fiestaturbo.com

[Pudnpepsi]

Awesome. just Awesome, how a Mk3 should have been. love the colour combo too. one thing.. how do you get the watermarks on your photos... photoshop?

Pud.

[AndyKam]

Truely amazing mate. Love the seats. Aldridge are just down the road from me. My retrim will be done by them too.

[Excursion]

Awesome. just Awesome, how a Mk3 should have been. love the colour combo too. one thing.. how do you get the watermarks on your photos... photoshop?

Pud.

Cheers! I wrote a PHP script for my website that automates the process, so I just upload the original and the script resizes, adds the watermark and then generates forum code.

You can use Photoshop too, in fact before I wrote the web script I used to set up a macro/batch to automate the process within PS.

[Excursion]

Truely amazing mate. Love the seats. Aldridge are just down the road from me. My retrim will be done by them too.

Thanks Andy! You definitely won't be disappointed

[Pudnpepsi]

so not only are you a clever cookie around a car, your good on the old commodore 64! hats off to you mate!

Pud

[mrorange2]

WOW i love them very nice work!!

[Excursion]

Thanks guys!

I've finally finished the interior wiring loom, which took a lot longer than I expected it to. The result to the untrained eye is something that looks like a factory loom; I followed the factory colour schema and used factory connectors to extend or add functionality. I've added 25 new features but to cover each would make for pretty dull reading, so I'll cover just one as an example:

Here's the standard set of multi plugs to join the interior loom to the engine bay loom. The four thicker red cables feed power from the engine bay fuse/relay box to the in car fuse/relay box...


As I'm moving the battery to the boot it would mean these wires unnecessarily feed into to the engine bay then back to the battery in the boot, so I stripped them out and ran them back to the boot instead.


I also removed the fuses and terminals from the engine bay fuse box so it's obvious that nothing should plug there. I've actually created a document which details all changes made to the loom so it's easy to maintain the car going forward.


Here's the finished result. The new black multiplug is from an earlier Fiesta and all its wires are for new functions. I created twisted pairs for any data lines in order to minimize RFI.


Wiring for four fuel pumps. I've used the existing grommet under the seat and run the new cables through and split them into two sets and covered with PVC sheath. There will be two lift pumps in tank, and two Bosch 044s mounted to the side of the tank, fed from an internal swirl pot. I don't need two 044's - the second is just for resilience. The looped wires to the right of the photo will be run to a dedicated fuse & relay board in the boot.


The wiring in place behind the dashboard. The thick red cable runs from the engine bay, across the dash, and down the right hand side of the car. I've used this route so that there aren't any 12v lines on the left hand side of the car that could possibly induce interference in the audio RCA cables that will be run on that side.


Here's the dashboard in place. I've now got to retrofit a passenger airbag and fit the HVAC controls.


There's now a layer of Luxury Liner Pro on all of the lower panels. Thanks to my Dad again for that!



The first new components for the rear suspension arrived and these new adjustable alloy arms replace two of the three standard arms on each side. They are currently fitted with spherical joints but I'm having them modified to accept Focus RS bushes, which are still a considerable upgrade for a Fiesta. The third arm on each side will be replaced with a billet 7075 pieces made to my specification, and I'm also having the rear hubs copied in billet 7075 together with some disc bells, and brackets specifically for the AP calipers. Everything will be anodised in Gold.

[heeman10]

Good update

Are those rod ends fitted with push-on rubber covers?

[- Danny Boy -]

Good progress Mark!

Any reason for mk5 dash over mk3?

Rear arms looks LUSH!

[RS EDDIE]

Mark.....its beyond words mate!!!! Pure amazing work!!!!

Cant wait to see it!!!!!

[andymac]

Good update

Are those rod ends fitted with push-on rubber covers?

Looking at the photo with the exposed bush I think it's safe to assume so.

Mark, are the pumps mounted either side of the tank to ensure that there's an adequate fuel supply under hard cornering ? I assume of course, that that would be a secondary consideration - honest...

