fiestaturbo.com

[jonyb4]

Top work as always, Mark!

Cruise control is one of the things I would LOVE to have in my car when doing long distance journeys!

what makes this feeling so much worse is having driven cars with it, even on a short trip to swansea its so nice to have

[Excursion]

Front Midbass Driver Installation
The standard Fiesta front speakers are 13cm which is really too small for a mid range speaker. The Lotus replacements I've chosen are 16.5cm, so there's a bit of work to be done. I've bought a pair of pre-made MDF rings which are 25mm deep to give plenty of depth to keep the larger speakers away from the window glass inside the door, and also to sculpt the rings around the various protrusions on the inner door skin.


Standard Fiesta speaker aperture on the passenger side.


Here's the drivers door aperture enlarged for new speakers. I opened the aperture using Aviation shears, and bent the excess metal outwards to create 'fingers' to help seat the MDF ring, and any excess was cut off. I etch primed and sprayed in Noveau Red to finish. At this point I had already sculpted the MDF ring and test fitted it to ensure the new speaker had sufficient clearance around the edges of the door card.


The first use of modelling clay on the project I did some quick research and it seems the material of choice to dampen vibrations and fill any gaps between the MDF ring and door. I wanted all black but could only find these multi packs, so I mixed a few colours to match the cars paint.


Clay applied around the speaker aperture and on the outside edge of the fingers.


I primed and painted the MDF rings and mounted them with stainless screws. There was one strip of black clay in each pack so I used that to seal the outer edge of the rings.


Seas driver mounted with stainless screws.


I put some metal covers on to protect the drivers for now. I'm still deciding what approach to take with the door cards; I can choose a stealth approach which leaves the door card mostly unmodified with the downside being some shrouding of the driver, or alternatively I can cut the door card and loose the standard look but ultimately ensure the driver can perform at its best.


This photo shows how I angled the mounts upwards and rearwards.

[Smo]

How much do you think the stealth approach will affect the audio quality? If it's almost negligible, I would definitely want to keep it looking factory! Are you intending to use those covers if you cut the door cards? If so, I think with your interior, seeing the driver covers would almost be an insult to the quality of everything else that surrounds them! Or are you planning to modify the door cards with a larger grill area?

[andymac]

Mark, did you consider using butyl tape as a dampener ?

[bassboy]

Mark, the Silent Coat would have acted as a better seal between the door and the adapter...

Also dont forget to deaden the big holes in the doors either otherwise even your great midbass will be severely lacking

[Excursion]

Thanks guys.

I didn't think of using the Silent Coat actually. Doh! I'm going to cover the inside panel with Silent Coat and then finish with some acoustic underlay The inner panel is pretty flimsy around one of the large openings so I will put an alloy brace across it first.

[bassboy]

Get some 4mm Silent Coat mate on there, you will not need any bracing

[Excursion]

Cool, thanks mate!

Just seen this:

3.0 Litre 32 valve V8 made from two Hyabusa engines. It's smaller and weighs less than the Duratec-HE but produces 400HP @ 10,000 rpm with standard cams. Obviously, low down torque is minimal, but then that does mean no gearbox breakages.

[Fraggle]

stunning attention to detail as always...

[rsturbonutter]

Very tempting.
Have you seen this video
http://www.youtube.com/watch?v=TNDkeX4sTCI
I reckon it would be awesome but unsure what it would be like to drive sensibly

[- Danny Boy -]

Sounds good that ^

But I dislike how slow it looks with the engine reving so highly and so quickly

[Excursion]

That Escort doesn't have the V8, does it?

Normal bike engine no good in a 'regular' steel chassis car IMO

[~nomad~]

got a link to where that pic came from?

[Excursion]

got a link to where that pic came from?

http://www.h1v8.com/page/page/1562068.htm

Will let you know prices. I've asked for an MTX ready 3.0 crate motor.

[jonyb4]

i agree danny i also thought it wasnt moving very fast compared to the noise it was making, probably less than 200bhp imo

mind saying that, bike engines are incredibly well tuned in comparison to a car, i remember my bro having a older GSX-R 600 (one with air ducts on side of the headlamps) and that 600cc engine was making about 93bhp!


that V8 hayabusa engine is a beast!

considering it are you?

