fiestaturbo.com

by **heeman10** on Thu Jul 20, 2006 12:17 pm

FezzR - As I say, the system I have (Armtech) holds the engine speed wherever it was when the clutch was pressed. So if I rev to 5,750 and press the clutch to shift up, I keep my foot flat on the throttle and the revs will hold at 5,750 on a spark cut limiter. The first two gear changes are taking me quite a while, but no more than a second. More expensive engine management systems do allow specific "secondary" rev limiters when flat-shifting's being used, yes.

My main "fear" is that exhaust gas temps will be elevated when using the limiter/flat shift function/launch control, something my pistons wouldn't enjoy for prolonged periods of time. Using a spark cut limiter means the fuel passes through the chamber largely unburnt, then ignites in the exhaust manifold/turbo, hence the pops and bangs. If I make use of it all too much the heat would back up to the cylinder, and get the turbo a bit hot, but as I say, we're talking less than a second each time

Launch control is a different matter. The speed used for launching is set by pressing a button and holding it, then bringing the revs up to where you want them held during launch. Once set, when you come to launch, the button is held in, and the throttle floored. It limits the engine speed to your preset limit (using spark cut, as above) until you release the button. That way, I can practise starts over and over, and find the optimum engine speed for launching. Consistency's key in launching, so being able to keep the throttle planted with controlled revs ought to help. It's tricky not to use too much throttle and just spin, or too little throttle and have no boost pressure when it grips. So the ideal compromise is enough revs/boost to pull away cleanly without bogging down, and being at the beginning of the boost curve when it finds full traction. Hence the launch control switch I now have!

gary - The brakes are now sitting next to the car, turned up this morning

Huge thanks to lockesRSparts, extremely fast service, top notch!

Will get stuck into them after lunch.

Bit of a hold-up with the braided lines I wanted to run to the master cylinder. Because the Fiesta pipes don't line up, I was going to cut all four original pipes back to the inner wing, then run braided hoses from there up to the master cylinder. Lee@Fusion's just come back with the price for the hoses and fittings - £70+, so I'll do it the cheaper way. Brake pipe flaring tool will be on its way shortly, plus some brake pipe, and Lee will send the necessary fittings for me to make up the pipes myself. I can make it look neat for much less than the braided setup, plus braided lines up there tend to look a bit spaghetti-junctionish anyway!

by **FezzR** on Thu Jul 20, 2006 1:22 pm

you should get a certain amount of cooling from the unburnt fuel though weather that is enough or not is a different matter.

ive never seen the fasination with running full length braided hose, as surely your going to get more flex(ballooning) from braided hose than from solid pipe

by **heeman10** on Thu Jul 20, 2006 2:35 pm

Unburnt fuel igniting in the turbo won't help keep it cool that's for sure! The only braided hose I was going to run was from the hard pipes at the inner wing up to the master cylinder, to give me the necessary flex. You must read things better Ian! :lol:

by **MAD_Adamski** on Thu Jul 20, 2006 2:44 pm

does this mean i get to paste you on the 0-60 now at ford fair??? with my stg2+ bernie box

if i have around the 200-230 mark i should have a chance as you can't change gears for any number of sheep in the world

...

by **heeman10** on Thu Jul 20, 2006 4:08 pm

It certainly does mean you have a good chance, yes! The weight of these RS2000 brakes is unbelievable!

One of the flexi hoses has snapped at the caliper (though thankfully some careful teasing got it out without shearing it off in the caliper body). Also they're rather tatty, as you'd expect, so need tidying up before they're fitted to the car. I'll be waiting 3-5 days for my brake pipe flaring tool anyway, so can spare a leeeedle bit of time anyway. Will put some pics up tonight

by **MAD_Adamski** on Thu Jul 20, 2006 5:00 pm

good man james

keep it up and get it done for FF and get pics up you queen

by **FezzR** on Thu Jul 20, 2006 5:38 pm

im a s**t reader, or just lazy

you said you were worried about piston temperature, and petrol in the combustion chamber will have a cooling effect! i can think of better fluids to inject to keep it cool but we wont go there. This is one of the reasons ignition is cut instead of fuel, as if fuel was cut you would end up with a very lean mix (probably only for one or two cycles) with left over combustables being ignited rocketing the temps throught the roof.

(now tell me youve already said that and i havent read it)

by **heeman10** on Thu Jul 20, 2006 8:45 pm

Ian - If fuel is cut, there is no mixture to burn. Granted, there may be remnants of the previous cycle or two, but if no fuel is injected, no power is produced and air is just being compressed and exhausted. Cutting spark alone allows detonation to occur over and over, and exhaust gas temps to go crazy high.

