fiestaturbo.com

[jonosi]

gona be one hell of a minty Si when complete

dont spose you'd wana swap with mine when your finished

[Excursion]

Thanks chaps!

The inner arches were from my local bodyshop supplier, they are pattern parts.

Part of the Mk3's deisgn which I find absurd is the sunroof drain locations - why drain water into the most vulnerable area of the car, where 3 sheets of metal are spot welded? I have run each drain out and clear of the sills:


Panel alignment:


O/S now complete:


I got this far on the N/S:

[Max M4X WW]

Swift progress and looking great!

[MattPym]

Fantastic work you are doing on this.....Wish i could do this to my own....maybe someday

[Sphinx]

I've run out of positive things to say about your projects so I shall resort to fruit:

Pear

One more thing, are you using the copper grease as some kind of weld through primer?! Looks like you've protected everything with it and then needed to weld bits.

[Excursion]

Cheers again.

Tom - anything on a welded seam is Copper based weld-through primer. Any seams that are left alone have copper grease on them. If you look hard you can seea slight colour difference.

[Sphinx]

Ah gotcha! Good thinking batman.
How are you finding the weld through primer? I tried with some and it wasn't pretty but I would definitely want something like it in the seams.

[Excursion]

Ah gotcha! Good thinking batman.
How are you finding the weld through primer? I tried with some and it wasn't pretty but I would definitely want something like it in the seams.

It does affect the weld a little, especially if you'e welding thin material and need to keep the heat down. If there's a nice thick seam then the weld pool is usually hot enough to burn it off before you reach it - then it's fine.

To be fair it's designed for spot welding

[jonyb4]

im a bit confused to what this weld through primer is actually for

ive been doing welding for a bit now privately and done a course in college but never really heard of it untill recently on here

[jayrs]

its primer with metal in it mate, you spray it over the edges of stuff you have removed then when you clamp the new panel in place and put a spot welder on it, the metal in the primer allows the current to flow through it (as if it wasnt there) and thus creates a weld.
fot normal welding its not really needed and wont work in the same way, but..., it stays in the joints so it serves its purpose of protecting the bare metal between the welds.

if your welding something else like patching a sill or $hit like that theres no point using it really

[jonyb4]

ah right so aswell as serving as an electrical bridge it helps protect the metal from corrosion

cheers jay clears it up nicely

ever considered tutoring?

[jimmyesh]

Awesome work

[RS rob]

whats news on this then mark?

[Excursion]

Headed back this weekend, time is so short these days!

I had repaired my back panel but decided to order a Mk5 back panel and reinforcement, just in case there's anything hidden in the seams. This weekend should see the outer panel work finished once and for all, and maybe see the application of some primer!

I now have a Puma dash and A/C Airbox, and I'm keeping my eye out for a low mileage Escort Zetec engine from which I will take A/C pump & brackets/Alt/Pas pump arrangement (front cross member will be modified slightly for this). XRSi is cutting out a Mk5 Bulkhead for me so I can fit the Puma dashboard correctly.

I have these sitting on my desk today:


Mk4/Mk5/Puma (Fiesta DX) front strut top inserts. I'm going to drill out the Mk3 turret inserts and weld these in, front and rear (xrsi is cutting out the rear turret inserts from the same ZS as these aren't available separately from Ford). The strut tops are a massive weak point on the Mk3 - even Poly bushes can only limit the amount of deflection so much; I had considered comissioning a pair of machined cups to fit around the base of the front mounts when fitted, to prevent deflection, but even then the car would be compromised. The Mk4/5 tops are superb so will give be a quieter ride and much less geometry change. I'll be running Sport Ka front hubs (I'm fitting ABS), and Zetec-S struts.

I'm also waiting for an equal length drive shaft from a ZS, to further improve handling.

I have a full Zetec-S loom that I got from a year old car back in '02 - this was destined for the 'quattro' car but obviously no longer required! I will fit this to get remote locking and the A/C wiring (which is easy enough to wire up anyway) and switchable ABS/TC. I have a spare EECV ECU from which I'm going to chop off the connector and make a plug and play EECV-EECIV connector lead so I can leave the ZS loom largely standard.

As my 2.0 EECIV ECU is from a Mondeo it already runs code for ECU-based control of two primary cooling fans and 1 A/C fan. The ZS loom has this wiring present which will save me time! In the engine bay, I'll modify the (all black) plug-in engine loom to suit the Zetec-E. This way I maintain the main EECV wiring so I can plug in a standard ZS engine loom whenever I want in order to fit a Mk1 Focus RS Engine and run it from EECV with relative ease.

EECV PATS is internal, so PATS wiring will be removed from my Si loom and integrated into the ZS loom. I already have the matching key for the ZS GEM so the remote locking works, and I had a key blank cut to match the Si. I've yet to see if the Mk3 PATS Key transceiver fits inside a Mk5 remote locking key, but I don't anticipate any big headaches.