[RS rob]

hey mark, not been on here for a while
looks like you've been mega busy with this
looking epic!!

[jonyb4]

like eddie said, i cant even comment!


id love to know these 24 other changes to the loom though!!


my mind has been blown

[285Andy]

mind boggling Mark i havnt seen this thread for a while and back then i thought f**k me thats so well thought out and inovative. then i take a catch up look and youve kicked it up a gear!! just stop it!!!! actually i kid, keep it up man! i love it

[Dave G fsi]

Excellent work mark

The only difference I would have made would be a mk3 dash rather than mk4/5

[AndyKam]

The only difference I would have made would be a mk3 dash rather than mk4/5

I prefer the MK3 dash too, but I suppose fitting the aircon behind a MK4/5 dash will be a lot easier as these came with aircon as an option.

[Excursion]

Thanks everyone! Feedback is always appreciated Questions answered below.

Are those rod ends fitted with push-on rubber covers?

They are mate.

Any reason for mk5 dash over mk3?

I like the Mk3 dash but I've grown to like the Mk4/5 dash. The main reasons are here:

1 - Mk5 dash is actually structural, and when fitted as intended it stiffens the A Pillar and scuttle area and makes for a quieter ride. I find the Mk3 dash is prone to rattles/noise.
2 - I wouldn't be able to wire up the car with a Mk3 dash as there's not enough room behind it for the loom. The high line Mk5 loom is a fair amount thicker than even a deadlock equipped mk3.5 loom, and that's without the features I added.
3 - Mk5 dash has more area for a larger heater box. Mk5 matrix and A/C Evap are much larger than Mk3 so offer better heating/cooling. Matrix and Evaporator can also be removed from the engine bay.
4 - I wanted dark grey trim, OEM 'wood', OEM glove box lighting and glove box A/C.
5- The Mk5 dash protects the driver from being crushed by the steering column, and allows fitment of a three piece column which also helps in that respect. Not a deciding factor for me but is nice to have.

Mark, are the pumps mounted either side of the tank to ensure that there's an adequate fuel supply under hard cornering ? I assume of course, that that would be a secondary consideration - honest...

Hopefully the following image explains (blue is exhaust):

It's mainly due to the new exhaust route which will create a well in each end of the tank.

id love to know these 24 other changes to the loom though!!

I will upload the document when finished

[Pudnpepsi]

One Clever, clever Cookie...

[jonyb4]

[andymac]

It's mainly due to the new exhaust route which will create a well in each end of the tank.

Ahh, fair. Happy coincidence re fuel scavenging then.

Think you'll have her ready before winter ?

[Dave5300]

theres so much done to this mk3 it baffles me pure awesome

[- Danny Boy -]

With regards to that reply Mark, it answers my question perfectly!

I never knew it helps with structually. Learn something new everday!

Does this mean the mk5 is a flimsy car?

[Capri]

I think I've run out of superlatives to use on this car.

[Max M4X WW]

OEM 'wood'

[Cant find a photo!]

Really

[Excursion]

OEM 'wood'

[Cant find a photo!]

Really

Absolutely

[fiestarsturboblack]

mate thats an aswum fezz ur buildin, cnt wait to see it complete

[FRS_Steve]

OEM 'wood'

[Cant find a photo!]

Really

???

[jonyb4]

wheres the "sick" emote smile then i need it?!

[Excursion]

OEM 'wood'

[Cant find a photo!]

Really

???

That's it I wanted to have the parts redone in Maple veneer but it wasn't possible for the heater panel sadly.

[mrorange2]

Awesome i honestly cant believe some of the things you have done to this car very very clever!

[dontpannic]

I actually bought that kit from eBay for my MK5. I love de wood!