Ad - Pics below you festering pussball

RS2000 setup on the right, Fiesta setup on the left, with the external drum above:

RS2000 brakes stripped a little, showing the fat new pads and shoes:

One of the calipers, painted in some weird enamel that looks as though it'd be more at home on an Edwardian dressing table :-?

Note the fairly new disc, covered in surface rust:

And as is customary now, as soon as something turns up for me in a box...RIP IT TO BITS!! :lol:

Although I'm in a hurry to get the car back into a state where it can be driven, I didn't want to bolt the brakes on in the condition they were in (albeit good for such components). So, I wire brushed the disc off, hastily masked it up and sprayed it Ford Moondust Silver:

Backing plate was skanky as well, and another rush job of primer and gloss black tidied it up a little. Not much of the backing plate is visible from the exterior, so I didn't take too much time or care:

The Fiesta drum on the right, and the RS2000 disc (comprising internal drum brake for the handbrake) on the left. The diameters of the two are about the same (if not identical):

It's the external disc that sets the two apart, and is clearly of a greater diameter:

The right hand setup is re-assembled minus the caliper, as both calipers have received a couple of coats of black to match the Wilwoods up front. Again, a rush job, painting on top of the old enamel, as I just need it all looking presentable then bolted onto the car. I know there are a few niggles yet to overcome, but I'll remove the right hand drum tomorrow, freshen up the left hand RS2000 assembly and see where that lot leaves me

by **rich_frst** on Thu Jul 20, 2006 8:50 pm

looking good fella

by **MAD_Adamski** on Thu Jul 20, 2006 11:12 pm

looks smart :aviator:

wish my car was this easy :rolleyes:

i got soooooooo much to do :oooh:

by **MarkRS2K** on Fri Jul 21, 2006 2:17 pm

good stuff mate, hows the bumper coming along?

by **alti** on Fri Jul 21, 2006 2:51 pm

looks really nice!

I plan the also the rs2000 rear disc change
which brakehoses and handbrake kabel do you use?
can you leave the large mk3 master cyl.?

thanks alti

by **heeman10** on Fri Jul 21, 2006 5:37 pm

Ad - What do you mean? We both have Mk3 Fiestas! WTF? :lol:

Weirdo

Mark - The bumper's coming along slowly, and causing some frustration. Even with reduced amounts of hardener the filler's going off to quickly, meaning I have about 2 minutes of work time before it starts hardening up and dragging along the surfaces instead of sweeping along and filling holes. It then makes air bubbles and scuffs that, when sanded down, need ANOTHER skim of filler, which then needs sanding and once again scuffs up and needs doing again. You can probably see why I've been focussing on the brakes for the moment! :lol:

I don't love it when a plan doesn't come together!

alti - I'm in the process of fitting the handbrake cable at the moment - please read below

I wouldn't advise leaving the standard Fiesta master cylinder in, whether you have the bigger one or not. With discs at the back and uprated from calipers I can't see there being enough travel, plus a long pedal is such a nuisance and gives terrible feel.

Update

I removed the passanger side drum this afternoon (much easier than the driver's side), and again found completely toasted brake shoes, which I'm happy about really - means I'll get a big improvement when the RS2000 stuff's on

The Fiesta and RS2000 handbrake cable ends differ, in that the Fiesta uses a small nipple to retain it inside the drum, and the RS2000 uses a hook and eye to retain it on the outside of the brake assembly. For this reason, the RS2000 cable is used in this conversion.

Handbrake cable removed from the car, lying next to the RS2000 handbrake cable:

The equaliser on the RS2000 is wider (and yes, more shiny) than the Fiesta counterpart, but I am going to see if the RS2000 equaliser will fit properly in the tunnel. I have the RS2000 cable on the car at the moment, but until the brakes themselves are on with the handbrake cable connected, the equaliser doesn't sit in its "rest" position, so till then I can't determine whether or not it can operate without fouling against the Fiesta's tunnel.

The handbrake primary cable exits the cabin and pulls on a clevis pin at the front of the equaliser, shown here, held in place with a small spring clip:

Offering up the passanger side brake assembly, it can be seen that the handbrake lever arm comes into contact with the Fiesta beam, stopping the assembly from fully seating onto the beam:

Removing the top left corner of the bracket face to allow clearance for the handbrake lever arm allows the assembly to sit closer to the face, but now the handbrake cable housing (a cast braket on the rear of the assembly) comes into contact with the Fiesta's flexi hose end:

As I'm no longer at uni, I don't have free access to the enormous metal stores or the same extent of machinery, so I can't machine the 5mm or so spacer plate I need to give the clearance required. I'll be calling a local laser cutting firm and Fusion Fabrication tomorrow for quotes - I suspect Fusion will be the cheaper option, as I need a pair of simple plates making up with four bolt holes, a hub nut access hole and two rivet holes. Excursion went the same way with his conversion, and precisely the same spacer plate came into mind as soon as I saw the problem. Only way to do it really folks!