[RS rob]

epic plans ahead then mark,
i was thinking of ka hubs for traction control etc etc


sorry to hijack
you ever done a power steering to manual conversion?
i think i'm missing something and its been quite a few months since i stripped the shell

[Excursion]

epic plans ahead then mark,
i was thinking of ka hubs for traction control etc etc


sorry to hijack
you ever done a power steering to manual conversion?
i think i'm missing something and its been quite a few months since i stripped the shell

From what I remember, the differences are:

Steering column & UJ,
Lower bulkhead grommet,
Mounting bolts,
Rack,
Lower arms

[THEHOG~]

wow I thought mine was striped lol

mega plans mate looking good so far mate

[jonyb4]

the column and uj joint are deffo different, had to swap mine when i converted the mk4 to pas

good plans mark, dunno if your just after them with an engine to have a spare engine, but i have the a/c pump brackets and pas pump off a mk6 escort zetec if your interested

[Sphinx]

Strawberry

[Max M4X WW]

Lower bulkhead grommet

I need one of those lol

[jonyb4]

Strawberry

still naming fruit to cover your loss of words?

[RS rob]

epic plans ahead then mark,
i was thinking of ka hubs for traction control etc etc


sorry to hijack
you ever done a power steering to manual conversion?
i think i'm missing something and its been quite a few months since i stripped the shell

From what I remember, the differences are:

Steering column & UJ,
Lower bulkhead grommet,
Mounting bolts,
Rack,
Lower arms

yeah i've got that list of bits,

any chance you got pictures of a manual rack in place from both sides of the bulkhead?

[Excursion]

epic plans ahead then mark,
i was thinking of ka hubs for traction control etc etc


sorry to hijack
you ever done a power steering to manual conversion?
i think i'm missing something and its been quite a few months since i stripped the shell

From what I remember, the differences are:

Steering column & UJ,
Lower bulkhead grommet,
Mounting bolts,
Rack,
Lower arms

yeah i've got that list of bits,

any chance you got pictures of a manual rack in place from both sides of the bulkhead?

Sorry mate, I've not done much the manual racks

[Excursion]

I have taken 2x Mk3.5 looms and 1x Mk5 Fiesta Zetec-S loom with me back to London so I can work on them in the evening.

I'm gathering some information to make adapter plugs for the ZS loom. As a recap, I'm going to run the ZS loom and make an adapter block to join the ZS EECV connector on the car loom directly to a 2.0 EEC-IV ECU from a Mk1 Mondeo (to run a 2.0 Silver Top Zetec-E). I think this will be a nice and neat way of running the ZS loom in a Mk3.

Non-ECU Connections on the ZS car loom that I need to change to suit the Mk3 chassis are:

• Headlamp connectors,
• Add separate front indicator connector connectors,
• Tailgate release button connector,
• Engine Cooling fan connector,
• Change position of screen wash pump connector,
• Add low-screenwash sensor
• Modify the ABS/Traction Control relay feed wire to be switched from the cockpit.
• I will use a Mk5 interior light, steering wheel and column stalks as they are all different to the Mk3.

ECU Connections on the ZS engine loom:

• Looking at wiring diagrams today I've found that pin 17 on the EEC-IV ECU (which goes to the STAR DCL Connector on the Mk3) can be used as a MIL/Check Engine Light, which is great - I will join EECIV Pin 17 to pin 36 on the EECV connector, which runs to a MIL in the ZS instrument cluster.
• The only additional sensors used by the ZS are knock, cylinder head temp, and a second (post-cat) 02 sensor. None of these are used by EECIV in the UK Mondeo application, so I won't need to bridge these to the EECIV ECU.
• The Mk3 uses a simple thermostatic switch in the radiator (we all know the cylindrical 2 pin fan switch), whereas newer models use the ECU to intelligently control the fan for a number of reasons (faster warm up, better fuel economy etc.). As my 2.0 EECIV ECU is from a Mondeo it already runs code for ECU-based control of a cooling fan. EECIV pinouts are:
  EECIV pin 13 - Cooling Fan relay - EECV pin 13
  EECIV pin 31 - High Speed Colling Fan relay - EECV pin 31
  EECIV pin 54 - A/C WOT Relay (cuts out the compressor during WOT conditions) - EECV pin 54

You can see that the Ford engineers kept some pins the same between EECIV and EECV for historical & ease-of-service reasons!

[jonyb4]

you sre very thorough mark

[Excursion]

I had a quick look at the ZS loom last night.

