fiestaturbo.com

[Excursion]

Brilliant as ever,

1 Q,

how do u mount the fiesta 4/5 3rd. brakelight ?

I had a problem with the backpart of the cover, it hits the headliner and sealing-lip
So the tailgate dosn't close nice.

Did u trim the cover or use spacer ?

.

Thank you. Maybe I haven't hit an issue because the tailgate seal isn't fitted yet? In which case I will have a problem I will resolve that by cutting the light cover, and using either fibreglass or a a piece of black plastic to seal the hole.

[GRP16V]

ok,

this could be the difference

I will try a cover from a Ka about '98 -'99

it's cover is a bit smaller at this area
http://www.ebay.co.uk/itm/Ford-Ka-Sportka-High-Level-Rear-Brake-Light-1996-2008-YS51-13N408-AA-/281006406807?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item416d497c97


i hope it fits to the tailgate glass

.

[- Danny Boy -]

Yeah the mk5 cover hits the seal which causes a problem. I have a spare one in the garage which I was going to fit yesterday but encountered that same problem, so didn't bother.

The only problem with the KA one I would think would be the fact the rear glass is different, so it wouldnt sit properly.

[Excursion]

Thanks both. I will modify mine, I'm not keen on the shape of the Ka one.

[AW0L]

hey Mark any news on the new machined parts???

[jonyb4]

they look the business

[Excursion]

hey Mark any news on the new machined parts???

Still not finished unfortunately, though some are ready for Anodising:

[AW0L]

Still not finished unfortunately, though some are ready for Anodising:

ahh shame, but the parts you have there are looking good, what colour you going to get them anodised??

[Excursion]

[quote="AW0L]

ahh shame, but the parts you have there are looking good, what colour you going to get them anodised??[/quote]

Cheers. Parts will be gold.

[jonyb4]

stunning, the anodising will protect the alloy from corrosion?

aluminium and alloy look worse than rust when they corrode

[Excursion]

stunning, the anodising will protect the alloy from corrosion?

aluminium and alloy look worse than rust when they corrode

Yes, it will. It's a decorative corrosion inhibiting coating.

[Excursion]

Secondary Door Seals
I've always planned to improve on the aperture seals fitted to the Mk3. They are a basic single seal which leaves the entire shut area exposed to the elements meaning undue corrosion often occurs on the hinges and seams. The exposed panel gaps also contribute greatly to interior NVH, so there would be little point soundproofing the car to the extent I have if the outer body fittings are left in standard form.

When I was last in the scrap yard I had a brief look around a few of the saloons and purchased some seals which were of a roughly suitable size to work with and modify. I chose some upper and lower seals, the upper covers the A pillar and the lower attaches along the sills (I may revisit the upper seals in the future if I can find a more complete secondary seal which attaches to the door itself).

Here are the seals and the upper mounting brackets which I removed by drilling out their spot welds. The brackets are from a car that was roughly the same colour as mine so I could save time when painting.


Secondary Door Seals - Upper
Photo to show the standard Fiesta aperture - upper.


Here's the new seal shortened, reshaped, and fitted.


Detail showing seal modifications to suit Fiesta aperture, rear.


Door closed demonstrating a perfect seal which will hopefully create a tangible reduction in wind noise.


Passenger side in place. Note: the main door seal isn't yet fitted.


Secondary Door Seals - Lower
Photo to show the standard Fiesta aperture - lower.


The fixings for the lower seals comprise a captive plastic fitting in the sills, and a removable plastic stud that pushes into a stainless steel channel on the seal itself. I drilled the Fiesta sills for five fittings spaced equidistantly, then etch primed and painted the edges of the holes. I smeared silicon grease over the captive fittings before pushing them home.



Modified lower seal fitted.


Here's a test fit of the stainless steel scuff plates I have to go on once the car is completely finished (blue protective film still attached).


Door closed demonstrating a perfect seal.


Again the passenger side was completed.

[Max M4X WW]

Looks great Mark.

My Octavia's door shuts are totally sealed up, not sure if its for NVH or aero-dynamics (its a Greenline) but I guess it helps both

[- Danny Boy -]

Very nice addon to the car! They look just the part.

[jonyb4]

impressive work

[rsturbonutter]

Everything on this car is taken to the next level absolutely astonished by the amount of thought going into everything. Everything serves a purpose as well. Great work fella

[Excursion]

Thanks a lot guys

[AW0L]

outstanding... that is such a great idea, all i done with mine is fit a very flexable tube into the existing seal to give it a better seal.

[ben17southport]

awesome Mark. out of interest, do you get a lot of time to work on the car?

[jonyb4]

no llama, how do you manage it mark?!

you even find the time to learn complicated wording

[Excursion]

I don't get much time at all to work on the car, and I also work quite slowly when I do, hence the project crawling along

[dontpannic]

I don't get much time at all to work on the car, and I also work quite slowly when I do, hence the project crawling along

I know Mark, you're getting as bad as Jay.





Sent from my Casio FX-83GTPLUS

[jonyb4]

[AW0L]

EPIC

[GRP16V]

Oh man u read my mind.

Superb work.

I tried some sealing parts from a Escort mk6
- lower door sealing
- bits from the b-pillar

not satisfactorily

- upper door- and a-pillar won't fit at all
i will try some fiesta mk4 parts


Another thing i don't like is the door-window sealing especially at the b-pillar area.

When u drive at the motorway and it rains, u see how the water hit the seal and runs down to the weatherseal(? between door and window) and "floot" the door.
very wet for the CL

the escort door-window sealing has a better design like a small "spoiler"



cheers..

