fiestaturbo.com

[Dave G fsi]

Wow, never expected that much surface rust! What are you painting/treating it with? Apologies if I've missed it!

Yea I know, ford are useless at protecting the undersides of their cars

At least it is only surface rust and nothing more, have caught it before it has the chance to get any worse

Painting it with a special direct to rust hammerite

[Dave G fsi]

Another update

Had some time free this afternoon so went down to the garage again to do a bit more on the underside. Did some more de-rusting then painted it up, getting there now

Pics of finished area:











All comments welcome

[Excursion]

Looking good, Dave. I wonder if the standard Focus has the additional welding around the Control Blade mount?

[Dave G fsi]

Thanks Mark

And I'm not sure, possibly not? It wasn't normal welding, it was a copper colour, can't remember what its called?

How are you getting on with the fuel tank?

[Dave G fsi]

Another update

Spent the day down at the garage and got some more done underneath. Really pleased with how its all coming together now

Finished all the derusting, and got paint on all areas I wanted to. Just have to give some areas a second coat now then the chassis is all done

Will let the pics do the talking:

Rear arch derusted:



Other side:



Painted (going to do these imperial blue to finish off):



Other side:



D/S chassis area derusted:



Painted:



Rest of chassis area painted:













All comments welcome

[Dave G fsi]

Another update!

Managed to get some free time this weekend to do a bit more, getting close to the re-assembly part now

Anyway, best told with pics:

Before de-rusting and painting (got new genuine bushes pressed in first and a couple of new captive nuts welded on where I had to cut the old ones off due to the studs being seized in):





Other parts before de-rusting:



New captive nuts welded on:





All parts de-rusted ready for paint:





All painted:









All comments welcome

[Excursion]

Interesting. The non-RS models do not have that vertical reinforcement plate welded between the hub mount bolts. This is presumably to support the additional track and 18" wheels.

I had the same issue with captive bolts

[Dave G fsi]

Interesting. The non-RS models do not have that vertical reinforcement plate welded between the hub mount bolts. This is presumably to support the additional track and 18" wheels.

I had the same issue with captive bolts

Ah right, I've never seen a standard focus one but was actually wondering if that piece was RS specific when I was working on it yesterday. Thanks for the info!

I assume it will be to support the extra track as you say. You dont realise just how many extras these cars have, apparently 70% of them are non-standard focus...

I managed to get the other studs out (6 in total, managed to remove 4), but they each took about 1 hour with a blow lamp and alot of swearing! I can guarantee I will be using copper grease when I put the new ones in!

[Dave G fsi]

Loving these lighter nights, managed to get a bit more done after work this evening

Got the other suspension components that I got new laquered so they match the gloss hammerite on the other components. Very pleased with the result:

[Dave G fsi]

Another update

Managed to get a bit more done over the weekend, getting very close to re-assembly now. Will let the pics do the talking:

Cleaned up and painted the exhaust:

Before:



Cleaned up:



Painted:



Cleaned up and painted the backs of the sills:

Cleaned up:





Painted:





Did second coat of grey underneath:







Painted brake pipes:





Second coat of black in the arches (imperial blue to follow):





Fuel tank cleaned up:



Exhaust hangers cleaned up:

Before:



After:



The rest of the rear suspension components laquered and fuel filler pipe too:







All comments welcome

[Turboboy67]

Looking good Dave, you'll not want to drive it soon though

[Dave G fsi]

Looking good Dave, you'll not want to drive it soon though

Thanks mate

And tell me about it, I'm my own worst enemy....

[FRSJON]

great work as usual

[Dave G fsi]

Thanks Jon

[Dave G fsi]

Big update!

I've been full on for the past two days working on the RS to get it back into one piece ready for the summer, and also taken tomorrow off work to get more done. Absolutely shattered but really pleased with how its all coming together and looking now though. Best to let the pics do the talking:

Heat shields cleaned up (horrible, longwinded and labourius job!! )

Before:



After:



Arches masked ready for paint (feel like your being watched...?!)





Painted:











Fuel tank cleaned:



New handbrake cable:



Fitted:



New fuel filter fitted:



Fuel tank back on:



New fuel filler pipe fitted:





Heat shields fitted (two rear ones are new):











Rear calipers cleaned up and painted:

Before:



Cleaned up:



Painted:





Exhaust re-fitted:







Rear subframe re-fitted:







Rear impact bar re-fitted:



Tomorrow will be rebuilding the rear suspension

All comments welcome

[Turboboy67]

That's looking awesome Dave

[Dave G fsi]

Thanks mate

[black2]

Looking stunning - Good work.

RE the amount of rust on these cars.... I had put a deposit down on one right at the end of last year with the deal being I would complete the transaction once I had a thorough look over the underside on a ramp, which I done.... I was amazed and discussed at how bad the car was underneath, needless to say I need not buy the car and had my money refunded.

If the car was only 2-3k I may have bought it but when your spending 8-9k on your "dream" car there was no way I was willing to pay that amount for a car in that condition. From the outside the car looked immaculate, beautifully presented and the interior was very very good, but it seems even the more modern Fords are terrible at resisting the elements, it actually really pissed me off.

