fiestaturbo.com

[jayrs]

it will be fine mate

[ianFRST]

only just seen this

glad you got the plate ok (was it really that long ago i sold it you )

[xrt-mart]

Yes it really is that long

It looks the part on the engine even if I havent had the chance to test it

[xrt-mart]

I really should update this thread more often

To start off I have bought a new shell I must admit its one of the best MK2 shell's I've seen. I have owned it for nearly 2 months now.

It is being sprayed white and having the kit put on to make a XR replica. My white XR shell is being scraped (monday whith a bit of luck)

anyways heres the pic of the shell





















I have swoped most of the interior trim over from the white car to the new one to keep it dry because I dont have space to store it. Ive had to leave the original headlining in because it is different to the XR one. Think Im gonna paint it black with some frauds interior paint as Ive had some good dealings with it before.

heres the pic's

before


after ( very dirty but have new ones now thanks to stewie )


xr rear panel vs 1.1 door card not the different colour


rear c pillar trim, parcel shelf holder and boot side capet trim. also sound deadener over rear wheel arch fitted.


finaly rear seats (very dirty) Hoping to replace with retrimmed 88spec


I also have my friend coming to detail mask the rear window surround on before the white car goes.

on the parts list I have a new garret -31 actuator as they are smaller and a AP 4 paddle clutch

oh and also won a remote ISCV from a XR2i engine. This will sort out the issue with the manifold/iscv clearance



mart

[jayrs]

scrapping it

gotta say that is one clean mk2 there, shame its a auto, means ya got to take the pedal box out of the xr now

[xrt-mart]

already stripped the white car mate of everything.
It was supposed to be going yesterday but the guy didnt turn up. Hopefully monday will be the day.

[jayrs]

get a pic up of the poor thing

[xrt-mart]

will take a pic tommorow

[jayrs]

cool

many years ago when i had a old silver xr2 i was waiting to be picked up i attacket it with a axe and a concreat block.
first time i removed a front arch spat with a blcok i must say
and a axe is great fun, cut through rearpanel and inner wheel arch like it was paper
i was young at the time though

[xrt-mart]

Doh just realised I forgot to take the picture

The white car has gone now to so its to late.

Anyway, I've been trying to make a good set of front seats out of two sets I've got. I have successfully managed to get a good pair, although they are both passenger seats but aren't they all

this is what it looked like earlier in the week (look at the original f**cked one on the right!!!)



thought id take a look under the carpet too while the seat was out. very impressed again





and ended up with this







mart

[jayrs]

doh no pic

shes a clean beast mate,, im hating it, im watch a couple of mk2 topics and it so makes me wanna get another one

but i cant

[xrt-mart]

ah go on you know you want to

[jayrs]

well funny you say that im waiting for a mate to get back to me about a silver D reg

[xrt-mart]

I have managed to take some of the engine parts out recently because I was feeling bored. So took a few pics while I was there









Now I have managed to source some rear seats from neilfree ( thanks again mate!! ) Just need to make some modifications to fit them as there MK1 items. The bottom piece fits fine but the catch area is smaller so needs the mk1 piece bolting on and the hinge is different but I don't know what I need to rectify this?

here is a pic anyhow



just need to change the carpet now as its bluer than the XR one and change to xr front door cards which are having a splash of 88-spec red dotted material added to them to match everything else

[Excursion]

That is one good shell, it could easily be concourse with a bit of work!

[Sphinx]

Catch those tiny bits of rust before they spread and go mad with some waxoil and that shell will stay clean for years to come!!

[xrt-mart]

I will be sorting the rust out along with the full respray and lots of wax oil over the summer.

Right well I decided to change the carpet because it was blueish like the rest of the interior :roll:

First of all removed the carpet and sound deadener to have a look at the floor. I was impressed











and the xr grey dash, clock set and steering wheel



with grey carpet fitted (note the blue centre console :wall: )



better pic of the rear seat and whole set






I had a trial fit of the intercooler just so I can get on with doing something while waiting to move house :evil:

Anyway here is a basic look of how I want it to be. The drivers side just needs lowering around a centimetre. There was a lot less cutting involved than my previous cooler which cant be a bad thing. The only reason for this is the cooler sits in font of the panel









Also managed to get the tb sorted. The answer was staring me in the face to. I bought a tb off stu a while ago and it turns out that it has a air volume mixture screw built in which Ive never seen before on a zetec. I don't know what car exactly it came off but it is the answer I've been looking for.





and here it is compared to the 1.6 throttle body



I've not got a completed pic but it was easy to sort out. Just needed to open out the spindle hole on the accelerator mechanism to 10mm and jobs a good'un

The engine is now OFAB engine management ready with the zetec manifold so it can all bolt together

mart

[heeman10]

That's one hell of a shell! What's with the wood inserts?

Looking good, that floor is really impressive!

[Choosey]

Looks fantastic mate. I'd be tempted to put some 15's on it, lower it then leave the exterior as it is!

