fiestaturbo.com

[Excursion]

Well, I've been through phases of wanting to sell her and wanting to keep her. I figure it's not worth anything other than to me, and as it's a fine base to start with I will be undertaking one last 'Fiesta Project'.

The rationale for this project is as follows; I've learnt quite a lot since the last Zetec turbo so the S4 project aside this will be an ideal chance to do something different. I also feel that the car could do with bringing 'up-to-date' as I enjoy learning about new technologies and I have plenty in store for the car.

As with previous incarnations I'm not looking to create the loudest, most powerful and ostentatious car. It's going to be firmly driver orientated and tastefully done. I've reconsidered my original engine spec which would have seen power up towards 400BHP. I want the car to be quick, and that doesn't always equal big BHP so revisions were made, however the engine will be built to allow for safe, future increases up to that amount.

The chassis will be as strong as possible without doing anything radical such as a weld in roll cage, seam welding is a possibility. I'll be making few braces for the running gear and chassis, particularly at the front end. However, there will be a firm luxury element. No knocks, bangs or harshness. Anybody can create a rock hard & unforgiving car, but it takes more thought to create one equally as good that is still comfortable. I like to use the car in 'everyday' cirumstances.

Enough of the talk, here are some quick (read poor) preliminary photo's of the components I have amassed to date. There are lots more but I will post when I fully decide what direction I take and Uni is finished.


SportKA PAS rack. Matched to my ST170/Focus RS PAS pump which has unique valving for sports applications. The Sport KA rack will enable me to run 20mm extra front track and provide a nicer feel on the road.


Believe it or not this is from a '53 plate car. Lots of farm tracks around here, it'll clean up fine.


Pedal box assembly from SportKA. I'm performing a hydraulic clutch conversion so that I can run a HD clutch without encroaching on pedal feel. Modifications to bulkhead and steering column required.


Master cylinder and brake booster from aforementiond KA. Temporary measure until a VAG setup is sourced.


SportKA front hubs, +20mm lower arms (cast for strength). Also hub carriers with revised gearbox mount, ideal for my gearbox conversion. The S brace is stronger and lighter than the mk3 version.

Hubs have integral ABS sensors, needed as I'm wiring in 4 wheel electronic ABS.


Puma VCT gearbox mounts, may be of some use yet. Not sure at this point.


The ST170 wiring loom, reason explained below:


The heart of any modern Ford electronics system, the General Electronics Module (GEM). I'm cutting this system from the ST170 loom to gain radio frequency locking, control of double locks and a security system. The GEM is integrated with many functions of the car including lighting and wipers. I will be utilising its functionality to the maximum to provide functions such as automatic wipe when wash, rear wipe in reverse, interior light delay etc.


The front brakes, Focus RS 330mm with 4 piston alu calipers. 16" Superleggeras to cut down unsprung weight. Billet hubs are something I'm looking in to. Front driveshafts are going to be equal length to cut down on torque steer.



The rear brakes. ST170 front 300mm discs and Brembo 2 piston calipers. Seperate handbrake caliper. A lot of people claim large rear brakes are overkill, this is horse, the rear brakes must be relavtive in size to the fronts to provide an even spread of torque across the system. A well balanced system equates to shorter stopping distances.

Porsche are a company that takes braking very seriously, look at their top steel systems and the rear calipers and discs are the same size enabling them to have powerful yet controlled brakes. An example of this is on track days,RS4's with Mov'it front 380 6's cant touch GT3's for braking unless the rears are done to compliment.



Focus, Mondeo and Golf IV A/C system's. Parts of each will be utilised to improve on the low capacity Mk5 Fiesta system. Wiring will be custom and I will be retaining the Mk3 dashboard.


Mk5 clocks with rev counter...in black (Thanks to Project for these (;)) )


GRS EVO3 I/C and rear strut brace. IC may be changed when the front of the car has been re-worked (tubular front crossmember to give clearance for a larger radiator & cooler):


Electric & heated mirrors, heating will be controlled by the GEM:


The powerplant, ST170 turbo. It will be all steel internals which are still to come across from the states. I've comissioned a custom inlet manifold that has been made a person who works on the US Indy series. He has taken a particular interest in the Zetec. The manifold has been designed around what I want from the engine, which is driveability and effortless torque throughout the rev range.

Pics of the manifold to follow, its at a friends place in Boston along with my throttle body and injectors.

ST 6-Speed gearbox. I'm worried about it's torque capacity, Getrag don't put a very high torque rating on the box, but then neither did Ford on the B5. It's a gamble at this stage. The ST gearbox is geared for 185mph at 8krpm in 6th. It'll be flat out whenever the opportunity arises.



