fiestaturbo.com

[jon-ross]

hi peeps im copying my threads from passion ford as i feel they will be more appriceated here and this is a fiesta forum after all and i have 3 mk3's

this is my very first car which i cannot face getting rid of even though i bought it cheap. During the thread it goes though highs and lows with the car and it current state is a bare shell in my garage and will be built into a track car next

so here goes

hello everyone introducing my daily runner and first ford. As with all cars she comes with a little story, hear goes
about 2 and a half years ago i bought her in a fair but sorry state for 500 quid as buy it now on ebay, the previous owner owned it for not long but in the time he owned it he spent alot of money have servicing and maintence and also recent clutch, but it was slipping as stated when advertised. it was a good car but needed tidying up, the front bumper had loads of chips but on closer inspection found it to be a white bumper underneath and it also had damage to the front panel and the offside door used to be white. I started to tidy her up doing what i could being an apprentice and living in a rented house at the time but got her looking quite good hears a few pics of the early days and after loading these im going to bed [ERRR] its 12am ill finish tomorrow















after a good cleana nd polish and a bit of paint in the engine bay she came up alright















il carry on threat tomorrow nite nite

[jon-ross]

right hear goes from day one (all i can remember).

when i drove her home from portsmouth the first time i hit the brakes there was hadly any atal and i went flying around a roundabout, so i bled brakes the next day at work and nearly knocked myself out on the wheel when i braked. i bought it with a slipping clutch and i was told it had a new one (which it did) and it was probly the quadrant so i thought its got to br easyier than do a clutch so i got a quadrant and cable and set to work. how wrong was i?? the quadrant was a horrible job and took about 4 hours (i can do a clutch in 1 1/2 hours) and it still slipped, so i put a clutch in and found the gearbox was input shaft seal was leaking oil all over the clutch. i had to put it back to gether as i was my only car and it lasted a month before it started slipping again. so thinking i want to do it properly i saved up and brought a ebc fast road clutch, rear main oilseal, and a recon stage 2 escort turbo gearbox with modified gears and big bearings and lsd. my mate terry bought a red frst for cheap and broke it down so i had the front bumper to get rid of chips, bonnet and frontseats. time went along and she was very reliable until she got side swipped on a roundabout. so i quick fixed it and thats were i lost interest and it went downhill from there and i got my rst around then and started to restore(not intented) she went on for a very long time until she overheated and blew the head gasket, so time for mini overhaul, due to lack of space and time i only got half the jobs i wanted done but did fit my ported and polished head which i done myself but only smoothed the ports but i didnt get it skimmed so it blew again. i was so pissed off i was going to scrap it [ERRR] it even still looked like s**t, but after a while to calm down my dam unconditional love came back and decided to do a mini resto on engine and body so heres some pics of the crash damage, wot she looked like after 2nd time head went, and pics of the mini resto (ill tell you about that tomorrow [ERRR] its late AGAIN!!!lol





















now the mini resto pics

































































i know it needs to be mopped but not bad for first paint job

[jon-ross]

hi peeeps ive got and update but still need to load some pics on photo bucket so ill do that 2muz.

all was going really well and i was enjoying the car, i had it dyno'd at my mates mark and pete's garage (south coast performance) and it run 130hp at the flywheel and 140ftlb of touque which is quite good for the 105 ecu, then i was driving down the road and as i come on the bypass i had the typical bmw right up ur ass syndrome so booted it on to the bypass, as i hit redline in 3rd went to hit 4th and hit 2nd intstead gearbox fuked!!, to keep the car on the road i just got a standard new clutch and the stage 2 geartorqe gear box with quaife diff and fitted that. All was great but times got hard and i had a mate keep asking if i would sell my gearbox and kept saying no but he asked again at the right time so a deal was done for £350 and a good lsd box, we swaped over and straight away gear box sounded awfull. CHEERS MATE. i know i should of taken it off the road but i had no other car and seeing how id be waiting an age for my mate to sort a good box i thought id limp about till the end of the month. one morning going to work down the bypass doing 55-60mph gear box s**t itself, locked up and before i could dump the clutch it smashed my engine to s**t, and hauled me up so quick i nearly went through the screen. so over haul number 3 on the cards. we got the driveshafts out of te box and towed it to my work and during being moved in and out everday it picked up some nice scratches and dents, but im not too worried as my mate arron is going to redo my crap paint job while i build a 2 litre lump and rebuild the first box i blew up, im also going to sort a load of little jobs aswel, i get a few pics up 2muz