A random picture of the car:

The calipers are painted and dry, so once I've sorted the contact problems with the handbrake cable at the back using spacers, things should be REASONABLY straight forward. I think I'll make up my own hard brake pipes to travel from the Fiesta's flexi hose fixing point in the rear arch up to the caliper ports.

by **rich_frst** on Fri Jul 21, 2006 5:44 pm

nice update jamms!!!

by **MAD_Adamski** on Fri Jul 21, 2006 8:16 pm

i meant your lucky your a bum and can owrk on your car all day

!!!!

i have to work my butt off and try and do things when i can effectivly 2-3 spare days till FORD FAIR :aaah:

NOT GOOD

by **heeman10** on Fri Jul 21, 2006 9:18 pm

Yeah for that I can be thankful - it won't last forever though, unless I win the lottery! Guess I'll have to start playing! :lol:

For those who keep asking about the bumper...a random shot I took just now in the failing light:

The smoothing ought to look ok in the end, it's just taking much longer than it should because of the small holes I'm getting from it dragging.

by **Captain Tightpants** on Fri Jul 21, 2006 9:34 pm

Nice one BABY!

:bonkers:

by **xrsi** on Fri Jul 21, 2006 9:54 pm

the rs2k equiliser doesnt fit in the fiesta tunnel, you have to use the fiesta one!

still say you should have bitten the bullet and gone zetec-s rear beam and focus rear disk setup!

by **heeman10** on Fri Jul 21, 2006 9:55 pm

xrsi :the rs2k equiliser doesnt fit in the fiesta tunnel, you have to use the fiesta one!

You're timing's impeccible! :lol:

Guess I'd better go and take it all off again then!

by **heeman10** on Sat Jul 22, 2006 10:50 am

xrsi :still say you should have bitten the bullet and gone zetec-s rear beam and focus rear disk setup!

And I still say you need to listen to me every time I tell you I don't want to because I don't want to gain that much track width and give myself scrubbing issues!

by **ScottP** on Sat Jul 22, 2006 11:27 am

zetec s/sport ka beams come with the spacers that you will want. i have some, but sold them on ebay, but the buyer has not paid yet :rolleyes:

by **heeman10** on Sat Jul 22, 2006 1:40 pm

Hmm..I think Scort is making some up for me now, if your eBay man is weeks late with payment or something I'll take yours off you if Scort hasn't made some and yours are what I need

by **ScottP** on Sat Jul 22, 2006 2:10 pm

my bro says that they are different, yours is a mk3 beam, and these are off a zetec s beam, which has different mountings. could get you some pics to show what you would need though

by **heeman10** on Sat Jul 22, 2006 4:13 pm

I know what I need matey, will let Scort carry on making them for me

I'm tempted to go back to do a Masters degree at uni just so I can have full-time access to the workshops again!! All I have is a pillar drill and an angle grinder here!! :rolleyes:

by **scarlet_pimp_mobile** on Sat Jul 22, 2006 4:35 pm

Welldone for posting that info dude!

Will be hugely useful for me when I do this next month!

Keep crackin on the bumper too!

And I liked the way you'd cut that Brunters vid BTW

by **xrsi** on Sat Jul 22, 2006 10:49 pm

lol at timing, i do try and help

scrubbing aint too much of an issue mate, each to their own tho. Do you have a genuine turbo beam on the car as the handling aspect i was thinking of after getting the coilovers!

looks sweet tho mate, roll on ford fair!

by **heeman10** on Sat Jul 22, 2006 10:51 pm

Cheers matey, RS2000 stuff will be complete by about Thursday next week all being well - depends on when Scort can get the spacer plates made up

I'll be buying brake pipe and the necessary fittings on Monday I think, and get making up the pipes I need in the engine bay and at the back to join from the Fiesta's flexi-hose solid mounting point and the caliper. Glad you liked the vid! It's good to have videos of these things to remember them by, and for those who didn't go to see what we got up to!

And now just for you...

