fiestaturbo.com

[heeman10]

I'm sure I've done a bit of one of these before, but now the car's practically complete, I thought I could do a fairly all-encompassing brief history. It always used to be a case of "Yeah I'm finished now"...but knowing more would happen in the future. But now I've brought the car up to the level it's at now, and can see more power wouldn't be of much use, I can feel that I won't be taking it a great deal further. Anyway, on with the pics!

I got the car for my 18th in April 2001. The pic below shows it 8 months down the line (the earliest pics I have of it sadly) with its spoiler, clear repeaters and wheel trims. I had no idea modifying even went on at this point. 1.8 Diesel, the most basic Fiesta ever produced in terms of luxuries, and 53,000 miles:



Uni meant I had a bit of money to personalise it. After some frantic moments on the skinny 155 tyres, I opted for 8v XR2i alloys for the grip, and the cosmetic improvement was a bonus that hadn't been a driving factor in buying them. I found Fiestaturbo.com around this time, and sourced the front and rear bumpers and 8v XR2i interior through the site:



After much nagging, one FT member finally had me and I bought his skirts and arches, de-stripped the sides and fitted colour-coded door handles. I'd also fitted the rear wiper, centre console, remote boot release and central locking at this stage, and it suddenly became a really nice car to own in terms of comfort and looks:



Sliding off a roundabout with two passengers in the pouring rain forced me to buy two new alloys which I refurbed a little and painted using an anthracite paint. Green Cotton induction kit made it all sound better, and it was looking better than ever, with XR2i calipers and vented discs to boot:



Then came some more serious modifying. Gmax full Supersport -35mm (over 60mm from base model) suspension kit, 15" alloys, anti-roll bar and XR2i crossmember. I bought a mint Recaro interior from Rawli at this point too....something I always saw being sold/bought on FT and thought I'd NEVER spend that kind of money on a set of seats! It now felt pretty special, actually handling well as opposed to "better than it was":



All this had been done with a power hike in mind, and I had been asking about the FRST engine conversion for a while, being shot down because of the shift from diesel to petrol. Two weeks after the intense modifying leading to the picture above, I decided to buy Excursion's Mondeo TDI conversion off him. Diesel for diesel should keep it simple, but give me torque and economy, and something interesting:



This was my first engine conversion, and a very simple one looking back. The last month or two had seen me really getting to grips with the mechanics of the car, not just changing interiors and polishing it. So, with the TDI engine in and the car looking quite crisp, I decided to go the whole way and make the engine bay something to be proud of. Cue a huge box to send all the metal parts down to Fusion Fabrication, giving this result:



Sadly, the TDI didn't last long. Having had all the polishing done, custom metal boost pipes made up and a pricy rolling road session (seeing it make 150bhp), the cylinder head wanted no more. A water pipe sprung a leak on the way to Fiesta In The Park 2004, without me knowing, and the damage was done. It let go memorably on August 1st on the way to Ten Of The Best. I had done precious few miles with it, and had enjoyed having the "go" to match the looks, but was considering putting a standard 1.8 Diesel in it and selling up. I'd spent quite a bit on the TDI conversion and it had all gone to waste almost immediately. It sat for 6 weeks doing nothing, then I had a change of heart. It was an "all or nothing" moment....sell up or do it all over again, but do it to achieve my dream, not just achieve something similar.

The plan was a big power 2.1 ZVH in a mint FRST shell, but the shell turned out not to be mint, and arguments with space at home put at end to that plan. Just as my dreams were fading, mikee_rs dropped me a PM saying he was contemplating selling up. After some very brief discussions, I drove alllll the way down to pick up the 1.8 Zetec Turbo he intended to use in his car, built by Excursion. This was in December 2004. The winter term at uni ended about four days after I collected the engine, but I had to wait till after christmas for the space I needed back home. A six-day flurry saw the removal and sale of the TDI engine, and the transplanting of the Zetec Turbo:



It was a harsh winter, and a lonely one, working away on the car on my own with numb fingers. Each obstacle had me thinking "What am I doing? Is it really worth getting up at 7am, going to bed past 1am and bashing numb fingers into cold steel?":