Loom overview: 2002 Mk5 Fiesta 1.6 Zetec-S
Spec:

• ABS
• Air Conditioning
• Air Recirculation
• Deadlock Central Locking
• Door ajar warning
• Electric Mirrors
• Ford Alarm
• Front Fog Lights
• Headlamp Range Adjustment
• Heated Front Screen
• Low Screenwash warning
• Passenger Airbag
• Remote Locking and Tailgate release (RF)
• Seatbelt pre-tensioners
• Tailgate Release
• Traction Control

Front Indicators - These are in fact on a separate connector to the headlamps and use the same AMP Junior Timer Housing type connector as the Mk3, so are a straight swap.

Headlamps - The ZS headlamp connector is completely different to the Mk3 and incorporates 3 wires for the headlamp range adjustment motor. I dismantled a scrap Mk5 headlamp and found that the headlamps internal loom forms a perfect adapter loom to go from the ZS headlamp multiplug to a H4 main bulb, a W5W sidelight bulb and separate 3 pin plug for the adjustment motor. I will purchase some Mk3 motorised LHD headlamps from German eBay, and swap the front glass for a RHD version to leave me with fully-operative MK3 range adjustment headlamps.

Heated Screen - This is the same setup as Mk3/3.5 - the screen loom plugs in underneath the dash.

MAF - This is part of the 'main' loom and uses the 'next generation' all plastic style multiplug rather than the old Junior Timer Housing. I don't want to cut any of the main loom so I'm going to swap my MAF for either a 1.7 Puma or Focus/Mondeo 2.0 Series 3 Zetec MAF.

IAT - Part of the main ZS loom. EECIV uses only ACT, so IAT isn't required for the Series 1 Zetec. I will fit the sensor to my Air box for neatness.

Front and Rear 02 Sensors - These are part of the main ZS Loom and use a newer Cylindrical female multiplugs, so I will solder a ZS male multiplug to the Mondeo 02 sensor. The rear 02 sensor isn't used in the UK Mk1 Mondeo so will remain disconnected.

ABS/Traction Control - The Mk1 Mondeo had this as an option, and used the same style switch as the Mk5 tailgate release (like the Mk3 Electric Window switch). The Mondeo switch is now discontinued but I have bought one from a breakers:

I got the multiplug and some wiring with it. I will wire this to a latching relay to control power to the ABS/TC module.

The remainder of the engine sensor plugs are split between two separate sub looms which can be disconnected from the main ZS loom. Most connections are by the next-generation all-plastic style connectors which weren't used on the Mk3 Fiesta. The Mk1 Mondeo did however use them, so I have the option of replacing all of my current sensors with either Mk1/2 Mondeo or Mk1 Focus sensors, which would enable me to keep the ZS engine loom standard.

PATS, and fitment of an Ice warning/outside temperature display clock will be my next areas of attention.

[STOKE7UP]

Mark I have a gen ford NOS bulkhead mk5/puma if XRSI isnt usccesful

Alex
stoke7up@yahoo.co.uk

[Excursion]

Mark I have a gen ford NOS bulkhead mk5/puma if XRSI isnt usccesful

Alex
stoke7up@yahoo.co.uk

Nice one! Emailed.

[jonyb4]

your know how amases me mate, im excited to see the outcome of this Si

[Excursion]

Thanks Jon

Thanks to STOKE7UP I will now have a Genuine Ford Mk4/5 upper Bulkhead panel, so I can correctly fit the Puma dash, wiring and heater box/pollen filter.

I changed my mind regarding the centre console layout - I was planning to use a Midnight Black (phase 2) Mk5 console and mounting the Mondeo TC button above the Mk5 tailgate release button. I'm no longer going down this route and instead I just bought a complete ST170 centre console with TC and heated seat buttons, along with an additional Focus gear gaitor for the ib5 type gearboxes (non lift-up reverse).

[jonyb4]

ahh that will look good

i noticed the lift up reverse in a mk2 mondeo GLX in a yard, was a bit suprised

[Excursion]

ahh that will look good

i noticed the lift up reverse in a mk2 mondeo GLX in a yard, was a bit suprised

Yeah, I think most of the Mk2's had the MTX75.

[Excursion]

Thanks to tompetRS for some Focus Mk1/1.5 wiring diagrams.

xrsi has taken some pics of the parts that I'm buying from him.

Mk5 rear turrets:

ABS/TC module

Equal length drive shaft:

ZS brake servo, brake pedal and link bar - I have a suspicion that the Pedal ratio is higher in the Mk5:

I also bought these last week, from a Mk1 Focus:


I'm going to fit Cruise Control. I'm pretty sure I can get the cruise control buttons mounted to the Mk3.5 steering wheel and end up with it all looking OEM. The only challenge will be the lack of contacts on the Fiesta slip ring/clock spring. I will either double up the standard clock spring ribbon, or modify a Focus one somehow.

My temp clock:

I'll be back this weekend to carry on with it.

[Rhinopower]

Are you converting to drive-bi-wire for the cruise control or is it a different system used?

[jonyb4]

for drive by wire, the mk6 duratecs is probs the best resource