fiestaturbo.com

[HCS PIMP]

http://www.ebay.co.uk/itm/REAR-DEMISTER ... 2a199fd92f

[Excursion]

Thanks guys for the suggestions. I will look into it this week.

[andymac]

I doubt very much that solder or paint will stand any amount of abrasion.

It might be better to find some helpful soul with a mill who'll CNC you a new board up. If it's ONLY double sided, it might be possible to scan and trace the existing tracks then trace them out on a small milling machine.

[DanFraser]

The rollers leave a large footprint between each side don't they? Why not connect there?

[andymac]

Because a seamless transition is ideally required - dip function will become "bulb on" as opposed to "dip filament". As the roller traverses the track it's likely there will be a moment where the bulb supply will cut; this is only for a minute amount of time but will do no favours for the longevity of the bulb in the longer term and replacement HID bulbs & ballasts are not inexpensive.

[jonyb4]

whoa double negetives!

[Excursion]

Focus RS gear lever mechanism (short throw) fitted to Rivnuts in the floor pan. I had previously welded up the original shifter mounting aperture.
Front left to right: Airbag module from a 2002 Fiesta, gear change cables and weatherproof grommet, new mounting studs for the Mk4/Mk5 Dashboard, original circular bung for automatic gearbox models, Focus RS linkage and brand new cables. It all just about fits in the centre console area!


Top left is the steering rack universal joint weather seal I'm using from a later Fiesta, and top right is the rack to bulkhead reinforcement straps I'm using which have come back from being shot blasted and powder coated.
Bottom: New Street Ka/Sport Ka steering rack. To recap this is identical to the original rack at 2.4 turns lock-to-lock, only it is solidly mounted for improved feel and the track rods are +10mm.


Bulkhead sound deadening mat fitted, upper and lower sections of the new weather shroud/seal fitted using stainless fixings, and the rack itself in place.


Brake servo brackets fresh back from powder coating. I'm rebuilding everything with brand new parts.


Here's the new Evo X servo mounted, and detail of the hydraulic clutch pipe and mount on the servo bracket. The clutch line is from a Racing Puma and I bent it to fit.


Everything in situ. Please ignore the dirty wheels and suspension components as all that will be replaced in due course. I slid the wrapping over the RS cables to prevent dirt getting to the ball joints.



Focus RS Gearbox mount fitted. It's clear in this photo how far the top of the Evo brake fluid reservoir protrudes from the master cylinder. I'm going to cut this down and plastic weld the cap on a little lower.


During the last few months of Mk5 Fiesta production seat airbags became an option on some models and I've been fortunate enough to track down an undeployed module,the two Bosch side impact sensors for the seats and the loom which is plug and play with my interior loom. The period Recaro’s I've sent for trimming do not actually have seat airbags but I'm still making up my mind if the Recaro CS would suit the car, and if I go that way, I would want functional seat airbags.


I have also picked up a couple of Bosch Parkpilot systems with sensors, one of which comes with a late Ford spec loom. I will install a kit on the rear.

[jonyb4]

more mind blowing attention to detail and clever little mods that will have big effects in the end!

love it mark, was going to say that reservoir was tall but knew that would be covered


im eager for more!

[Dave G fsi]

Excellent fabrication/work there Mark

[RS EDDIE]

Cant put it into words mate....Gobsmacked!!!!!

[SEG1]

nice work mate
so is that the ka servo brackets? its looks like the servo is closer to the bulkhead

[Minstral]

recaro cs's are awesome but would they fit in the mk3? they are pretty big

[jonyb4]

i wouldnt been in a corsa VXR?

they have big recaro's in and they take up far too much room in the small corsa, makes it hard to move around in and getting in the back was a nightmare

[Excursion]

Thanks all!

Seats would fit. They are a fair bit smaller than the S3 8L seats I had originally

I'm not worried about rear seat access as this will be a dry weather fun car for occasional weekend use It's doubtful anything will go in the rear seats other than some luggage when it goes on a Euro trip.

[andymac]

Seat pics? Was looking at putting mg seats in mine with "heritage" leather which matches rest of interior, but would prefer a set of recaros.

Sent from my GT-I9100 using Tapatalk

[Excursion]

S3 8L:


Sportster CS:


The S3 seats were like the rest of the car, alright to look at but performed badly! Pretty surprising for a Recaro seat but Audi obviously influenced them somehow. They've got their act together now in terms of dynamics, but the S3 was so crap!

The FRST seats are better and a hell of a lot lighter. CS are as good again.

[EUFez]

Qualifactions Mark?

[Excursion]

Qualifactions Mark?

Qualify my seat opinions? I owned an S3, FRSTs and have driven cars with the CS.

[Minstral]

if you can get CS's in an money is no object clearly, then get the CS's.
such an awesome seat

[Dave5300]

cant believe the attention to detail thats going into this, staggering! love it!

[- Danny Boy -]

I want them seats!

Good update again Mark

[jonyb4]

sod it go for the CS seats then!