[FRS_Steve]

I think the wood will be a nice touch, and should go well with your seats and door trim. I've said it before and I'll say it again, I'm amazed at the amount of thought and attention to detail that has gone into this car, it is going to be something really special. I've never seen so many wires in a Fiesta! Hours of work gone into that wiring alone. Keep up the good work man

[:: blade ::]

Not been on this site much lately but just gone through this whole thread :O omg so much work gone into this, its sooo good cant wait to see it finished

[dontpannic]

Not been on this site much lately but just gone through this whole thread :O omg so much work gone into this, its sooo good cant wait to see it finished

No, you haven't you fudgekin traitor.

[Excursion]

Thanks guys

The sound deadening and vibration damping is now complete. There were some voids between the roof skin and headlining so they have been covered with a layer of Silent Coat Sound Absorber 15 over Silent Coat Noise Isolator 8. The base is RAAMmat BXT II which covers the entire roof skin.


Rear section complete.


I've used Silent Coat Noise Isolator 4 on edges of any apertures in order to protect against chaffing.


I removed the dashboard again in order to apply Silent Coat Sound Absorber 15 to any surfaces which were in close proximity. The material is great for preventing any squeaks or groans, not that there are many from the very solid Mk5 dashboard.


Next I moved onto the roof furniture. I was originally going to spray the original accessories to match the new headlining, but as time went on I decided that they weren't special enough.




So, I went out and purchased some accessories from an Audi B5 A4 Facelift 'Sport' model which included new interior lights and a section of the surrounding headlining, then using some spare Fiesta headlinings, I figured out how to modify and mount the parts.


The position of the fixed mount on the Astra sun visors is different to where it was on the Fiesta, which wouldn't have been an issue except one of the screw holes in the new position fell over a recess and punched hole in the overhead chassis box. I made a couple of removable brackets up to get around this as I wasn't happy securing something with only one screw when it should have two. The connectors in focus are for the auto dim mirror and rain/light sensor.


I have fitted the re trimmed headlining and A pillar trims. I used pads of Silent Coat Sound Absorber 15 behind all trim to prevent any minor squeaks etc.


A4 roof handles modified to fit. They are silicone damped.


A4 Sun Visor clips fitted.


Re-trimmed Astra VXR Sun visors fitted.



A4 Rear interior light fitted.


I had to tweak the A Pillars slightly to get the Mk4/5 trims on. I'm pleased with the fit.



Here's the cut-out ready for the Audi front light which I shall cover later in this post. I haven't fitted the door seals yet which is why exterior paint is visible. I have a set of new original door seals but before they go on I'm going to investigate if any of the velour finished door seals from Audi/BMW/Mercedes etc. will fit.


I've purchased a set of door looms from an Audi A6 that was equipped with the 'interior light pack'; the clear objects in the front of the photo are lenses to direct LED light into the interior door handle reveals. I will incorporate these looms into my doors together with the A6 puddle lights and door marker lights. I had already got Peugeot courtesy/puddle lights but the quality and design is, as to be expected, not a match for the Audi parts.


Here's the new front interior light which is actually more of a multifunction console than a light; it is from a well specified model so has LED based submarine lighting, map lights, and provision for a Telephone Microphone. The on/off switch is dual pole so has dedicated control of the rear light i.e. the rear light comes on with the front light in position 1 (that isn't as straight forward to achieve as sounds). The unit mounts by two screws through the lugs outlined in the photo:


I enlarged the original Fiesta light recess and fabricated the two Top Hat shaped brackets to secure the new light.


The first test fit in a scrap headlining.


I carefully cut the original Audi headlining and mounted it to the Fiesta attached to the light. I got the sides to fit perfectly but the front and rear edges were a problem, particularly the front as highlighted in the second photo.



I fabricated a metal part to fill the gap.


Next I welded the infill piece to the light mount frame, and then used Epoxy to reshape the outer edges of the headlining.



It doesn't look like much, but I've used a combination epoxy, adhesive foam and finally fabric tape to reshape the Audi headlining to fit perfectly against the Fiesta headlining. The next step is to cover it in Alcantara.