[xrt-mart]

That's one hell of a shell! What's with the wood inserts?

Looking good, that floor is really impressive!

What wood inserts mate? You mean the things on the inner sills? If thats what you mean it is sound deadener, looks original to. There is loads more sound deadener on the whole of the car. Must be because of the 1.1 engine

Also mate I have managed to get a set of beige injectors now along with a good condition friction plate for the AP 4 paddle clutch what I was asking you about

CHOOSEY The car is going on 15's and being lowered but will be having the kit put on and painted white as per my original XR2

[heeman10]

Good good, glad you sourced what you were after And yes, I was talking about the sound deadening panels, I think David Dickinson would be interested in those bobby dazzlers!

[xrt-mart]

[thorny]

looking very good so far dude!! ive never seen a mk2 shell in that good a condition!! congratualtions!

[xrt-mart]

[niracka]

tis been ages since i looked at this thread dude! looking good. That new shell is spot on. Looks like it was destined for good things

oll

[JayC]

great thread mate, good luck with all the work zt is the way to go

[JayC]

oh yeah a couple of 5mm drill bits do the job for setting the cams.. but get a tool!!

[xrt-mart]

oh yeah a couple of 5mm drill bits do the job for setting the cams.. but get a tool!!

Missed your reply mate SORRY

I have got the propper zetec cam tools for the job though

[xrt-mart]

Thought id better get an update in

Got some pictures of the 99% finished throttle body.



Now has the correct linkage on it just needs a big washer to hold the second bolt at the bottom of the cable bracket.



and a washer inbetween the spring/throttle body base as its loose and when up against the body full throttle cannot be had



Managed to do something to the car for a change as Im getting bored of waiting to move house.

removed the engine













then gave it a quick clean up.







Fitted the engine but please bear in mind that it needs a good clean. I will do this when the build gets done.









This is the position I originaly had in mind for the radiator. The screw you can see is in a newly drilled hole, the old mounting point can be seen to the right about 6 inches at a guess. The bottom part is moved into the front panel by an added braket. You just make out the original retaining flaps in the chassis.

This allows the fitment of the cooler but makes it tight against the headlight. It was like this on my last conversion though and didnt give me any issues







I've placed some of the parts in the bay for a mock up so I can see where I need to cut the cross member and front panel for the rad. Also I wanted to check the bonnet would clear the crossover pipe which it apears to do just about

I took some pics of it so you can see where Im goin with it







I have had to move the radiator again though as it was touching the turbo actuator bracket.

It now sits right down in the front panel and uses the mount bracket originaly intended for the lower spec small rads . It does move it away from the head light and leave more room for the fan to be fitted with it being lower down

mart

[heeman10]

Zetec Turbo in a Mk2, it's so funny! It'll be a hilarious thing to drive! I run my turbo about 6mm off my radiator. As long as you have good mounts you can run them pretty darn close. Have you trial-fitted the bonnet yet? It looked as though the cam cover would probably be close to hitting, let alone the charge carrier! What are your plans there?

[xrt-mart]

I've placed some of the parts in the bay for a mock up so I can see where I need to cut the cross member and front panel for the rad. Also I wanted to check the bonnet would clear the crossover pipe which it apears to do just about

Although I may try and lower the engine a smidge to allow for engine movement

I have sorted what im doing now with the managment BTW. I going to run the beige injecotrs with no chip for now and low boost.

Ian Howell recommended this until I can afford the upgrade so that will do for me. Should see me to the 200BHP mark anyway and still have loads more torque than the last ERST conversion

[heeman10]

What a w@nker Clearly got distracted during my reading

Sounds like a good compromise, it'll still terrify everyone inside and outside the car

[xrt-mart]

Im sure it will keep me entertained for a while

[jayrs]

looking good mate

[xrt-mart]

Well things ground to a halt again after moving house. I still have no access into the rear where I need to work on the car.

After contemplating going megasquirt for a while. I have decided its to expensive and to much of a gamble at the mo so have decided to stick with the OFAB for now. I figured that I might as well continue with the management side of things as much as I could so I have a little progress.

First of all back to the throttle body. I have put a spacer in front of the linkage to stop movement on the main spindal. This work a treat



Then it was back to it with the die grinder so I could get back full throttle.





I have drilled and tapped the fuel rail mounts out to M10*1.5 the same as the 15mm munson ring all I need now is some threaded bar to complete the sandwich plate.



Then I made a start at modifying the throttle position sensor adapter so it would fit on to the throttle body first I drilled the mounting plate for the zetec end then put the spindal in and worked out roughly where I wanted the sensor. Next I cut the D shape into the spindal and positioned the sensor half a bolt hole back as that is where the original one was and mounted the FRST item there like so



Next I dummied the two together again and I noticed that the fuel return pipe was heading straight for the inlet. So I got the die grinder out again and made a passage for the pipe and all is well again



So at the moment it looking something like this



mart