[jon-ross]

hi peeps little update for you, the plan was to tow it to another garage i work at sometimes called auto upgrades (jap specailist:sleeping::sleeping:) but wen we got there the main gate was closed so we towed it too our unit (not far from a.u). heres some pics of it at work looking very sorry for itself











here some pics of the damage it picked up at work









a little bit of rust bubbling again:wall::wall::wall::wall::wall::wall:



the next weekend in moved the 2 litre silver top lump out of storage and took that down the unit and also i pulled the lump out out the car





















with that done i got it rolling again and waited for the next weekend. wen that came around the next plan was to remove the parts i need from the 1800 engine for cleaning and painting



and then strip the 2 litre lump and fit on the engine stand, strip the bottom end for measuring for the new parts and cleaning, clean up block and paint red















while having quite patches at work and during lunch breaks ive been busy with the parts washer and wire wheels and black paint and got this lot done







i did the gearbox cradle aswel but no pic.
today ive been striping the engine bay ready for cleaning and painting. I didnt get any pics because wen i left this evening i was going to break it up, but after along think ive decided to keep it as it only needs to be on the road till the saph is done, the reasons i felt like this was,

i found my offside subframe mount has rot and snaped again (i happen ages ago and i rewelded it)

some wiring in the main loom has burnt through the insulation (everything works though??)

front engine mount has been welded to the chassis leg:wall::wall:

rear engine mount stud fitted so that the mount is under the braket and the stud put through the hole in the braket with a large washer and then bolted down (baisicly the bottom part of the stud has a tapered collar larger than the hole in the bracket and it was siezed so i had to cut though the stud (ill get pics as that probly makes no sense)

fudgekin cowboys get back on your horse and f**k off, you know who you are!!! sorry to all the other people that do things properly.

the carpets are soaked were its been outside. It comes in through the door seal but the car has been crashed and you can see that the hings have been welded back on, but not badly just slightly off i think

its not much but wen ur borrowing your sisters car and have hardly any money and you find bits that add to the final bill it dont take much to think f**k it, break it, but ive calmed down and decided to carry on

more pics next weekend

[jon-ross]

right peeps ive been at the unit today for abit so firstly heres some pics of the bodged engine mounts and the striped bay ready for cleaning and touching up











in the pic below were the engine mount was bodge fitted as i explained in previous update it needed cutting out, but i couldnt get in there even with my little 3" cut off tool, so i had to cut out a smal piece of the mount bracket off so i could get the cutting disc low enough to cut the base of the stud. i have kept the piece i choped out so it will be welded back in wen ive got my welder sorted



i didnt get a pic of the subframe mount but i wil wen i sort it out

as i couldnt be down the unit for long today i thought id drop the fuel tank and clean and paint it, remove all fuel lines and the rotten fuel breather pipe, and replace the brake pipes. heres some pics







below this is why i'm replacing the brake pipes!!! people that do brake pipes this bad should be shot!!!!:angry::angry:




firstly i droped the tank out and cleaned it right up. the bottom of the tank was platered in undersealer and took an age to remove but got it clean in the end with about 15quids worth od brake cleaner:tiff:.
i then painted the tank and left hanging to dry. by the way the tank is mainly being removed due to the fuel sender not working so im replacing the whole unit with an rsturbo one as its laying around, i then went on to replace the brake pipes and first problem.....no lock wheel nut:top:, i realised ive left it at work in the bolt box for my car as i was cleaning all the bolts in the parts washer!!!! so i tryed with out it but the brakets that hold the rear hoses to the inner arch have been welded back on in totally the wrong place and that means my at work made brake pipes (i had some old original pipes from a fiesta that failed mot on them to make copys from) wont fit.
ill take pics of them wen i fit them
heres the tank and thats all folks till next weekend. cheers for looking

[jon-ross]

right peeps bit of a large update for this one as i need it back on the road. i managed to raise the funds to sort it out properly so ive ordered all the parts i need apart from 2 or3 parts so here goes

ive still got small jobs to do on the car so heres the pics of the weekend i clean it all inside and out









i removed the seats because the last time i fitted them i was in a rush and fitted them n/s to o/s and o/s to n/s:wall:







also my son has to ride in only the best aswell so some money was put aside for this beauty.
its almost too nice to ruin!!



