fiestaturbo.com

[dannyboy]

Excellent news mate, I used Lee and Roose aswell and feel the same, top guys and top products. Chrome gets the thumbs up from me

[heeman10]

Andy - The badge will certainly be going, for what...I'm not sure yet...

danny - That's one person that likes it then!

I know I'm doing a stupid number of updates, but it always bugs me when people do fairly big projects and we don't see much apart from the finished article. On top of that, it lets me feel I've achieved something!

The mad dash didn't go so well. My dad kindly cooked dinner, but at a crucial light fading point, so all the light went while we were eating. As the car's outside, I don't have the lights of the garage to work in, so I've had to stop early. I wanted to get as far as getting the intercooler and bumper on, but the light just wasn't there. Got a few things done:

Turbo, actuator etc all bolted in and plumbed in:



Radiator in and plumbed in at the bottom:



Engine bay looking more like an engine bay:



Intercooler with fan wiring complete for now. I don't have any good enough 2-pin multiplugs, so I'll have to make do with a "2 in, 2 out" type connector block till I have one. Note the fans are now wired onto the cooler with locking wire, as opposed to using the ugly black block fasteners:





They're hardly noticeable from the front at all, and the fans are solidly mounted

Came in cos this was all I could see!



I'll be up early tomorrow to bolt the cooler and bumper on, plumb in the final few bits of coolant and breather system then get out on the road. Had a panic today when the brake pedal went right to the floor. A bit of careful nipping where the hose meets the caliper did the trick (it's very easy to over-tighten into aluminium, hence the extreme care!), and they're re-bled and solid as anything now

Bed time

[MAD_Adamski]

looking ace james good lad not too sure bout the wire on the fans tho .... but the proof is in the pudding as they say

know you and few others are moaning at me so just to let you know i'm starting my engine v v soon after my hols so watch this space

[Xr_Dub]

WOW james

nearly there

need to get a move on with my engine!

[heeman10]

Ad - What do you mean about the wiring? The connector block? It'll do the trick for now, I can get a suitable plug for it before too long Very glad to hear the engine's under way now...feel free to tell me what you're going for via PM

Mr. Unit - There's nothing like seeing someone else cracking on to get you shifting your own work along is there?

It rained last night, I KNEW I should've put it in the garage!! Time to get to work anyhoo

[StreetDragster]

Looking good James, i've not checked this post in a while, progress is outstanding. What bottom boost hose are you using?

Is it MOT'ed now then?

Thanks

Matt

[RS_Rawli]

good luck jimbo

[MAD_Adamski]

Ad - What do you mean about the wiring? The connector block? It'll do the trick for now, I can get a suitable plug for it before too long Very glad to hear the engine's under way now...feel free to tell me what you're going for via PM

i meant holding the fans on i'd be worried it may damage the core??? and i'll catch you on msn on day and let you know the score on the engine

[andyhardy]

Ad - What do you mean about the wiring? The connector block? It'll do the trick for now, I can get a suitable plug for it before too long Very glad to hear the engine's under way now...feel free to tell me what you're going for via PM

i meant holding the fans on i'd be worried it may damage the core??? and i'll catch you on msn on day and let you know the score on the engine

No worse than radiator pins which is how alot of intercoolers with fans expect you to mount them! (it's a very old method - one that I don't like very much!)

[heeman10]

Matt - Thanks Bottom hoses: reducer from pump diameter to about 38mm I think....pipe reducer from 38mm to 34mm with a 45 degree bend, then 90 degree 34mm hose from bottom of rad up to the metal pipe.

Rawli - Need lots of that

Ad - There are four wires per fan, and the fans don't weight much. As Andy says, you're usuall expected just to use pin kind of things anyway, same thing, if not better and kinder


Update:

I finished it, bar one or two things (two exhaust clamps, a bolt in left lower arm, plumn breather hoses in and tidy interior) but have issues with the fans, as my post in general says. It's getting close on the "N" of "NORM" and the fans still haven't come on. The thermostat opened when it should, but I need those fans working. I still had the header tank cap off and it boiled over a bit. Would I need the tank cap on to pressurise enough to bring the fan switch on?

Otherwise, it sounds cool

[Rhinopower]

fan switch works on heat, but if its not in right place wont be getting hot enough to kick in when it should, on my 1.6si if you were standing in front of the car it was on the lower right hand side, next to the pipe where the cater goes from engine into rad next to water pump and alternator, if its not fitted there i expect will give you problems!

alternativly fit a manual switch for now

[MAD_Adamski]

ok cool well i didn't like the idea of them black thingys anyway i had alloy tabs welded on my rad and the fan is bolted on them proper job

[heeman10]

If I had room for tabs they be in there

Well, as I said in my post in the general forum, the diff in my gearbox is knackered, so the box has to come out and be sent away. I can't say I really wanted my car to be looking like this the day after I bolted it all together...