[andymac]

Thanks pal, the S3 seats look (to me) remarkably like the ones fitted to the ST200 I had. That didn't provide much lateral support / grip but were comfy as hell.

Edit : No, quite different actually, the bolsters on the ST's seats looked less "lumpy" and quite a lot taller. I'd love to shoehorn a set of those ST recaros into the coupe though.

[Excursion]

Thanks pal, the S3 seats look (to me) remarkably like the ones fitted to the ST200 I had. That didn't provide much lateral support / grip but were comfy as hell.

Edit : No, quite different actually, the bolsters on the ST's seats looked less "lumpy" and quite a lot taller. I'd love to shoehorn a set of those ST recaros into the coupe though.

ST200 seats were unique to that car. The S3 seats are an improved version of the 'Sport Trend', which is in the same family as the Honda Accord Type R and the Mitsubishi Evo 4-8.

[andymac]

Really?! I'm very surprised at that as I've seen very similar seats in other motors.

Sent from my GT-I9100 using Tapatalk

[~nomad~]

CSs are wonderful seats, do it. The older S3 was lacklasture, new one is a great car imho.

[Excursion]

I have fitted an ECU bracket from a later Fiesta. I will retain the Ford ECU to control the engine fans, A/C compressor and a few other functions. I'll make use of the existing PATS immobiliser to secure power to the fuel pump and the Pectel ECU I'll use to actually run the engine.



The Mk5 heater box is now in together with the air ducts. The eagle eyed may spot that the sound deadening material around the scuttle now has a grey finish; I found out that some models had a layer of mass loaded vinyl on top of the standard underlay type material (as per the bulkhead below). This arrangement offers improved sound deadening over a layer of foam alone.


My Dad kindly helped out again by adding vibration damping material to the front floor pan and rear seat area. I ran out of pads which is shy there is a square shaped gap at the bottom of the first photo The other cut outs are for the seat mounts and handbrake.



The Mk3 Fiesta never came with a bonded windscreen and instead it used the traditional rubber seal arrangement. I'm using a bonded screen because it actually adds to the cars structure and it also looks neater, but the downside to that is the Mk3 headlining doesn't finish flush with the screen; it finishes around 10mm further back to leave room for the standard rubber weather seal. To ensure everything looks neat I had Aldridge send a strip of Alcantara which I've glued to the windscreen aperture, so when the headlining is finally fitted everything will look neat.



I bought this product from Dynamat. It's supposed to attenuate rear wave from the front midrange drivers (or in fact any speaker you place it behind). Like speaker cable choice it is a fairly subjective thing, but given that many people have said they do make a difference and they aren't expensive, I have fitted a set anyway.



New Ford heated screen bonded in.



Mk5 Fiesta pollen filter housing and new charcoal filter added.


I rebuilt the Mk3 wiper motor and linkage using new Ford parts and some of the old parts that I had Zinc plated. I have new Ford wiper arms and wipers to go on too.
It probably looks more complicated than it actually is!


These parts of the spindle usually rot away underneath the outer cosmetic cover, so I have smeared them with grease.


Mk5 heater matrix pipes and Air Con evaporator pipes. I fitted a new Ford heater control valve/solenoid, it's the latest revision which has finally cured a long standing issue with the part which can leave the HVAC either stuck on cold or hot.


I'm pleased with how the AC pipes have turned out, they look like they were meant to be there.



Even though I bought new Ford door catches I've had them re-plated in a thicker coating. They look better now.


Another add on: one touch electric window relays from a Mondeo. I will use three to provide one touch down for the two driver switches and the passenger switch.

[dontpannic]

Well done on getting the later revision part for the HCV. Having said that my "AC" revision part still had occasional issues until I dismantled it and attempted a self repair.

Like the air-con pipes, and good work with the Mondeo relays.

Nick

[SEG1]

OMG looks sick!
aircon and 500 bhp

[- Danny Boy -]

Those air con pipes look like a factory fit!

Looking good Mark

[Excursion]

Well done on getting the later revision part for the HCV. Having said that my "AC" revision part still had occasional issues until I dismantled it and attempted a self repair.

Like the air-con pipes, and good work with the Mondeo relays.

Nick

Thanks Nick! I see Ford also changed the routing of the hoses so the inlet and outlet were swapped over, hence that big curvy hose instead of the earlier L shaped hose. Do you know what the latest revision is?

Cheers

[Excursion]

OMG looks sick!
aircon and 500 bhp

bit of a squeeze

[Excursion]

Those air con pipes look like a factory fit!

Looking good Mark

Thanks mate.

[AndyKam]

Amazing, love what you are doing, you're a Fiesta God

[rsturbonutter]

Absolutely fantastic fella. This is going to be 1 of no no scrap that the best fiesta in the world unless anyone else knows otherwise. The attention to detail is second to none. I would defo be contacting ford to show them what you have done and give them a spec list to show them what could have been. Epic build and I love reading this thread. Keep up the awesome work fella