right, now remember the gearbox story?? heres some pics of what i did to the first gearbox:wall::tiff::wall::tiff::wall:

















also all the bearings had exploded but i didnt take pic as you can imagine what a pile of metal fragments and ball bearings (some balls were split in half!!!)
so i got on the phone to G.E.A.R.S (gearbox engineering and rebuilding services) as he built the first one and was faultless til i f**cked it:wall::wall:. I was going to buy all the needed parts but because i needed both main and gear shafts plus needing them modifiyed to fit my spec box it would be cheaper to just buy another one. but this one is abit better spec. its got better over sized roller bearing, altered gear ratios, stronger sycros and selectors, diesel final drive, escort lsd set to 90nm instead of the 60nm standard, and a modified s1 rst casing to accept bigger gears and bearings





after a lick of paint



right now back to the car ive fitted the 2nd hand pump and sender into the tank and cut out those bodgey brake pipes which were realy soft so wouldnt of lasted much longer. as the brake hose braket was on incorrectly and i had already made the pipes up i removed i bracket which were rotten behind anyway and welded them on in the correct position and fitted the pipes and fuel tank and then run new braided fuel line as mine was really brittle all the way to the engine bay



















remember me mentioning that the o/s subframe leg had rotted and broken again well heres the fix
what did was i put a jack under the subframe andremoved the bolt and rotten captive nut, then measured on the good side from the bottom of the chassis leg down to the subframe and jacked the other side to match the measurment then chop ed out the rotten bit and made a new base and cleaned up the captive nut [ERRR] i couldnt find a nut to fit. then bolted it to the subframe then built up the sides useing 2mm sheet steel for everything, and then gusseted the sides so everything inculding the base is double skinned:top::top:

















while i was in the engine bay with the welder i done the engine mount bracket aswell



also i finshed re painting my rocker cover. i got my mate to shot blast it and i took my time doing it this time and it looks sweet



i have started building the engine but im going to save up the pics from the head build and the engine build and do them as one update but here some pics of some parts ive got ready to go







hope you like:top::top::top:

[jon-ross]

right peeps this is the engine updateso hear goes starting with the head

i started with a standard head and thought id try to do my best head yet (as ive ported a few now) so heres some pics of the rough porting and smoothing of the combustion chambers









it looks rough there but i had not smoothed them out yet, this prosess was to just get the size of the ports right. also i ported and smoothed this breather plate as i didnt think to do that last time



once id finished the ports apart from polishing them i had the head skimmed by 8 tho for a bit more compression (max on zetecs is 10 tho)



i then polished the combustion chambers and smoothed ports and posished. i couldnt get a good pic of the ports though [ERRR] when you really close the flash reflects back and when you do it without its just a black hole:angry: so heres a pic of one of the polished chambers



heres some pics of it built back up and ready to go!:top::top:i spent 4 hours putting it to gether in my kitchen stuffing my face with lindor truffles:top:

]







also i got this from a car i was breaking , it was very corroded but ive cleaned it up and im going to paint it black




and now for the engine , heres the bottom end built back up



and heres some of it built up ready to go!!!:top::top::top::top::top:













looks sweet i think. i cant wait to fit it now, and i start working for south cost performance next monday and boss said i could finsh it there so it will get done quicker (yay) just waiting on my techniclutch now

[jon-ross]

hello peeps small update. sorry it hasnt been for ages but ive had quite a few headaches and delays with the car so ill start from the begining

when i got my job at scp my boss mark said i could take all the stuff in my unit down to the work shop to make it easyer and save me money so the car was towed with no engine and no light in twilight darkness! the next weekend me and terry eptyed the unit including his black escort and my saph

the next weekend i painted the engine bay and during the evenings after work i stared to working on it again, its so much easyer with a ramp



and aslo my toolbox right to hand instead of loads of tools piled in a small toolbox, ending up on the floor and getting lost:wall:



first job was to bolt the engine and gearbox to gether. I was going to use a ebc organic clutch cos i had one before and there faultless and have a light pedal feel. Typicly i forgot my camera the night i put the engine in and my fone aint even worth trying.
After a very late night putting it all together i couldnt start it as i had no fuel, oil, gearbox oil, coolant, or volts in the battery.







