fiestaturbo.com

[Excursion]

Tke off the'plus' - that was added to the original 'Popular' spec, I think you got a clock and heated rear screen or something

[RS_Rawli]

clock and rear speakers i think

mine was a popular with a clock, had been wired in by someone, had the coin tray in the boot though

some of the base spec ones didnt have a parcel shelf or supports

or speakers come to think of it

[Smo]

I thought this thread had died

The "PLUS" is staying, sorry It's what it is so I'm leaving it

The 16v bit went a while back though People were 50/50 about it. I liked it for a bit, but got bored quick

I don't know what the Popular had, but mine had split folding rear seats, cigarette lighter, radio cassette (as opposed to just a radio that some had), glove box door, heated rear screen, rear wash/wipe and the parcel shelf (lol). No rear speakers though

A guy's at work had literally none of them except the parcel shelf

[Excursion]

clock and rear speakers i think

mine was a popular with a clock, had been wired in by someone, had the coin tray in the boot though

some of the base spec ones didnt have a parcel shelf or supports

or speakers come to think of it

or a passenger mirror

[Smo]

Update 06-07-07

Hmm, where to start...

Exhaust Manifold

Purchased a 4-2-1 from purple_fiesta, back at the beginning of the year, with the intention of seeing just how far I could reasonably go in NA form. The idea was to get it before I did anything else engine-wise, purely to see what gains it would give on a totally standard 1.8 105PS engine.

I chose this over an Ashley as it would have cost me about the same, but was something a bit more unique (hopefully), and a bit more better-designed (also hopefully ). I've heard of Ashleys cracking on CVHs, which of course could be down to a million things, but decided I would try something different nonetheless

It required a bit of messing about to get it to mate up to my midsection, and the photos below are of the initial stages, so aren't very neat! Plus my welding isn't exactly the best anyway I'm not sure exactly what the manifold was used on originally, but I'm guessing it was probably for an Escort with a rear-mounted starter, due to the fact I can only fit it with my 1.1 starter motor - not a big issue, but when it's hot, it does suffer a bit... I have a few possible solutions to this when I get round to it


Old restrictive cast jobby:




Standard downpipe and cat:




4-2-1 with a piece of Ashley midsection to get the angle right:






Bolted up to head (clears the rad and fan fine, although it was a little tight to get it in):






Correct routing for the Fiesta/Escort/Orion sump (not the tidiest of joins, I know):




Where the 2-1 downpipe meets the 4-2 manifold:




That's about it for manifold photos, as there's not an awful lot else to show. Once I'd got the positioning as good as I could, I welded the piece of Ashley to the downpipe with the intention of connecting it straight up to my current midsection, only to find there's the slightest difference in diameter; just enough to not give it a good seal! Luckily I had another piece of exhaust in the garden which was the perfect size to go inbetween and give me a good seal. So at the moment, it's not a tidy setup, but it's something that works, and can be improved on when I get round to it

Definite change in exhaust note... I'm running a standard midsection and back box still, but I can only describe it as sounding like the old MK2 Orion 1.6, if you can imagine the sound those make Strangely enough, I didn't notice a huge difference at first, and it's only since I've gone back to the standard manifold, cat and downpipe (temporarily), that I've noticed that it did in fact give me quite a nice increase in low/mid range torque

The engine also felt a lot freer at the top end, however the 105PS cams are seriously restrictive (the exhaust cam is the same as the 1.6 90PS cam), and so I can only imagine that a change of cams will really release the full potential of the manifold... Or at least I hope so! I think a change of exhaust system would probably help no end also - something I'm looking at


Next up, brakes

First of all, big thanks to Steve (Scort) for the calipers!

I wanted 260mm discs as I didn't want to get rid of the 14" steels. I like the wheels as I think they suit the car, they fit perfectly without rubbing (due to being standard Si steels), they give me the grip I want (due to the width), the tyres are relatively cheap to replace, and also they don't shout "nick me!" when parked somewhere dodgy And obviously I'm still trying to keep the car sleeperish


The calipers:




(Believe it or not, that's after some cleaning up )

I wasn't entirely fussed about how good they came out, as they were going to be pretty much hidden, but I want them a little tidier than the norm, so after rubbing them down, cleaning them up, etc, as much as I could by hand, I sprayed them up with metallic grey VHT paint. I had no idea how long the paint would last, but thought I would give it a go. I didn't want a shiny/glossy look to them, because even though they were going to be hard-to-see anyway, I can't stand how tacky standard Ford calipers tend to look in a bumpy lumpy gloss red or yellow paint - even in black they tend to look untidy once a tiny bit of brake dust gets on them...