A little dusty..she's been in there for a few years now..Still only on 38k miles..


More updates soon.

[adz]

guna b a beast

and how wikid are those rear lights!

keep us updated, will b very one off and amazin

[PaulFRST]

Wow, where did you get those rear lights

I want some asap, please sell them to me

[Sphinx]

Your a god! serious balls and knowledge to take on that for a project!
I have something that you have, electric heated mirrors from a mk 4, if you need any help just ask although i havent even wired them in yet

[Ash_si]

That is going to be one hell of a car

Ash_si

[XR_Craig]

i think he knows you think he's a god mate.

edited because i forgot to say that this looks like its going to be one hell of a project and to say good luck.

Oh, and nice brakes.

[djtom69]

dude thats gunna be pawnage.... cant wait to see it come together. keep us posted

[Statey]

Gulp

That is going to be one hell of a fiesta keep us updated

[andyhardy]

Wow - what a final project to undertake mate!

I hear what you're saying with the rear brakes and the examples with Porsche, I have major respect for Porsche cars and was thinking about the massive rear brakes they use. Hmm, so perhaps I should get that ZS rear beam and Focus rear disc setup to compliment my Cossie setup up front (which may well upgraded soon anyway).

Excellent choice of engine - the gearbox should be ok, I've also heard that Getrag massively under-rate their gearboxes on torque levels, but that I think is because torque is what destroys a gearbox so could be a nice way to get out of warranty repairs when people up the power output.

Keep us updated dude - what rear beam are you using btw? I noticed the difference between Fiesta mk3 and Focus wishbones before, the new Ford construction used is alot tougher than the old mk3 style setup, so good choice with changing that over from the Sport Ka!

I really can't wait to see this project unfold - great stuff mate

Cheers,

Andy

[Captain Tightpants]

The mans on the ball!



Give me my rear calipers back!

Seriously though mate, top bloke to undertake such a mammoth task! Your gonna have more wiring than a Boing 747!

Wanna race to completion?!

Steve

[sleeky]

Wow.

I know for a fact that this will be one project that I will be following very closely. Ive always admired your work, both in terms of quality and the way you always seem to break the boundries and try new and exiciting ideas.

This car, i have no doubts in my mind, will be truly amazing once done.



Lee.

[heeman10]

Weight lost due to CNC hubs: 900g
Weight gained due to wiring: 15kg

All the best with it, it's gonna be a busy summer

[Excursion]

haha cheers for the comments chaps

The rear lights were clear rears, I told Project what I wanted doing and he painted them. He's done a bloody good job.

Really looking forward to spending a bit of time working on the car, should be good when it's done. You cant beat Mk3's for the driving fun factor. Newer cars seem boring after a while

Steve- your on, although I gotta feeling you will be finished first. How about arace you down the runway when we're both finished

[FezzR]

nice one mate,

this is the sort of thing i wanted to do to my fez, dont think itll ever happen tho lol, glad yours will tho

why VAG servo? if i can help with any measurements on them that you need, give us a shout

[Excursion]

Andy sorry mate missed this off - it's a ZS rear beam

Ian, it's easier to get hold of the larger capacity versions. I'll give you a shout when I get on to the brakes. Cupra R may be a good bet

[Captain Tightpants]

[MAD_Adamski]

nice one mark outstanding project, many ideas so much passion gonna be a very interesting conversion gonna keep my eye on this defo......

Ad

[Excursion]

LMFAO!! WHAT A BELTER

[Excursion]

Cheers Ad

[RS_Rawli]

good stuff mark, you clearly know your stuff, shame the audi had to go, im afraid im gonna chop all my stuff in and get an a4 then look back in regret

[FezzR]

capacity V's space tho you gonna have a enough room to go bigger than focus or like? altea/mk5 golf might be a good bet for size, dont think you get close to audi size tho

[Excursion]

Rawli - no fear a B5 S4 will be along in a couple of months, and I've still got the RS4 front & M3 lip. I'm going for B6 S4 wheels this time though, I let the RS4's go with the TS. I've pieced together a complete stage 3 kit ready for the full 440 Saved myself a packet by buying the parts seperately.

Great cars, cant beat a nicely done B5.

Ian, yeah your right, its easy to forget how tight the Fiesta engine bay is! Could do with something off a car that had the Brembo's on...

[RS_Rawli]

shame mines gonna be a clunker, think im really gonna have to try and keep hold of the white one for some fun....