Over our pit:



Going nowhere fast



*sigh*

Trying to take a gearbox out on your own is the most impossible task ever, couldn't finish it today so will see if my dad can help for the final part of the removal tomorrow. I'm very determined to have it back in and running before the end of next week, though I'm completely drained from the last ten days!

[Captain Tightpants]

Good work mate.

Loads of red-bull usually helps! Not to mention a loud radio!

I've been up messing about with the bloody ka today too. Looking forward to getting that completed!

What were you on about Street the other night dude? Confused me?! (Not that it takes much you understand!)

Is Bernie going to rebuild your box, or are you planning on doing it yourself?

Steve

[heeman10]

Loud radio was helping a bit, till the fooking crazy frog came on DICK! There was a shoot-up in Street a couple of nights ago, quite random for such a small, quiet place

I've only ever stripped one box, and with no care whatsoever because it was there just to be ripped apart by students I know nothing about the ERST boxes, but I suppose it COULD be doable for me to put in a new diff. Is it as simple as taking the old diff out and bolting in a new one do you know? If so, then yeah I could get Bernie to send up one of their diffs and slap it in here, save a load of time and money (about 200 quid!!!!!).

Do let me know if you know enough to direct me dude, that would be a real let-off

[Captain Tightpants]

Damn, really? Deffo wasn't me! Mines locked up!!

Taken a couple apart now. It proves a little tricky. The 5th gear is a mare. You should have it apart and back together in a day though easy mate!

http://www.quantums.info/gearbox.htm May prove usefull.

Steve

[heeman10]

Cheers for the link. I'm not willing to attempt something like that as a "learning experience" when it needs to be done properly and with no risk of damage afterwards though....best left to the experts for something like this IMO. Shame, would've been nice to do it all, but like I say, not worth the risk in my mind.

[Captain Tightpants]

Deffo mate, fair enough. I've never done it on a gearbox thats running decent power in fairness.

Plus if Bernie does it, you have the added bonus of a warranty!

Steve

[heeman10]

Indeed. Gay bank holiday weekends!

[andyhardy]

Indeed. Gay bank holiday weekends!

I feel exactly the same way mate - oil pump failed on the Cabby earlier tonight and killed the engine!

Got my eye on a blueprinted 1.6 CVH lump with 6k on it going for £200 though - complete with gearbox and nearly new clutch

I didn't expect to have to be forking out for that before I set out to the FordSport pub meet this evening I can tell you - should have taken the reliable turbo out!

Good luck with it all mate - roll on Tuesday. Is there anything else you can be getting on with on the car on Monday mate? If there isn't then I'd suggest taking a break from the car - they can really get on top of you especially just sitting staring at them (or glaring in my case) when they're broken!

Cheers,

Andy

[heeman10]

Argh that's bad news Andy! Do you know exactly what's wrong with the engine? What happened exactly? Hope you can scoop up that cheapo lump

I've still got things to do to finish the interior...wire in the head unit and speakers, cigar lighter, boot release etc, soundproof rear bench a bit more then re-fit rear seats and belts, make spacers for the crossmember to clear the gearbox cradle now it's 10mm lower, all those kind of things. Was going to put the battery in the boot but the filter's actually in a fairly good place, and the chatter's certainly loud enough on 2psi without an enclosure, so I'll leave it as it is for now! I've had two lie-ins the last couple of days, which has brightened me up after the 1am bed times at 7:30 wake-ups, so I'm still not down and out...still ready to get back at it!

[heeman10]

Update

Gearbox is now out. Took about 2-3 minutes with my dad's help as I'd readied it all yesterday. He told me yesterday/today that a friend of his used a guy near us (about 25 miles away max) to build the gearbox for his Caterham....and he builds Quaife boxes and diffs for rally cars!! :D:D So I can get his number tomorrow and start talking business. Could I possibly have it done by the weekend?

These pics show the state of the brand new washers supplied with my Deflex gearbox mounts. The bolt passes through the gearbox cradle, through the mount, through this washer then tightens on top with a nut. So tightening the nut has caused the washer to look like this:





Not good! Will email these pics to Deflex and see what they think. Looks like a case of cheap materials being used to me...and they haven't taken any abuse yet!

[FezzR]

do they supply any tightening torques for them? oh so easy to over tighten things.

good to see your still cracking on with it

[heeman10]

No torques supplied. I didn't over-tighten them Ian, plus gearbox mounts should be able to take huge torques, and I wouldn't expect any mount to deform this badly just on tightening. Because of the washer deforming so much, the nuts on both mounts had loosened off. Deflex are sending out more sturdy washers that can deal with the job they're supposed to carry out.

