma rear beam setup?

Cheers,

Andy

[rich_frst]

Anyone know if the RS2000 rear disc setup will work with the Zetec-S/Puma rear beam setup?

Cheers,

Andy

no mate it wont the stub axel pattern is different...

[Jays_si]

arent your wheels sticking out past the arches there mate?

One side is a bit more than the other. Maybe cuz all the bits are from breakers and bin in crashes!

say no more

[DeanoW]

which brake master cylinder will you be using once the fronts are done?

[PUREtom]

arent your wheels sticking out past the arches there mate?

One side is a bit more than the other. Maybe cuz all the bits are from breakers and bin in crashes!

say no more

Nope, its all ok really, just an optical illusion!

[PUREtom]

which brake master cylinder will you be using once the fronts are done?

WHen i get cosworth fronts. Don't think i will need a dif one.

[PaulC]

arent your wheels sticking out past the arches there mate?

One side is a bit more than the other. Maybe cuz all the bits are from breakers and bin in crashes!

If one side is more out than the other, the beam might not be lined it squarley - it is possible for it to be slightly too far forward/backwards or too one side.

Good guide tho

[AdamB]

the passenger side will generally be a bit wider... this is done because of the fuel filler pipe,

mine is exactly the same

[MAD_Adamski]

the passenger side will generally be a bit wider... this is done because of the fuel filler pipe,

mine is exactly the same

as was said my beam also sticks out more on the 1 side this also may be to do with the camber of the roads

[MFkev]

Excellent guide, on my to do list.

if [ERRR] only in basildon u should come see us in Grays,

it is a fiesta house, three of us live here and own:-

1. Turbo Diesel Fiesta
2. Soon to be zetec turboed fiesta (mine)
3. 1.6s being scrapped soon because bits going into...
4. brand new engined FRST build
5. XR2i 1800 16v runabout
6. One soon to be started Rs1800i

and Andys girlfriend has a mk4 one, thats makes 7

thats gotta be a record for fiestas registered at one house, technically number 7 is not registered. but she stays over loads

Cool someone else from the dive that is Grays!!

[PaulC]

the passenger side will generally be a bit wider... this is done because of the fuel filler pipe,

mine is exactly the same

as was said my beam also sticks out more on the 1 side this also may be to do with the camber of the roads

The wheels/beam on the red Type-R doesnt stick out of one side

Surely it would bugger the tracking up if the back wheel sticks out further than the fron passenger one

[mmogenius]

Hi,

When me and adrian first fitted the rear beam we spent some time aligning the rear beam correctly as the position that you put it in streight away is not always it's final resting position.

With some gentle aligning this can be solved and as paulc mentioned how could you ever expect a car to be tracked and even drive correctly if the rear beam is offset to one side?

[PUREtom]

Hi,

When me and adrian first fitted the rear beam we spent some time aligning the rear beam correctly as the position that you put it in streight away is not always it's final resting position.

With some gentle aligning this can be solved and as paulc mentioned how could you ever expect a car to be tracked and even drive correctly if the rear beam is offset to one side?

But it doesn't seem to effect the tracking. Mite loosen the bolts though on the chasis and see if i'll be able to pull it over a little.

[wyll_2k]

If its OK when the time comes Tom, can I ask for yr help with a rear conversion? I'll soon be getting me fronts done having atlast found a nice set of cossie calipers

[Adam_W]

with the rear beam conversion, does it have to be a ZS rear beam or can it be any mk4/5 one? and also can anyone clarify how much it widens the track by please?
cheers
adam

[PUREtom]

The track is only really made wider by the Focus calipers by about 20mm, the beam is only about 10mm more i think.

The beam can be any mk 4 or mk 5 but best to use ZS as they are stronger and hold the road better.

[beanyfrst]

When i change my beam over to a Z's one can i use cossie 4x4 rear calipers and on what discs