[DanFraser]

At 20,000 us dollars he better be taking some serious consideration about it!

[Excursion]

Yes, exchanging emails with John at the moment. 20k USD works out to a similar GBP package price of my ZT spec.

[Smo]

Are you actually considering this or just interested?

Would there be any issues with 10,000rpm going through the input shaft of an MTX box?

[Smo]

And isn't the V8 $33,000? $20,000 looks like it's just for a 4?

May be I read it wrong!

[Excursion]

Are you actually considering this or just interested?

Would there be any issues with 10,000rpm going through the input shaft of an MTX box?

I was considering it, but after speaking t John it seems there is little in the way of economical upgrade for the MTX. The first one of these motors with an MTX had a full Quaife gear set (the owner was a quaife supplier) but as you've pointed out already, the RPM is too high for the bearings.

I'm glad actually, I don't need any more diversions or distractions

[Excursion]

I've riveted the one touch relays to the inside of the doors. I'm now about finished with the doors so can look to getting the cards back on.


Boot Floor Battery Box
My Dad put his Architectural skills to good use by drawing up a template and creating this card model of the boot battery box.



In situ. I can now de-construct the model to create a cutting template for Aluminium sheet.


Golf Armrest
I wanted an armrest of some kind because I'm both used to them and because they are good places for an iPod dock. I looked at several armrests from the VAG range of cars as I like their designs the most, and eventually settled on the Golf Mk4 item which was dimensionally most suited to the Fiesta.


The first step was to modify the armrest bracket to suit the Fiesta. This was to be the first time I'd welded alloy, so it was pure Argon at the ready together with a spool gun for my MIG welder.


This photo shows the spool gun, and in the top left hand corner is the Golf lower bracket which I cut up to begin modifying.


This was the best I came up with. I think it's OK given this is a MIG welder and the base alloy is cast, so has impurities, and I was also using 5356 wire when ideally I should have used 4043 to match the silicone content in the Golf bracket.


I cleaned up the worst welds with a file, and here's the finished result. Increased height and a smaller footprint to match the Fiesta exhaust tunnel.


Armrest carcass test fit.


I sent the lid to Aldridge to be covered in matching leather. I also drew a small diagram to illustrate some stitching detail that matches all of the seat bases, and Karen copied it perfectly.


Test fit and I'm happy. I shall tweak the inside seat bolsters slightly to provide a little more clearance for the armrest.

NB White balance is out in the above photo thanks to mobile phone camera. I keep forgetting to take my SLR when I work on the car.

The closest plastic colour trim in the Golf is black, so I've ordered some specialist trim paint from America which is colour matched to the 'Midnight Black' trim in the Fiesta. I can then build up the armrest and create a filler piece for the Focus centre console.

[Smo]

Very smart

Even my MK4 Golf didn't come with a MK4 Golf armrest!

[- Danny Boy -]

Top work! Looks brilliant.

I have always wanted an arm rest in my car. Can you make one for me?

[Minstral]

more vag parts

[Spunkymonkey]

Loving this Project!! Keep it up!!

[jonyb4]

nice work, ive been planning an arm rest for mine for a while now

did you know theres a company (among others) that make universal ones? would have been easier to make a base stand for one of them than welding and cutting that vag one


im currently bidding on a mk7 fiesta arm rest, so see how that goes

[Choosey]

Even my MK4 Golf didn't come with a MK4 Golf armrest!

Jony, 'easier' doesn't always mean better though!

Mark, have you just looked at every new car's gadget list and decided to fit them all to the Fiesta?! Looks great. What's next?!