Yours however is stunning,

Gareth.

[Dave G fsi]

Been down at the garage again today and got most of the rear suspension re-assembled (with loads of copper grease...!!)

Pics of how she stands now













All comments welcome

[Dave G fsi]

Looking stunning - Good work.

RE the amount of rust on these cars.... I had put a deposit down on one right at the end of last year with the deal being I would complete the transaction once I had a thorough look over the underside on a ramp, which I done.... I was amazed and discussed at how bad the car was underneath, needless to say I need not buy the car and had my money refunded.

If the car was only 2-3k I may have bought it but when your spending 8-9k on your "dream" car there was no way I was willing to pay that amount for a car in that condition. From the outside the car looked immaculate, beautifully presented and the interior was very very good, but it seems even the more modern Fords are terrible at resisting the elements, it actually really pissed me off.

Yours however is stunning,

Gareth.

Thanks Gareth

And I know what you mean, ford put next to no underside protection on these cars which is rediculous seeing as they are a special limited run model with so much heritage, and 70% of the parts are RS specific too

Its very hard to find a fully rust-free one now they are at least 10 years old, maybe its best for you to look for a restored one?

[Excursion]

Looks awesome, Dave. One of those cars you can take for a service/MOT with pride

[Dave G fsi]

Looks awesome, Dave. One of those cars you can take for a service/MOT with pride

Thanks Mark, and yes, nothing like the moment you see the face of a mechanic when he gets under a restored car without expecting it

[Dave G fsi]

Update

Another full day down at the garage today. Really pleased with progress, close to completion now

Will let the pics do the talking:

Hubs fitted:



Shocks re-assembled:



Shocks fitted:





Then it was time to set the correct ride height. Now the Haynes manual says to remove the springs then use a spacer 130mm long to set the correct height, but I know from previous work that it is then really difficult to re-fit the spring, so I did it in a more practical way. Leave the spring in place, jack up under the lower arm, then fill the boot!



Yes, that is two wheels, a very heavy generator and a massive rock

All torqued up and sitting nicely:



Discs fitted:





Brake hoses replaced:



Fitted and calipers re-assembled:



Calipers fitted:









All done



All comments welcome

[Excursion]

Awesome Dave. By setting the ride height I assume that's just getting the suspension compressed to normal ride height so you can tighten the nuts/bolt, so they aren't excessively twisted?

[Dave G fsi]

Thanks Mark. And yes, although I have found out this morning via RSOC that the RS has a specific ride height (the haynes manual only covers standard focus), and should be 102mm

Back to the garage it is.......

[Excursion]

Where do you measure to and from mate? I will need to do mine at some point.

[Dave G fsi]

Where do you measure to and from mate? I will need to do mine at some point.

See my update below matey

[Dave G fsi]

Another update!

So last night I found out that the ride height is different for the RS vs. the standard hatchback. The Haynes manual doesnt cover the RS but thankfully someone had access to a ford workshop manual on RSOC, and it should actually be 102mm. This therefore meant going down to the garage again this morning and loosening off all the bolts again, put even more weight in the boot, then go down to 102mm (as is required for the RS). I then re-connected the brakes, ABS and handbrake cable whilst down there

Pics:

The weight:



The measurements:





Brakes connected up:





ABS and handbrake cable re-fitted:











Done:



All comments welcome

[JasperJ]

Top work amigo well done, as usual plenty of hard graft from you there m8.

NOW STOP POLISHING AND PAINTING THE GODDAM THING AND DRIVE IT FFS.

or will it turn into another garage ornament to pull out in 20 years when it be worth a few bob.

Anyhow let me know when you want a go in a propa 1 thats used every day and i ain't cleaning it for that malarky

[Excursion]

That is absolutely lovely

[Dave G fsi]

Top work amigo well done, as usual plenty of hard graft from you there m8.

NOW STOP POLISHING AND PAINTING THE GODDAM THING AND DRIVE IT FFS.

or will it turn into another garage ornament to pull out in 20 years when it be worth a few bob.

Anyhow let me know when you want a go in a propa 1 thats used every day and i ain't cleaning it for that malarky

Haha, cheers mate

And dont worry, will be back on the road mid May Will have to do a photoshoot over the summer bud

[Dave G fsi]

That is absolutely lovely

Thanks Mark

[Dave G fsi]

Almost there now! Got some more re-assembly done yesterday, will let the pics do the talking:

Bumper 'bracket' cleaned up and re-fitted:



Arch liners cleaned up:

One done:





Both clean, one laquered:



Both Laquered:



Bumper cleaned ready to re-fit:



The back end before re-fitting:



Handbrake cable and springs re-fitted:





Arches before re-fitting liners:





Liners fitted:





Almost a car again!



All comments welcome

[Excursion]

Stunning! What paint did you use on the arch liners?

[Dave G fsi]

Stunning! What paint did you use on the arch liners?

Thanks Mark

I was going to buy some new arch liners as originals go grey with time, but at £75 I decided otherwise....

So after some testing, I found that laquer works fine on plastic, and brings it up like new