[Excursion]

Another thing i don't like is the door-window sealing especially at the b-pillar area.

I hate this too. I'm not so worried about the water ingress more the wind noise that they create at high speeds. Let me know how you get on with the Escort seals; I had planned to bond a small spoiler to the Fiesta seals but if the Escort ones use then I'll swap to them instead.

Steering Column Brace
One of the final parts to be affected by my change of steering wheel position was a small brace that joins the dashboard to the steering column mount. This is one of the new parts I incorporated from the Puma/Mk5 Fiesta and is there to add a bit of rigidity to the dashboard.

The standard bracket is an 'L' shape. Mine now looks this this:


Fitted.


Cruise Control Module
Cruise Control is amongst the final area of interior wiring to be completed, and firstly I needed to mount the module somewhere in the engine bay. I'm using a brand new Ford CC kit for the Mk1.5 (2002-2004) Focus 2.0 Zetec.


I'm trying to package everything as neatly as possible and use every last free space to keep the area around the engine as neat as possible. I chose the following position on the upper bulkhead to mount the module.


The CC kit comes with new wiring but for whatever reason is missing the instrument cluster indicator lamp wire, which it is the white/black wire present on the used connector (left).


I cut off the CC module plug from a scrap Focus that had factory fitted cruise control and rebuilt the retrofit harness with the additional indicator lamp wire. Once that was finished it was time to find a route into the interior for the CC loom, and for this I chose the hole for the original Speedo cable which is now unused thanks to the Mondeo instrument cluster which runs off of CAN bus, rather than a mechanical cable.

The retrofit loom came fitted with a small rubber grommet to suit the Focus engine bay, so what I did is to cut a hole in a larger grommet that suited the old speedo cable hole, and then pushed the two together.


Here's the loom fitted.


The new CC wiring now exists exactly where I need it, behind the cluster.


The CC module is mounted the black bracket which is then bolted to the car. I modified the black bracket to suit the confines of the Fiesta engine bay, and then I fabricated a new bracket (left) for it to mount to.



I taped off the area on the bulkhead and applied bedding sealant to ensure everything was watertight. The masking tape was removed once my new bracket was riveted in place and left a neat edge on the sealant.


All finished. Harness plugged in and the actuator cable fitted.

[RS EDDIE]

Amateur!!!!

Looking very good mate!!! When ya reckon its gonna be ready to run???

[- Danny Boy -]

Very nice, Mark. Will you make some sort of cover to go over the CC unit's wiring ect seeing as it is in area where water can easily get to it? Or will there be no problem?

[ianFRST]

will be awesome when its done

[FRSJON]

its all unreal stuff but im still holding out for the engine is ian howell still doing it as i recently heard he'd stopped doing them again

[robp-tt]

looking great mark, the bits of mk look good but its a shame he takes so long to make the bits,

its all unreal stuff but im still holding out for the engine is ian howell still doing it as i recently heard he'd stopped doing them again

i think his engine is all built jon, his head was being done the same time as mine last year, the engine for this will have a few trick bits on aswell from what i have heard

[jayrs]

great stuff mark, liking the new seals round the doors alot

[Excursion]

Amateur!!!!

Looking very good mate!!! When ya reckon its gonna be ready to run???

Hopefully next summer.

Very nice, Mark. Will you make some sort of cover to go over the CC unit's wiring ect seeing as it is in area where water can easily get to it? Or will there be no problem?

It's actually a sealed unit and watertight, but I'm going to see if the Mk5 pollen filter cover will fit over the top. Clearance is quite tight though due to the wiper arms.

will be awesome when its done

Cheers Ian.

its all unreal stuff but im still holding out for the engine is ian howell still doing it as i recently heard he'd stopped doing them again

Haha, yes these current jobs are little things really, but the suspension and engine will be more interesting. I don't know if Ian has stopped, but thankfully that wouldn't be a problem as I've known him for years. The current hold up is my oil system; we're trying something different and it's been difficult getting someone with the machining knowledge to come up with the goods.

i think his engine is all built jon, his head was being done the same time as mine last year, the engine for this will have a few trick bits on aswell from what i have heard

It should be good when finished. I'm going further with it to get good throttle response and tractability along with a healthy power figure - it definitely won't be a run of the mill ZT

great stuff mark, liking the new seals round the doors alot

Thanks mate.

[fiestarsturboblack]

mate awsum as always, wen do u thnk ul b startin with the engine an all that? an wats ur plan to get the power down????

[Excursion]

mate awsum as always, wen do u thnk ul b startin with the engine an all that? an wats ur plan to get the power down????

Cheers The engine is already built, the hold up was the oil system but that's now completed. Power delivery will be managed by air injectors and mapping that bases boot against throttle angle. I'm also using the Renault Clio front suspension system that employs the 'Revoknuckle' type hubs as per FRS Mk2. I also have switchable traction control and adjustable front suspension.

Oil System
Thanks to fezzablower I have seen what my oil system looks like. Unusual that the photos come from a user I haven't met before rather than Ian, but I think he's several years past the photo sending stage now

The new oil system for my engine is finally complete. The standard oil pump is a known weak point on powerful Zetec engines and there is not currently a known root cause, only speculation and theories including crank nose flex induced from high cylinder pressures, or harmonics. I'm not taking any chances and so commissioned an external single stage pump that will enable me to remove the standard pump altogether, and my requirements were that it had to work with PAS and AC.

The following photos show the first kit that will be used on my engine, though the hose routes and fittings will be subject to some slight tweaking.