The number of parts I was changing, buying and looking at was growing all the time, and this was the biggest thing I'd ever attempted, and when you're working on your own with something you're doing for the first time, it's hard to stay positive, specially when it's snowing outside and everyone else is inside by the fire! I realised my Diesel loom wouldn't allow me to run the Zetec, at which point I gave up hope. I was pushing it attempting to do the engine conversion on my own, but a full loom? I'd never taken the dash out, let alone remove every wire on the car. I priced things up to sell, but got shot down by the FT crew, and even my dad said I should probably finish. It's been a huge disappointment throughout my modifications to the car the way my dad's been so negative about it, so a mildly encouraging talk from him turned it all around. So I put my head down, ordered all the parts I still needed, and got cracking on the loom:



Things began to get rosier each day. The weather started to pick up as I moved through the year, working in intensive bursts during the holidays from uni. Shopping around, ordering parts home for when I returned in the holidays worked well. A random shot of the car:



The loom all in, it was a relief to be checking things so basic as "do the lights work?" rather than "Is the engine in?":



The exhaust was a major grief point, but it was good to get the car out of the shed for the first time in almost half a year to get the exhaust modified in situ:



Then, when it was all back together, the "1,000 pound, 250bhp gearbox" I'd bought was in fact ruined, with the diff in pieces. So the day after I'd bolted everything back together for the first time since August 2004, it had to come apart again:



A new, Stage 1 gearbox was ordered from CTS, fitted, and everything put back together again, with precious minutes to spare to make it to an MOT booked a long long time ago to allow me to get to MSD for the mapping:



Sadly, a fan switch issue stopped me from making the MOT, and subsequently I missed my mapping date, and the next date was 6 weeks down the line So I used the time to complete bits and bobs that needed doing. Long story short (how ironic at the end of such a huge thread ) I made it to the next mapping date, and it was handed back to me running immaculately. The rest is history really. One or two minor issues in over 2,000 miles have left me extremely happy, and though it still brings a feeling of gloom back momentarily when I think back to the early stages of the conversion period, I'm very pleased I've accomplished my original dream, and can now move on knowing I succeeded





So that's largely it for now! I haven't gone into any detail as that's mostly documented throughout this site. As I say, there isn't a lot remaining. A repsray and minor bodywork to have it looking perfect is in the pipeline, otherwise I don't see me doing a great deal more. Almost every component bar the doors, tailgate and windscreens has been replaced to a high standard, so there's not a lot more to be gained....which has had me looking at what the next car will be. I'd love to keep the Fiesta forever, but I can't see myself spending the thousands of pounds required to make these cars last another ten years. Safe to say it won't be going anywhere in the near future anyway

[F.U.K FESTA]

absolutly superb read! good job youve done on it, wish i could do the same!

[andyhardy]

Good read James!

[heeman10]

F.U.K FESTA - Thanks matey I could've drivelled on about it forever but tried to keep it shortish with a few pics! Who says you can't do the same? We all have to start out somewhere. Two years ago, I paid someone to fit the XR2i brakes for me, and to fit the suspension originally. This time round, I chose a set of racing calipers and sourced some aluminium caliper brackets. I had to mill 3mm off the face of each bracket, drill the mounting holes out on the beautiful brand new aluminium calipers, then tap M12 threads into all eight holes. If I'd made a mistake, it would've been 170 odd quid for a new caliper. Provided you're willing to try things, and learn and get your hands mucky, you can progress too matey. Don't look up to me and think "Wow, he's a genius", I haven't even built an engine properly yet. All I know now is from tackling things on my car instead of sending it off to "a man" to do it all for me. It will have saved me hundreds if not thousands of pounds too!

[heeman10]

Good read James!

Cheers dude Amazing looking back at all the hundreds of hours we've put into our cars

[ooral]

That's a great read, bound to inspire a few folk when they are thinking of chucking it in!

Car looks super as well!

[SPo0n]

i'm gonna be late for work now i've read that

good read and a fantastic project. well done

[acrebo]

I could've drivelled on about it forever...

What, you mean to haven't just done that!?!

Only joking matey, cracking read and it's really good for someone like myself who's a bit newer seeing what you car was like when it first started out. I always thought it was just a converted XR or RS!

So what's your next plan?

[PaulC]

Great stuff mate, I remember most of this

[jdfiesta]

thats a fantastic read and it'll give hope to them who are considering what you did
JJ

[doggpk]

well done man...

