fiestaturbo.com

[- Danny Boy -]

Absolutely beautiful! Colour scheme works perfectly!

Cant wait to see the fronts in now

[Dave G fsi]

Jesus, that looks absolutely stunning Mark!!

[Fraggle]

simply stunning

[Excursion]

Thanks everyone. I am really pleased with the car

[dontpannic]

Thanks everyone. I am really pleased with the car

So you should be! Admirable work, Mark, very impressive indeed. I love it!


Sent from my iPhone using Tapatalk

[SEG1]

Fair play mate that looks amazing. The colour scheme works very well I think. This is going to a very quiet ride even with 500 horses under the bonnet. You won't hear much of the under bonnet goings on unless the windows are open
This as got to be the best specced fiesta in the world when finished and it will certaiunly be a very much talked about car on the fiesta scene for many years to come and I challenge any man to try and better this example of the mk3 fiesta. Honestly every person I have said have a look at this too has been gobsmacked by your work mate. Can't wait for it to be finished and I think I will be standing in the queue to have a look at this in the flesh. Top work fella

+2

[Smo]

Just amazing!

And yes, I can see that the vinyl isn't really noticeable!

[Max M4X WW]

Yep, I need an interior that colour!

[Dave5300]

your going to need a matching velvet rope to put around this at shows whens its done because its going to be swamped with people wanting to see it!! amazing!

[FiestaBen]

Absolutely spot on! Can see this being the best Mk3 Fiesta on the scene when it's finished and it will be for years to come!!!

Well done buddy, you should definitely be proud of it! Just don't ever look at the receipts

[FRSJON]

wow....again

[Choosey]

VERY nice Mark!

Out of interest, how long will the engine build take?

[Excursion]

Thanks guys

Ian actually finished the engine build last March, but it was torn down again because I changed a few things It's not been a priority for me yet as I see the engine as the one of the final stages, so Ian has been getting on with other builds in the mean time. Once the suspension build is complete then the engine will start to become a priority.

The oil system is the latest phase of the engine and Ian and I are trying something different: I'm no longer going for a dry sump system so there's a bit of re-jigging to make room for its replacement, which will better suit my requirements. The oil system project has actually been under way for the past six months or so because there have been two custom orders to Pace Products for pumps that suited my spec and both times they completely failed to deliver, so my advice is stay well clear of that company! A billet adapter has been machined for the WRC manifold and the plenum has been sectioned and spaced to suit my intended power. That's just about finished. What's left to go is dynamic balancing, and that's being held up by the clutch; I want an organic clutch which is obviously a struggle with the power target, so I've done quite a lot of research in that area and found something to suit my needs. I just have to pull that together now so the motor can be on the dyno this summer.

Incidentally the engine would make a lot more than 500 if it weren't for my driveability requirements, which are that it must be as tractable and well behaved as a standard car That's more important to me than a headline power figure.

[mrorange2]

Thats brill i love the rear seats this car never fails to amaze me well done mark.

[Choosey]

So there's not actually THAT much to do to finish the car off then really?

[Excursion]

Thanks both!

Not a huge amount to go, but it will take time because there are so many custom parts and modifications. Nothing ever goes back on the first time, there's always something that needs changing or improving

[jonyb4]

mark wow, so impressive, the seats are stunning, i completely changed my mind to what i first said, its so nice to see

[heeman10]

VNT?

[Jur]

[quote="Max M4X WW]
That's it I wanted to have the parts redone in Maple veneer but it wasn't possible for the heater panel sadly.[/quote]

Why do i find this hard to believe after looking thru the rest of the project :-p

[bassboy]

Absolutely love this build! Been keeping an eye out for updates more than ever lol!

If you need any help/advice/bits for the audio/sound deadening side of things, please dont hesitate to drop me a PM or email me on support@teamspb.co.uk

Could I bother you a moment by any chance and possibly ask the part number for the rear view mirror mounting nut you used from the BMW? I need one for mine and id rather walk in and give them the part number rather than playing a guessing game...

Im doing similar to yours, however, using a Mini rear view mirror as I prefer the 'rounded' ends which I find fit in better with the shape of the Focus (the wing mirrors)

Thanks for any information you can provide!

[jonyb4]

mark, i also need that code for one of them buttons, i damaged one of the tabs (1 of 3) on the button, the mirror wobbles and shakes when going at motorway speeds

my windscreen cracked the other day so ill need a new one anyway, id appreciate any help

[Excursion]

Thanks bassboy!

If both of you can wait a couple of weeks then I can probably send each of you one FOC. Drop me a private message with your address details.

Cheers

[AW0L]

amazing work Mark truly inspiring!!!

one question do you have the part no for the carpet and cost please?