[FezzR]

No torques supplied.

theres a suprise

I didn't over-tighten them Ian,

i didnt say that but i admit you could have read into it that way

plus gearbox mounts should be able to take huge torques,

technically that comment isnt correct but i know what you mean and yeah

I wouldn't expect any mount to deform this badly just on tightening. Because of the washer deforming so much,

completely agree that the washer doing that is very badly designed

the nuts on both mounts had loosened off.

that would indicate to me the washers deformed under load as if it was due to the washers deflecting under tightening then it would still be tight

Deflex are sending out more sturdy washers that can deal with the job they're supposed to carry out.

glad to hear it


and weather you do/did over tighten things or not (which obviously i have no idea either way) it is very easy to do, and i do it so i should know hense my extensive use of a torque wrench

[heeman10]

How on earth do you word your replies in such a way? Your wording's just a red rag to me, I'm sure it's not intentional though. I go with your comment about them deforming with the minor loads they've been given so far (like I say, no more than 2psi boost yet, and nothing like full throttle) as opposed to deforming under tightening. The mounts should take a good amount of tightening, as they cannot afford to have any free play in them when in use. I'll see what the next pair of washers are like and hope they're suitable.

I found someone else (the guy who did my exhaust and has done a great deal of work on lots of rally cars and motorsport cars) to sort my gearbox out. He will strip it tomorrow morning and I'll see where things stand tomorrow afternoon. Looks like I'll have the box ready to go again by the weekend though, which would help tremendously.

[FezzR]

i dont know mate but i seem to manage it rather well,

i still dont 100% agree on gearbox mounts needing to be very tight, as the loading under tightening is on a different plane to that excerted by the gearbox, hense why you can rip a perfectly serviceable engine mount in half by over tightening it (ive done that too was a long time ago tho )

[RS_Rawli]

i dont know mate but i seem to manage it rather well,

i still dont 100% agree on gearbox mounts needing to be very tight, as the loading under tightening is on a different plane to that excerted by the gearbox, hense why you can rip a perfectly serviceable engine mount in half by over tightening it (ive done that too was a long time ago tho )

just to clarify these are conventional mounts

there is a big bolt going thro the mount and the mount is just a rubber block with a hole through it

[FezzR]

i dont know mate but i seem to manage it rather well,

i still dont 100% agree on gearbox mounts needing to be very tight, as the loading under tightening is on a different plane to that excerted by the gearbox, hense why you can rip a perfectly serviceable engine mount in half by over tightening it (ive done that too was a long time ago tho )

just to clarify these are conventional mounts

there is a big bolt going thro the mount and the mount is just a rubber block with a hole through it

that just makes it easier to overtighten
and thinking about it and force pulling the mount apart so to speak would only act apon the washers and not the mount as such

[heeman10]

Well, over three weeks since the last update, it's thread revival time!

The last jobs to do before the gearbox involved some major machinery. Cleaned the front and rear windows and applied a sticker in each FT stickers at the back, Clifford ones up front



It's good to have the FT stickers back, they just give a bit of a feel of completion if you ignore the front end of the car!

The coolant temperature sender on the thermostat housing needed swapping for a CVH temp sender instead of the Zetec item, which I had completely forgotten. I adapted the loom to fit the Zetec sender rather than swapping and adapting the sender to fit the Fiesta loom So this might have been giving me incorrect temps on the clocks in the car....hopefully over-reading rather than under.

So here is the temp sender from an Escort in the scrapyard, with a washer under it for earthing purposes (the CVH sender screws into a metal thermostat housing, the Zetec thermostat housing is plastic). I soldered a wire to the washer, which will then be earthed on the battery tray:



And a pic of it in position:



My soldering iron decided to stop working, so I didn't quite complete this job, but it's only 1 minute's work to finish it.


The gearbox will be arriving from CTS tomorrow morning, but my parents are out all day so I'll just have to look at it till Sunday. So I'll be building all the front end back up again on Sunday, then it's time to rock and roll again! First job will have to be to wash it, as it's 11 months since it was washed!!!! Unbelieeevable! Then I'll check over everything for the MOT, and get that in either on Monday or Tuesday :D

[MAD_Adamski]

poof!!!!!!!! na good job james i long for the time when i get to fiddle with this sort of stuff

[Captain Tightpants]

Gearbox here mate?

Steve

[heeman10]

Yeah, pics in General Will stick a couple in here, just for the record!

[Captain Tightpants]

Eyyyyyyyyyyyyyy!!

Steve

[heeman10]

Eyyyyyyyyyyyyyyyy!