the battery went on charge over night and i got some fuel to take with me and got the oil i had in my shed that i niked from hi-Q were i used to work. I had to connect the fuel lines because due to fitting braided lines i couldnt remember which was which so i had to put fuel in and switch the ignition on and see which line spat fuel at me. the next step was to oil her up so in went the gearbox oil no problems, then moved on to the engine and pourer 4.5 litres of oil into the engine and it just sat in the head:wall::wall::wall::wall:
i could just see a deep puddle of oil in the filler hole, then i noticed a drip and found oil running down the block!!!

so off with its head!!!:fume::fume::fume:



i found i had put the head gasket on upsidedown:tiff::oops::oops: so i kinda lost my temper abit and kicked my fog light out witch inturn broke my big toe:cry:



so after a s**t load of s**t ripped out of me my my work mates and terry i refitted it proplery and twas all good

the thing was when i built the engine i didnt start till late in the afternoon and were i took so long being carefull building the bottom end i forgot time existed for a while and it was very late when i finished it but i was despirate to see the engine together i persisted and my tiredness bitt me in the arse

so on to starting well baisicly it dosent:top: at this point im wondering what sausages taste like cooked off and xr2i:cry:

first port of call was to check for spark, that came back ok. then i checked the fuel found the injectors to be fireing and fuel getting to the rail and fuel pressure was fine at 3.5bar but then i put my power probe to the cut of switch wire which ive cutout and soldered together with a take off and found that the pump primes when i turn the key then it goes back to earth as normal but when i crank it the wire stays earthed and when you throw a live to it, it still doesnt fire!

i found i needed a fiesta si loom due to the edis control unit so i got a loom and fitted it and was worse off. I had no fuel or spark now!!!:fume:
i removed the loom and checked over the whole thing and it was fine

i found that due to the loom being a pats loom and the ecu a non pats there was differences in the pins in the ecu but no matter were i looked or who i called i coulnt get the exact pin data for the deep ecu and the exact wiring diagram for the si loom, so plan B was to revert back to my original loom and get an EARS ecu from an atuo mondy or rs1800 one. The story behind that is my mate woddy who lives fooking ages away from me has a garanteed working ears ecu and he only wants 30 quid for it but hes taking his time sending it to me. In the time ive been waiting ive finshed the whole car even some extras like fitting a new fog light and some road legal hid look bulbs in every light, fit a oil pressure gauge for peace of mind, and had it fully sign written on the windows of the south coast performance advert and given her a clean. I will take some pics tomorrow but its dirty again.

the next step is to start to lightly wet sand the paint and mop it then sort out the damage to to the door and hopefully some time this year i might get my ecu and get her running and on the road (rolling road that is).

im going to do al lthe runnig in mileage on the rolling road and then set up the cam timing and remap it and hopefully see 170BHP and more in torque from a non turbo motor:king::king:

pics to follow

[jon-ross]

right here goes peeps massive update including the finsh (for now). The reason i havent been updating as ive been very busy at work and when i found the mistious problem of no or weak spark and constant fuel pump (even with ignition off) and still not start, and also what i had to do to get it going resulted in me losing all interest for a while and once regained interest and got back to work there was alot of work to do so camera stayed on the side for most details but ive got enough to see the story.

also just got to say if you read performance ford then you may have seen the east sussex rsoc meet we have in this months issue and seen my car on the left on the main pic, and yet when you red it noware does it mention me and i save my guts out everyday on that ramp (it even had my current job at the time, the white esort having new big end and topend rebuild). also i was the only one that went to FITP from SCP and me, the mrs and my boy took the fiesta cossie (done donuts in the grass, mrs s**t herself, boy cracked up laughing and i got a bolloking from a ginger c**t:top::top::top:) still no thanks and also only got one crummy little photo in the mag and i was on there stand!