[LeedsOnTour]

CONGRATES!!

what a feeling you must get when you look at your car and know that you did it all yourself, and it looks ACE!!!

well done and great read almost got caught by boss two or three times reading it!!

Sweet!!!!!!

[The Modfather]

nice story and awsome car well done chap

[Captain Tightpants]

There you go see, learn something new every day. I was under the impression it was an XR2i for some reason!

Good work mate, throughout. Not having been here from the beginning it's good to see it through all those stages.

It's too easy to give up on these sorts of projects, far too easy. There are only a people that actually see them through to the end. How many posts do you see per month, 'Giving up project, all parts for sale'. Glad yours didn't turn out like that.

It's gone from strength tp strength. Makes me wonder whats next? 2.1T? 2.5TT? 4x4?

Looking forward to seeing it in the flesh Saturday.

Steve

[xrsi]

Don't look up to me and think "Wow, he's a genius", I haven't even built an engine properly yet. All I know now is from tackling things on my car instead of sending it off to "a man" to do it all for me. It will have saved me hundreds if not thousands of pounds too!

thast my sentiments exactly! i have paid companys to do the rebuild of the engine and the spray jobs but everything else i do myself! if i cant do it before i do a bit of research and give it a go and see what happens!

the pictures remind me of my car being on axle stands for months at a time during the rebuild and the constant changing of bits as i find out even more about how different bits work together and find better combinations!

yes i have spent stupid money on the car over the years but i feel that its all been worth it when i do manage to drive it for the short times i do! not only have i got a fiesta exactly how i want it but im happy knowing that i have built it from the 1.1 shell up and am able to diagnose alot of the problems myself and know how to rectify them! but also in buying duff bits it has also taught me valuable lessons, dont try to cut corners and make sure you know what each bit does and why its there!

if this engine does let go then i will attempt to build one myself, but the car would be off the road for a long time should that ever happen!

i cant see me stopping spending on it, but the money availiable to the project is being cut back all the time, just a case of deciding the most important things that will be f use in the future and doing them first!

good post tho of how its all come along!

[heeman10]

Thanks for the replies everyone. I enjoy reading through monster, 8-page restoration and project threads on PassionFord, so thought my small montage would appeal to a few people who don't mind reading for a few minutes! It really needs a website to catalogue everything I did...maybe something for the future.

ooral - I hope so. It's too easy, and makes too much sense to pack in a project like this. I added up that I could've broken for around 5,000 pounds when I was going to give in, and still had a few thousand left to spend. That 5,000 could've gone towards a Mk4 Golf GTI, but it wouldn't have been as quick or as individual as the Fiesta, and I didn't want to fail another project (I gave up on a kit car a couple of years ago, that really was crap though!). Thanks

SPo0n - Cheers gimp, hope you didn't get fired

acrebo - Cheeky get! I wish it had been an RS! Then I wouldn't have had to fit the bodykit, opening rear quarter, central locking, petrol tank, wiring looms, rear wiper, bonnet.... Next plans are limited. Fit the oil cooler, finally get the bodywork seen to after all this time, perhaps extend and weld the cage in, but not a lot more I don't think. Like I say, it's got the power it needs now, and any more would be wasted IMO. Rear/four wheel drive is on the spec list for the car that follows the Fiesta, it's the only way to USE the power you have once you're comfortably past the 200bhp mark.

PaulC - Good man! Just not enough old schoolers on here anymore

jdfiesta - I really hope so, glad you read it all!

LeedsOnTour - Cheers matey Yeah it is satisfying to know I did everything on it....but equally annoying when I see things I'm not too pleased with because I'm the only one I can blame I'm aiming for utter perfection on the next car, the Fiesta has been a great learning platform though. It's hard to end up with a perfect car when it's the one you "learned" on, but I'm glad the Fiesta's been that car I don't want to be getting you people fired!