So the result:





Fairly matt, a subtle colour, and a happy me


Not a proper test fit obviously, but I tried them under some RS1800 wheels I have with an RS2000 disc to see how they'd roughly sit; more than enough clearance






Fitting...

Old discs and calipers! Eeek!




Scary!


Almost completely hidden even with the big gaps in the alloys I've got on at the moment:






Old discs were a bit knackered(!):








... and weedy:








Test fitted up:






(Excuse the hairs!)




Behind XR2i 16v wheels:





Just about clear OK


However...

Behind a mucky steel:



... you can see light between the top surface of the caliper and wheel, but...





... the front edge of the caliper is incredibly close! So it looks like I'll have to use some 3mm wheel spacers before I can put the steel wheels back on, just to be on the safe side. Rather annoying as I didn't want to use spacers at all, but bigger brakes were far more important

After making sure the calipers and discs did fit fine, I then fitted them with some braided hoses which I had made up by Rally Design:


(Edit: Image added as I've just found it )


I've still to fit the rear hoses, but I was holding fire for one of these...


Zetec S Rear Beam

Been after one for ages now and finally got one the other day from Max, whom I've nagged numerous times to sell it to me





Needs a good clean up and paint (which I'll be doing shortly), but it comes complete with Powerflex poly bushes:



... and some inhabitants...



... that shall be rehomed in a humane manner


Rear hoses to go on at the same time:




Other Odds & Ends


Front 16mm ARB poly bushes:



Will hopefully help the front ARB do its job a tiny bit better, but I'll just be happy if it saves the rubber ones wearing out so quick


Steel wheels to go back on:





They were clean the other day, but with the amount of rain we've had, they've got absolutely filthy! They do need a tiny bit of paint again as they've gotten chipped a bit from various moving about, tyre-swapping, etc, but can't wait to get them back on


Focus 1.8/2.0 Inlet Manifold








... and just in case the part numbers are interest to anyone ...





Having checked the part numbers out, the injector flow rate is almost identical to my current side-fed 1.8 injectors, and should therefore be fine on standard management I have got the figures noted down somewhere, but I think they're on another computer, so don't have them to hand right at this moment.

I'm not actually sure whether I'm going to use it yet... It's something I was just going to have a play with to see how effective it is, but if I decide to go a lot further with NA tuning, then I may just skip it out and go straight to throttle bodies... We shall see If I do use it though, I don't want to use the plastic Focus throttle body if I can help it, and use the 2.0 silver top Mondeo throttle body instead. However, even though the Mondeo throttle body will physically bolt up to the manifold, it will not seal correctly due to the different way the gaskets are used on the Focus and Mondeo setups, as well as the mating surface on the Focus inlet not being completely flat.


The two throttle bodies:





You can see above that the rubber gasket is situated in the grooves of the Focus throttle body, whereas on the Mondeo setup, it is part of the inlet manifold. Unfortunately I can't use the Fiesta/early Escort type gasket either because of the mating surface issue. I did find a Mondeo throttle body that will attach to the Focus inlet properly which had a more normal opening like the 2.0 alloy one, so I may resort to using that for simplicity, if I do decide to use the inlet eventually


Not a lot else to say really at the moment, although I do have some 2.0 cams on the way. I was never going to play with the 1.8 engine, but before anything bigger does go in (it IS going to happen ), I've decided to have a play to see what I can see out of it (hence the 4-2-1, Focus inlet, etc., above). So once they arrive, I'll look into fitting them, along with the 2.0 throttle body above (with or without the Focus inlet) and a 130PS XR3i ECU. Next up will be different management (haven't decided exactly what I want yet), along with a decent wideband lambda controller (probably the Innovate LC-1), all in preparation for whatever I do with the next engine This engine will serve as a good engine to learn and practice setting the management up with before destroying something that I've put a lot more money into

Well that'll do for now

Cheers

[knuckles]

Someone has been a busy boy

Loving the new brakes - those old ones were certainly knackered....
I so want that rear beam

[Smo]

I'm sorry, but even I almost didn't get it

Not sure how many times I told him I wanted it

[Max M4X WW]

Cool, beam looks like quite a state there Just surface rust though and doesnt really matter what it looks like

Inlet looks good, looks like you should run an external breather! Bit of a mess in there

[Ollybee]

Nice to see an update.