anyway back to my car

the story from here goes

When i got the ears ecu i set about fitting the orginnal loom back on and pluged in the ecu and still no start and constant fuel pump and no or weak spark, so i got poking around with a power probe and found everything was interfearing with everything else so i decided to get the dash out and see what going on and what i found was the burnt out wire i found and repaired a while back went alot further back and had burnt out a main part of the loom:wall::wall::wall:. so now i needed a 180 xr2i complete loom!!! after a month i still coundnt find one and then and silver rs1800 poped up in the fort sale bit of fast ford and snaped it up for £350:top::top: heres some pics to ease the bordom:sleeping:













also has iwas making the engine bay nice i thought id best make the outside look nice too, so i started wet sanding and moping the sand paper paint work



more to come on that. i did the whole front end and tokk me 4 hours:cry::cry:
going back to the rs1800 for a second. I had to travel all the way to bristol to get it but it turned on well worth it:ban-split:. when i got there i was presented with an rs1800 with no more than a completly nakerd shell. There was rot in places id never seen before and all the usual places gone to the extreme. The worst bit was the n/s/r suspention turret was so rotten it had completly ripped out and smashed through the rear speaker panel:top:. unfortunatly i took the pics on my fone and i cant get them on my computer:cry:

i wasted no time in gutting the rs but brfore i did i made sure everthing worked ok and then realised id didnt have a heated front screen (yet another job to do). also i had to cut out the very gay alarm that dont let you start it for half an hour:wall:. included with th rs was a quite nice and grown on me louvered bonnet witch i do have a pic of and some brand new set of red dot grooved discs, also it had mint seats and door cards and a black steering wheel so yoink;-)









also i niked the inlet manifold (something i never managed to get hold off during the build):ban-split:







so now i had what i needed on the floor i got to work on the xr starting with striping the loom out of the engine bay and then stripping the interior and removed the whole loom and then fitted the new one before i for got were id all went!

more pics












just a reminder of what sort of driver i am;-);-)



once i fitted the loom i tried the key again and WE HAD SUCCESS:banana::top::banana::top::banana::top: finally it runs and everything worked!!! All i had to to now was cut the heated screen circuit out of the old loom and fit it to mine and cut my clifford alarm out and fit it to the loom. as i got so exited i forgot the camera at this point but it was only wiring but i do have pics of the interior. As i put bits back in i cleaned it all up and it looks and smells awsome, just like new:top:









now all back to gether and all niggles sorted all i had to do was get cleaning which actually ment getting very messey first wet sanding and mopping, anthother six hours later making a grand total of sanding and mopping 10 hours:cry::cry: after that i cleaned it off as the compond gets everywhere and that was it for the night

before





after







got loads more pics to do but far too late i cantt keep my eyes open ill finish 2muz a correct all the mistakes;-)

[jon-ross]

hello peeps, ive had a very weird day to day. first thing this morning i got some fuel for the car and started it up and all was good so off to the mot station, YAY:top:. it was there for a while as they just squeese our mots in and when it come back, MAJOR DISASTER. The oil was mixing with the water but wasnt over heating:tiff::wall::angry::tiff::wall::angry::tiff::wall::angry::fume::fume::fume:. but to my suprise i just shruged it off and yea i felt so gutted it felt like my guts were upsidedown and i felt propper sick but i just laughed and said off with its head for the second time then:top:. so instead of driving the car home, i stayed late yet again and got the head off and while i was in the prosess i drained the coolant and it was just oil, creamy fudgekin oil:wall: from that point i just new it wouldnt be the gasket:cry:. when i got the head off i found that the gasket was perfect and you could easly see with the creamy oil so the problem is either cracked block or head:king:. im going to have the head crack tested and hopfully comes back ok as i sent f**k loads of time on the head and id rather rebuild the bottom end than port another head that neatly.
ive gone to far now to give up. it would be such a waste of time and money, and it passed mot with no advisorys!!!!:top::top: i just think that maybe its just paying me back for the 3 years of constant s**t and abuse i gave it;-). i going to load upsome other pics 2muz including the mess its it now.

[jon-ross]

above is video on rollers 148.8 bhp atw

[RSGeorge]

Looks good mate, prefer it with the S2 wheels on

[Michael!]

fair play for sticking with it! i was like this with my zetec s, its gone to car heaven now though
i agree with george on the wheels too mate


im with you on the foglight, i got so angry i threw wrench at my windscreen, bad times

[jon-ross]

cheers for comms guys and yea i liked the s2 wheels aswell but they were borrowed off an s2 in the workshop as my front arms rubbed on the rollers when the car was strapped down and only just cleared with the s2 wheels