The Modfather - Why thank you

Scort - I'm sure you say that each time it comes up in conversation! Far from an XR2i dude! You're right though, LOADS of people have given up on good projects, but like I say, it usually makes very good financial sense, so it's hard to blame them all. I don't think there's a great deal more in store for it. 4x4 would have to go ahead for me to hike the power anymore, but I want a more modern 4WD/RWD car with at least 300bhp/tonne first. I'll keep the Fiesta for a while, the shell will decide when I give it up though I think. See you in a few days, it'll be good to see the Ka too!

xrsi - It was good to see yours out and about after only really being aware of the car being in bits since I first noticed it all that time ago! Was nice to see it looks so good too, it always looked a bit half-hearted in the pics, but it's a different story in the flesh

[D.J]

Hi Mate

I have been looking at the conversion thread ever since you started doing it, and i thought that you had done an amazing job. Reading through this shows that the modifying bug will bit everyone eventually!!!

Reading through all of the conversion threads does make me want to start something of my own. Back when i had my turbo, i wanted to spend loads of money on it and get her running perfectly, with the possibility of bigger BHP, and even ZT power. Why did i have to grow up and by a house?!?!?

I have promised my self that if the engine dies in the Puma, i am going to build a 2.1 ZT Bring on the rev limiter!!!!!

As said WELL DONE

PS, love the pigeons!!! (sorry, couldn't help it. Best chatter i think i have heard!!)

[heeman10]

D.J - Yeah you're right, modifying just takes place really. I never set out to "create" anything, this was my first car after all! Now I know I'll be looking to modify the next car I buy without a doubt, every car can be improved upon. 90% of people no doubt have to give up their pride and joy when they "grow up" and get a house. I certainly wouldn't laugh at a 30 year old who decided to buy a FRST to rekindle what he started but had to give up. You only live once, so go ahead and do what you want to do Maybe let the oil run low and make use of the rev limiter in the Puma

[rs-wannabe]

congratulations mate!great to read a thread like this

[StreetDragster]

Another good thread James, its been a challenge but i bet you certainly feel better for solving those problems, the experiance will help you for the rest of your life.

Now, you need RWD forced induction next, join the revolution

Thanks

Matt

[heeman10]

StreetDragster - Yeah, the experience is one of the most valuable outcomes of all I've done, as you will know RWD forced induction in the shape of a Supra TT or Skyline is what I'd like as the next proper car, or Escort Cosworth/Skyline if I can go 4WD. Either way, no less than 350bhp and RWD! Bring it on you cheeky yellow chappy!

[StreetDragster]

Did i mention that i've already priced up a smaller S/C wheel and a remap of the DTA??

I can't help myself!!

Thanks

Matt

[heeman10]

S/C = supercharger compressor? Just get the bloody thing first I found I got used to my dad's with 230bhp in a matter of a few laps of Three Sisters, so I can see you wanting more power before too long!

[random_dav]

minter fella

[AGAR]

I know alot of people have said this but i feel i must do the same - Top reading, really good for inspiration.

The Mondeo TDI conversion was a bit different from the norm, shame she didn't last longer with the motor as it would have be interesting to see where it would have lead you to. Could have been an old equivalent of the zetec-s diesel only faster Im sure it would have held its own up again many a modded FRST with all that low down torque, saved a few pennies on fuel too

I myself am at the bottom of a very long a windy road to what will finally be a mint FRST (i hope) - starting from a mk3.5 1.1 Im really at the very early stages of the project and am begining to think "What have I let myself in for?" but i think once I start seeing the results it will all be worth while. You've given me some hope as far as the mechanics of the cars go. Im fairly competant with most things but really wouldn't know where to start once i get round to fitting a turbo lump (that'll be a few years down the line though). Still since joining here ive found alot of people who know thier stuff and whom i will no doubt be turning to for advice.

Once again well done its deffo something to be proud of and be able to look back in years to come and think "I did that all myself".

[heeman10]

random_dav - Thanks! Nice to know others like it too

AGAR - Thanks dude. I've only done this because I've seen others on here do similar things. It really helps to be able to see what can be created from the humblest of beginnings. I would've described myself as "mechanically competent" before I started this too, but the nature of the Fiesta's structure means it's easy to learn and get used to, and learn from. That's what makes it such a brilliant little car to modify in my eyes.