Update

In such amazing weather I decided to carry on with the bumper outside rather than grovel under the car in the dark. So the top strip is 98% complete now, just needs the odd tiny imperfection re-filling and sanding. This evening before dinner I tackled the two cracks in the lower corners. The cutout is made by fibreglassing a ledge in right at the bottom of the bumper, and that had begun to part company with the bumper body. So today I keyed up the area (the crack had grown quite long under the paint, as you can see) by jabbing the angle grinder in at intervals to give a good surface area to adhere to (cheers for the tip Rawli):

I then mixed up some P40 and smeared it in as deep as it would go, and as smoothly as it would go:

This next shot shows where the original bumper body ends and the "ledge" begins, which is the crack site:

Hopefully this extra strength will stop it propagating any further and hold it all together a bit better. A similar, but much smaller crack had started to appear on the opposite side, so I smudged in some of the remaining mixture:

Tomorrow I'll sand it back and use filler to finish it all off and hide the repair, then, bar about 15 minutes careful final sanding down, it'll be ready to prime

A shot of how the top strip looks now, looking and feeling almost perfect, but the first coat of primer will tell how well I've really done!

And a random shot of the Mk6, because it's sitting right next to the bumper where I've been working on it:

by **mike_wall15** on Sat Jul 22, 2006 11:03 pm

It was good to get home today and read all the updates!

I can't wait to see some lovely discs and a nice front bumper at FF, make sure you get some more sticky pads for the number plate!

by **heeman10** on Sat Jul 22, 2006 11:08 pm

I had to buy some more sticky (velcro this time) pads for it to take it out when my mate came up a couple of weeks ago. They stayed on for about 30 miles then I took them off and got to work on the bumper! About £4 a pop from Halfords too! :rolleyes:

I've kept them, will see if they'll still stick. I might fibreglass them on if not! :lol:

What do you mean, get home today? You been away somewhere and not told me?? :cry:

BTW...potential Brunters Reunion after Ford Fair - are you going?

by **mike_wall15** on Sat Jul 22, 2006 11:18 pm

heeman10 :I had to buy some more sticky (velcro this time) pads for it to take it out when my mate came up a couple of weeks ago. They stayed on for about 30 miles then I took them off and got to work on the bumper! About £4 a pop from Halfords too! I've kept them, will see if they'll still stick. I might fibreglass them on if not! What do you mean, get home today? You been away somewhere and not told me?? BTW...potential Brunters Reunion after Ford Fair - are you going?

Mmmm velcro, I can see why you'd want to use but I've never had lots of success, it's so strong that it often pulls the sticky side off instead! :rolleyes:

Been to beach Jim-lad, Internet for without a week!

Managed to find a library in St Ives on Friday but the week was over by then...

Possible Brunters re-union is possible depending on how tired I am and if Carla wants to drive there! :lol:

No Ford for me to drive this time :cry:

by **heeman10** on Sat Jul 22, 2006 11:29 pm

Urrrrrrrgh you're coming in the Ka? :lol:

I'm sure she'll want to drive along - just think of all the times you've driven her around

Rawli's talking of one of his typical early getaways (about 10am) so we'll have to see when the show's winding down and how late in the day it is. Personally I really enjoyed just wandering around aimlessly at the end of the shows last summer

I'll be staying at my mate's in Shrewsbury the nights before and after the show again, so can leave pretty darn late.

by **mike_wall15** on Sat Jul 22, 2006 11:39 pm

Finger's crossed it'll be a very lovely shiney ka, just bought over £300 worth of stuff to clean it (and other cars of course! :wink:

)

LMFAO at Rawli leaving early! :lol:

Will see how the day turns out, it's always the early monrings that kill me

I really hope we have sunshine, if it's like FITP then I'll be gutted

Good news on shrews! :aviator:

by **Jay** on Sat Jul 22, 2006 11:41 pm

with regards to the handbrake... i managed to tension mine up enough so that it locks at its full travel... they need a spacer making for the handbrake cable outer to sit in where it meets the backplate on the rs2k brakes... if you end up getting this done then pm me and I'll get some aswell from whoever makes yours as I need some

by **heeman10** on Sat Jul 22, 2006 11:45 pm

Mike - Yup, the early mornings are tricky. I remember making plans to meet James (xrsi) at 4:15am for our drive down! He showed up at 4:45 I think :lol:

Git!!

Jay - I've heard they need spacers, and also heard they WILL function at full travel, but I'll see just what needs making when I come to that. I feel so dependent now I can't just make things I need, it's like having my arms chopped off! "Hi, can you make me a 10mm thick spacer plate with two 8mm holes in please? Thanks :rolleyes:

" It's only 5 minutes' work for these things and I'm having to get other people to do it for me then pay them! Must buy lathes and milling machines, pronto!! If I can make them with what I have at home Jay, I'll make doubles and send them along

by **Max M4X WW** on Sat Jul 22, 2006 11:52 pm

Bumper fiddling takes a while doesnt it!

Your rear disks makes me want some, but i couldnt go back to a mk3 beam after using the zs one!

fiestaturbo.com

My big ZT thread > 15.4.08 25bhp/20lbft extra and track prep

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