[Excursion]

nice work, ive been planning an arm rest for mine for a while now

did you know theres a company (among others) that make universal ones? would have been easier to make a base stand for one of them than welding and cutting that vag one


im currently bidding on a mk7 fiesta arm rest, so see how that goes

I only had had one experience of an after market rest and that was fitting an 'Armster' model to my Mum's new Corsa when she got it, and none of us were that impressed with it. They are too flimsy. The requirements for Armster are no doubt easy fitment with minimal disturbance to existing trim, which is fair enough, but for me I want something sturdy. I can grab hold of the Golf armrest base and shake the whole car from side to side without flexing the mount

[Excursion]

Even my MK4 Golf didn't come with a MK4 Golf armrest!

Jony, 'easier' doesn't always mean better though!

Mark, have you just looked at every new car's gadget list and decided to fit them all to the Fiesta?! Looks great. What's next?!

Would love the radar guided cruise control and massaging seats from my CLK, but that would be going to far

[Rhinopower]

Clk your currant daily drive?

[Excursion]

Clk your currant daily drive?

Yes mate, on my second one now.

[AW0L]

Would love the radar guided cruise control and massaging seats from my CLK, but that would be going to far

who said??? do it man!!!!!! lol

looks awesome Mark, cant wait to see more updates

[Excursion]

A few more things ticked off the list:

Focus Centre Console
The used console I'd been using for mock up had picked up a few marks, so now I'm happy with the fit I purchased a new one.


I ordered this white multiplug from Vehicle Wiring Products and fitted it in line with the parking sensor display loom, so I can disconnect the display in future without the need to disturb the rest of the loom, most of which runs under the carpet.


Handbrake
The Focus console sweeps up towards the gear lever and meant that the Fiesta handbrake rest position was too low and let the lever hit the console. I'm now using a Focus handbrake which is shaped to suit, but obviously there are differences in the Fiesta and Floor pan so it still doesn't sit perfectly. To correct this I added a screw to the handbrake lever so I could fine tune the rest position.


Console fitted,lever adjusted, and gear lever surround trim temporarily fitted. The surround trim is black at the moment but that will change.


Armrest Mounting
I made use of the handbrake to create the front armrest fixing point as the shell under the handbrake mounts is already suitably reinforced. I welded a raised stud on to the rear of the handbrake (top) to achieve this. In the foreground is the reinforcement plate I made to fix under the exhaust tunnel in order to provide captive fittings for the other two armrest mounting points.


Armrest bracket mounted. I can't provoke any flex in the bracket or shell using my hands, so I'm pleased.


I mounted the armrest so that the bracket protruded out from the rear cup holder mount in the Focus console. I've trimmed the rubber cup holder insert to fit perfectly around the bracket.


All that remained was to bridge the gap between the Golf armrest shroud and the Focus console. To achieve this I cut up some Kitchen extractor fan ducting and bonded it to the Golf trim. Once it's dry I can trim to suit and paint to match the Fiesta trim colour.


Lexus IS200 Door Loom Gaiter
Here's the additional door gaiter in place (top) for which I added to house the new speaker cables. There was a spare blanking plug in the A Pillar which I made use of on the car side, I used a Dremel to remove the centre of the plug and then bonded the Lexus gaiter to the end of that. SMS made the corresponding hole in the doors whilst the car was with them for paint.


The gaiters have a slight overhang on the inside which means cables are kept clear of the Fiesta's secondary inner door skin.


Door Misc
Door lock position sensors fitted. These are for the deadlock and alarm system.


New door lock shields/window runners were then fitted in place and sealed with Sikaflex 221. I sprayed these with Dinitrol once fitted as they have a tendency to collect moisture and rust.


The last of the cable clips fitted to the doors, and also the mounting brackets for the door cards. I'm waiting on another delivery of vibration damping for the inner door frame and then the door cards can finally go on.

[Choosey]

Even my MK4 Golf didn't come with a MK4 Golf armrest!

Jony, 'easier' doesn't always mean better though!

Mark, have you just looked at every new car's gadget list and decided to fit them all to the Fiesta?! Looks great. What's next?!

Would love the radar guided cruise control and massaging seats from my CLK, but that would be going to far

Fit them. Nuff said.

[jonyb4]

Top work again mark loving the work here

i get you on the universal arm rests, plastic mounts are gonna be very flexible compared to alloy