The TDI was great, would spin up in second gear, tramp on to impressive speeds and was oh so simple. The only wiring was for the oil pressure and coolant temp sensors and the glow plugs, plus the starter motor...that was it! It really is a shame it gave up, certainly surprised a lot of people. Anyway, another learning experience. I wanted to implement a coolant level sensor to avoid that happening again. I had no indication it had dumped all its coolant out, and continued for at least 50 miles on that hot sunny day at no less than 80mph all that time before I stopped for fuel and saw it The Mk2 Golf has a system that lets you know if coolant is low, so it's doable. Best of luck with yours, you just have to keep in mind what the rewards will be

[xrsi]

xrsi - It was good to see yours out and about after only really being aware of the car being in bits since I first noticed it all that time ago! Was nice to see it looks so good too, it always looked a bit half-hearted in the pics, but it's a different story in the flesh

yeah the digicam is quite pants so the car does look different to how it does in the flesh in the pics!
just a case of tidying the rest up now, want the engine bay painted now as its letting the car down! and sorting out the next set of mad plans to keep it off the road for another 6 months!

[Xr_Dub]

Wow u come a long way dude..

funny how ure car looked @ the start..

cars looking sweet and the engine is a minter

u need to hit the 1/4mile and get some times in me thinks

[chris-fiesta]

i agree dude, start hittin the 1/4 mile runs and enjoy it uve put alot of work into it so it will be well deserved

[jeek]

Great read mate!

I undertook a similar project with my 1.4 cvh which i converted to a 1.8 16v. not quite as impressive as your turbo! There was loads of times i wanted to give up and sell the lot! I had to change the loom as well which isnt as difficult as it seems!

My major problem was once i had a reasonably quick fez i decided to cover it in fibreglass and catty! BIG MISTAKE! i have now sold the car cos i was sick of it scraping of the road!

You can do anything you try as long as you have the space for it! and if you do try and create a mint Fez dont put a s**t body kit on it like i did!

Jeek

[heeman10]

xrsi - Don't even think about. I was tempted to do lots of things...eg stripping the underside components, sorting rear beam (or replacing with ZS beam), undersealing etc....but decided that it had been off the road more than long enough. It's cosmetically not perfect, and there are still jobs I want to do, but dammit, I'm going to enjoy it now I've built it. I think you need to do the same.

Xr_Dub - It seems like forever since it looked like that! I remember thinking it was SO cool with the spoiler on, and that was the only mod! You're right about the quarter mile thing, it's definitely ready for that kind of abuse now. As you may know, I was hoping to be ready for the TOTB qualifiers but missed it by three weeks....next year it'll be down there trying to break into the 13s to run at TOTB

jeek - It's quite different when you're trying to attack the bodywork as well as the mechanical side of things, I can only imagine what that's like!

[Max M4X WW]

Good stuff. I remember all of your previous topics of fiddling with things etc.

[BUTRE]

Great job mate!!!

Sometimes before I go to sleep I get aware of the silly amount of time I spend around my cars... ITS INSANE!!!
The next day I wake up and say: "Last night I was thinking about something... whatever cause its time to work on the car!".

I cant get enough of it... cars and ladies I mean.


Heeman, you came along way and I bet its far from over... RSpect!

[MarkRS2K]

good read mate, definately come a long way, hats off to ya dude

[DaveMCMkIII]

Two years ago, I paid someone to fit the XR2i brakes for me, and to fit the suspension originally. This time round, I chose a set of racing calipers and sourced some aluminium caliper brackets. I had to mill 3mm off the face of each bracket, drill the mounting holes out on the beautiful brand new aluminium calipers, then tap M12 threads into all eight holes. If I'd made a mistake, it would've been 170 odd quid for a new caliper. Provided you're willing to try things, and learn and get your hands mucky, you can progress too matey. Don't look up to me and think "Wow, he's a genius", I haven't even built an engine properly yet. All I know now is from tackling things on my car instead of sending it off to "a man" to do it all for me. It will have saved me hundreds if not thousands of pounds too!

ive bin on here long enough to remember your fiesta back in the day, riding high on stilts!but i gota say, ive thought alot in the past months while looking at your zt progression, when did you suddenly gain all this skill and knowledge?!?!?!?!??!?!?you knew just the norm 18 months back and know seem a complete brain box. I gotta start gettin my hands dirty, not engine building, just fitting brakes, suspension, lower arms etc (always concerned i'll f**k the thing up tho!). Anyway, the fiesta has turned out a treat, may even see one the weekends im up cumbria!