[jayrs]

nice update mate

Someone has been a busy boy

Loving the new brakes - those old ones were certainly knackered....
I so want that rear beam

why you want the beam?

[heeman10]

Those brakes are nice and snug in there!

[hb69]

its been a while since the last update, you have done well. get those rs1800 wheels on

[jonosi]

looking good Si

looks like yer hard work is coming together

[Jay]

Looks awesome dude! Some real work going on

Do you not have the front engine mount on???

[Jay]

Looks awesome dude! Some real work going on

Do you not have the front engine mount on???

[Jay]

Looks awesome dude! Some real work going on

Do you not have the front engine mount on???

[purple_fiesta]

Good update dude, manifolds looking sweet

[Smo]

Cheers for the replies, people

Max - Like you say, it doesn't really matter what the beam looks like (especially on my car ), but I will give it a quick going-over Inlet is a bit of a state! As I said above though, it may not even get used yet... Not sure really Would like to see what a difference it makes

James - They are indeed! I did worry at first that they might not even fit at all, but luckily they did other wise I'd be having to look at larger steel wheels (possibly with a larger brake setup), or a vented 240mm setup, which I really didn't want I could do with an uprated servo and cylinder at some point though as the pedal travel is a little more than I want, but it's not bad

Henry - I still don't know about them, not sure if they'll work... I might have another plan for them though

Jay - Nope I do not! I will get round to it eventually

Dan - Cheers I've got it off at the moment to try and tidy it up a bit more, and it's amazing how much I notice the difference with it removed! Will be getting wrapped before it goes back on too

Olly, Jay(rs) and John - Thanks

[Ollybee]

What were the brakes off and how you finding the pedal with the standard master cylinder?

[Percy!]

Can't believe this is still going, respect for not giving up

[Smo]

Olly - The calipers are Escort Turbo Series 2, and the discs are RS2000 - I have Jonezy to thank for telling me about the setup The pedal isn't great great, but it's not foot-to-the-floor either

Andy - Why would it not be going still? I have nothing to give up about I did the original swap in less than a few days total work back in September which went without any trouble at all, and then everything else I've done is just additional work to improve it and take it further It's great fun to drive, and I have no reason to get rid of it anytime soon - In fact, I have no intentions to get rid of the car at all, and will continue to use and abuse it along side anything else quicker and better that I may buy

[Jonezy]

hey long time no speak,

bout time someone else joined the rs2k brake club (maybe not then)

how do you find they work, my pedals crap but the performance is more than enough for my needs without being over kill.

[Ollybee]

You guys might want to look to upgrading to the Si/XR/RS master cylinder. It's a direct replacement other than the Escort RS upgrade and take the master cylinder from 19mm to 22mm. Makes all the difference.

[Jonezy]

really, i was gonna go for the escort mk5 one but seems a ball ache.


direct swap for an s2 erst one eh?

[Ollybee]

The fiesta one without vented discs is 19mm and even struggles when you uprate to vented fiesta discs. The Fiesta SI/XR/RS is at 22mm and may make all the difference. The bonus is it's a direct swop other than the Escort item.

[Jonezy]

so ive had an SI master cylinder sat in my garage for 12months and it would have made all the difference? grr if only id known they were different.

they looked the same size to me. definatly make a difference then yes?

[Max M4X WW]

The fiesta one without vented discs is 19mm and even struggles when you uprate to vented fiesta discs. The Fiesta SI/XR/RS is at 22mm and may make all the difference. The bonus is it's a direct swop other than the Escort item.

My std one was ok with cossie fronts and zs rear drums

[Jonezy]

well swapped em over and i now have a rock hard brake pedal,


Smo change the master cylinder and you can really make the most of the brakes

[Ollybee]

[Jonezy]

oh and cheers for that olly

[Smo]

Jonezy - It was on my to-do list anyway

I'm just waiting for one to come up locally for peanuts (seeing as they're not exactly worth much!)

[Jonezy]

just annoys me how i had one laid around for 12 months without realising

[Smo]

I just found my PM where I said to you that I believe it's bigger, and you said you were going to fit it and see

Tut!

[onslack]

coming along nicely Si

[Excursion]

Great stuff SMO, a nice selection of mods there!