[Excursion]

shame mines gonna be a clunker, think im really gonna have to try and keep hold of the white one for some fun....

Nah they aint bad if you get a facelift PD mate, the 115 is nice. You really cant tell its a diesel when your on the move.

You will miss the Fiesta though!

[housey]

hats off to you mate

Looks like a hell of a project

Good luck buddy

[FezzR]

B5s are DANGEROUS!
so far ive resisted mods, but god dam ive picked up the phone to "enquire" about 4 different suspension kits etc etc etc, so easy to spend so much

i must admit i do miss the fiesta, hoping it will inspire me to fix it tho

ibiza cupra Rs came with brembos, ill have a look at some listings to see if theyre diff servo etc when im on the laptop

[Max M4X WW]

A very much long awaited post, from me anyway. You are a true leggend when it comes to cars. Fiestas and audi's in particular! Everything discusssed above sounds awesome. Looking forward to more updates!

[VUK]

speechless............................

[Capri]

Crumbs, Mr Stewart, awesome stuff. Can't wait to see the finished result . Are you to be at FITP, good sir?

[fiesta_fras]

sweet, cant wait to see how this is when finished,

[Badgerboy]

Could this be the best Mk3 ever built?

What sort of timescale are you looking at to complete this? Its a massive undertaking, but the end result should be superb!

[xrsi]

this has got me thinknig about a few things!

did any mk3 cvh come with PAS?

also the s brace... is that the same as a zetec s or stronger/ lighter!

finally what are the front anti roll bars and drop links like? would these fit on to a mk3 and are they the stronger/thicker at all or same as normal?

does the lower arms bolt straight on? got 20mm wider track at rear so could do front to match

[Excursion]

Cheers again for the comments I'll take some pics over the weekend when I start stripping the underside for paint.

Alex - unfortuantely due to Uni stuff I won't be at FITP this year mate. With any luck I'll be there next year in this project car

Badgerboy - I'm looking at getting it done for the end of the year

did any mk3 cvh come with PAS?

Not in the UK, your best bet is to use PTE engine parts from a 1.4 Si.

also the s brace... is that the same as a zetec s or stronger/ lighter!

Mk4's and 5's don't have an S-Brace. They use a very substanital subframe which the gearbox and rack is mounted to. It's something I looked in to and may still do, but it's a lengthly project as the floorpan needs considerable modification.

finally what are the front anti roll bars and drop links like? would these fit on to a mk3 and are they the stronger/thicker at all or same as normal?

Just the same, however I've found a set of alloy replacements that are much better. I will post here when I've confirmed they fit.

does the lower arms bolt straight on? got 20mm wider track at rear so could do front to match

They do if you have a Mk3.5, if you use a Mk3 then FRST arms are the ones you want.

[xrsi]

the bolting points are same for both mk3 and mk3.5 arent they.... as the remanufactured ones list the xr2i 1.6 and 1.8 and RS1800 as same and the frst is also listed as same part!

would save alot of hassel by just getting these at same time if i ever find a sports KA in scrap yard!

PAS would be nice as well.. but not drastic for mine i dont think, but will continue to looking into it using the 1.4 PTE stuff then as its a cvh at end of day!

will just get some new drop links then and better bushes for the roll bar, want the handeling sorted as much as poss!

just to make sure the S brace is direct swap aint it... and have u got the part code for it to see bout new?

[Excursion]

the bolting points are same for both mk3 and mk3.5 arent they.... as the remanufactured ones list the xr2i 1.6 and 1.8 and RS1800 as same and the frst is also listed as same part!

Yes they sure are, but the ball joint OD is different on the mk3.5. The cars listed above will be Mk3's.

PAS would be nice as well.. but not drastic for mine i dont think, but will continue to looking into it using the 1.4 PTE stuff then as its a cvh at end of day!

Sure mate, it wouldn't be difficult at all, in fact it's just a case of finding a smashed Si and bolting everything across! Obviously the engine would need to come out. You would have to make a small modification to the bulkhead, but thats easy whilst the engine's out.

will just get some new drop links then and better bushes for the roll bar, want the handeling sorted as much as poss!

Poly bushes should be good for the roll bar, the stock rubber ones don't last that long

just to make sure the S brace is direct swap aint it... and have u got the part code for it to see bout new?

I'm not sure at the moment until I put the KA and Mk3.5 stuff side by side, the KA brace has square locating pegs that match up to the lower arm carriers. I know for a fact my Fiesta lower arm carriers don't have them..

I'll track down those cast aluminium drop links and give you a shout.