[Excursion]

amazing work Mark turly inspiring!!!

one question do you have the part no for the carpet and cost please?

Thanks. I don't unfortunately, and the packaging went in the bin.

[AW0L]

ahh no worries, i will visit the local ford shop

hows the progress on the lighting mods on the indicator stalks

[Excursion]

ahh no worries, i will visit the local ford shop

hows the progress on the lighting mods on the indicator stalks

I haven't started yet. The Focus centre console is next on the list so I can get the front seats in I will start on the light stalks after that.

[AW0L]

cool, i forgot about the centre console... when can we see the updates for that??? i know weather is a bit on the off side as i havent had a chance to get out and work on mine for 2 weeks having withdrawl symtoms....

[Excursion]

cool, i forgot about the centre console... when can we see the updates for that??? i know weather is a bit on the off side as i havent had a chance to get out and work on mine for 2 weeks having withdrawl sysmtoms....

I'll have a few days on it over the bank holiday

[AW0L]

[quote="Excursion

I'll have a few days on it over the bank holiday [/quote]

haha sweet i would love to see this car for real, (as would everyone else here) what about the rear axle gear any news for that???

[~nomad~]

[bassboy]

ahh no worries, i will visit the local ford shop

hows the progress on the lighting mods on the indicator stalks

I haven't started yet. The Focus centre console is next on the list so I can get the front seats in I will start on the light stalks after that.

Look forward to that Stewart...I have read through the whole build thread but cant remember what centre console your using but I have a spare Focus RS one here complete with push button start and carbon if you need/want one...

And thanks for the offer on the nut...I will drop you a PM in a moment...

[Excursion]

Focus Centre Console
The Focus console is secured by two screws under the forward cup holders and one screw under the rear cup holder. To help me determine what needed to be done I first secured the rear console fixing by installing a stainless Rivnut in the shell. Then, once the console was reasonably secure I could plan how to attack the rest.

The black powder coated object in the vice is a standard Mk4 Fiesta centre console front mount, which I had already modified my floor pan to accept as it acts as a stiffening brace for the Mk4/5/Puma dashboard by securing it to the floor. I modified the Fiesta bracket in order to create something that would be compatible with my dashboard, my floor pan, and also the Focus console.


After a couple of test fits of the console I wasn't happy with how far it encroached into the front foot wells, so I fabricated some U sections which the edge of the console could sit into, in order to pinch the width at the base and restore foot well space.


Here's the finished bracket. I added a strengthening rib on the lower edge.




The bracket was finished in etch primer and satin black. It clears everything it needs to and is a lot sturdier than a standard Focus bracket. The two out of focus white objects in the foreground are plastic captive fittings I installed to take the securing screws.


Next I made holes in the console for the Bosch Park Pilot display and buzzer, and the Fiesta tailgate release button.


I used some trim clips from ebay to secure the Parkpilot display harness. I was a bit sceptical about them but the adhesive is very good.


Here's how far the console encroached into the passenger foot well:


When clipped in to my edge brackets, the console is pulled in and its base width becomes close to that of the original console:


This photo shows where I have cut the Focus console to suit the Fiesta floor pan.


Here's the finished result. Incidentally it is mounted far more securely than in the Focus



Illuminated Cigarette Lighter Rings
A lot of Ford models came with illuminated Cigarette lighter sockets, so I ordered a pair and fitted them to my HVAC controls and the Focus centre console. I appreciate that most people hate the fake wood, but it works for me in the context of this build



Focus RS Gear Lever Adjustment
Following a test fit I decided that I wasn't happy with the position of the new gear lever: it was too far forward. The lever assembly was already as far back on the floor pan as it could go, so I stripped down the mechanism to see what could be done; it soon became evident that the RS lever has a very shallow rake compared to the original Fiesta lever.


I bent the RS lever to match the original Fiesta lever, and the gear knob now sits perfectly to hand.


Passenger Airbag Retrofit
The passenger Airbag is a straight forward fit now the wiring is in place.


I used adhesive felt pads around the circumference of the Airbag cover, to minimise any trim noise. They can just about be made out in the above photo.


Cover in place.


B-Pillar Trim Fitted
New B Pillar trims fitted with Sound Absorber 15 pads and new trim clips.



Front Passenger Seat Fitted
I'm using a pair of front seat belt pre-tensioners from a later Ford to compliment the new Airbag and restraints system that is now wired in. A quick test fit showed that the tensioners would bolt in place of the original buckles, but the gas chamber shroud fouled the seat runner.


So, I notched both inside seat runners to allow the pre-tensioners to fit.


The affected area on each seat runner was refinished in gloss black, and the pre-tensioners fitted perfectly into place.


I drilled three small holes in the seat cross brace to allow fitment of some cable clips to keep the pre-tensioner and heating element cables away from the runners.


Here's the passenger seat fitted.



Rear Speakers and Amplifier - Sinfoni
I decided that I couldn't live without some rear speakers, or 'fill' as its known. New components are Sinfoni 90.2x Amplifier and some S100 speakers, which are the same side as the Ford originals.



Sinfoni build quality certainly matches the sound.



One Touch Window Relays Fitted
I stripped down the Mondeo relay connectors to their component parts, as that way I could solder my new wires directly to the pins in order to maintain the correct wiring colour scheme.


Completed. The Orange, Black and Blue wires are for the Audi puddle and door handle lights I mentioned in a previous update.


Mondeo Instrument Cluster
I have always planned to upgrade the instrument cluster in the car, the criteria being something that offered increased features but at the same time wouldn't require drastic loom changes. I settled on the 2004-2008 Mondeo cluster which in visual terms it's not a huge step up from the Mk5 Fiesta cluster, but it is back lit and comes with a trip/fuel computer, temperature display, and ice warning, which definitely are an upgrade over the front lit and relatively simple Fiesta cluster.


The majority of information used by the cluster is read over the CAN Bus, so in order to use it in something as old as my Fiesta there is a requirement for both new data lines and a suitable ECU. You may recall I already integrated new twisted pair data lines with the interior loom in anticipation for an instrument upgrade, so that just leaves the ECU.

The Mk3 Fiesta used 'EECIV' Engine management which is now basic by today's standards and doesn't offer anything of use for my project, so that system and loom was cast aside and replaced with a modified loom from a later Fiesta, which gave me 'EECV'. This is a much more advanced Powertain management system that was in use up to 2008 and is actually available in two architectures: the more basic 60pin and a more advanced 104pin, which includes CAN bus amongst other things. The problem was that to my knowledge, the Fiesta only ever came with the cheaper/simpler 60 pin version of EECV so I fully anticipated I'd have to modified the engine bay loom to suit! This however wasn't a problem to me as the engine bay loom is separate entity and I hadn't yet started work on it: if I had, I wouldn't have attempted to fit this cluster. It was by chance that I stumbled across a Mk5 Fiesta 1.8 Turbo Diesel and noticed it used the 104 pin management, so I've since purchased the engine bay loom from that model which gives me basically plug-and-play pre-wiring for the 104 pin management. There are quite a few modifications I'll do to the engine loom but that will be covered in a later post.

Physically fitting the new cluster was actually quite easy even though it is larger then the original. My aim was to keep the dashboard standard and to modify the cluster, as it can be removed very easily if required.


I first stripped the cluster to determine if I could safely remove material in the necessary areas, and also inspect the PCB which also required a slight trim. All was well and the PCB wasn't printed in the areas I had to trim. Any cut areas will be made good with new plastic glued into place and I will also bond on some new mounting lugs, as the Mondeo lugs were in the way.


The Fiesta bezel shrouds the new instruments somewhat, so it will be removed, reshaped to suit and then repainted.


Billet 7075 Rear Hubs
Here's the first of many bespoke billet components for the suspension: Billet 7075 Focus rear hubs. The hub flange and body is thicker for increased strength yet there is still an overall weight saving over the original. The finishing touches will be a machined lip to mount the standard ABS ring, a groove to allow fitment of the standard bearing dust cap, and finally gold anodising.





Later Steering Column
I'm using the steering column from a later Fiesta because it came with a three piece steering shaft, which seems like it would be far safer in frontal impact than my original two piece shaft would be. The later column is also far sturdier around the mounting point which serves to improve location of the steering wheel.

The later column (top) is an evolution of the original steering rack and isn't a million miles away from the original, the main difference is that its smaller in diameter. To get around this I'm having an aluminium spacer turned which will allow the original rack locating bush to fit the later rack, which in turn suits my steering column mount in the shell.

A thank you and an acknowledgement:
RS Eddie - For the felt pads I used behind the Airbag cover.
Allking - For his project which first drew my attention to the Mondeo instrument cluster.

[Dave G fsi]

Once again Mark, absolutely excellent work

[- Danny Boy -]

Amazing! Simply amazing.

[jonyb4]

mark your a god walking amongst mere mortals!

your work is simply amazing and leaves me with a loss of words


im very impressed with your metal work, how did you do that console bracket, just how, its very professional and intricate

the interior is looking very nice, id love to see them mondeo dials once the shroud is honed in to suit them, and a trip computer is something ive always wanted, ill have to settle for the mk4 escort one which we both seen in the German fellows thread, which ive just paid for


i really enjoy reading your updates, it fills me with inspiration and is like a brainstorming session, i hope you enjoy doing this project, you seem to

you should go into automotive design and work for a certain company for designing they're new models