fiestaturbo.com

[RS rob]

heres a photo showing the difference on the two rear anti roll bar brackets
the top one is no longer available, difference being the metal inbetween





well time for an update on progress

i've stripped the front knuckle, hub and rear disc brake setup ready for shotblasting clean and powdercoating
massive thanks to wolze for pressing the hub and bearings out for me aswell as dismantling the rear shoes
as its going to be powder coated he also mentioned it would be a good idea leaving only the outer race of the front bearings in the knuckle
as it leaves the bearing surface untouched from shotblasting etc






next as i'm still doing the fiddly bits underneath the shell
the rear support under the boot floor was quite wide and stopped me attacking the rust and grime under it
so i've highlighted to show how thick it is originally





you'll notice the difference in the width of what i've highlighted in red again
i took the top piece back and shaped it nicely around the welded supports in the middle so it does'nt look out of place
quite happy with the shaping of the corners, it gave me the access i needed to clean up





much better now the rust is gone, you'll notice the pitting because it was quite rusted
but not too bad because otherwise the shotblasting would of blown holes through it





the rear arch more or less done, few awkward bits of sealer left to scrape off
as its too awkward to get any air tools in there





heres the front arch nearly done aswell, the masking tape is covering the factory holes to try and prevent the sand getting in,
even though it still finds a way, it gets everywhere!! !!





brake flexy fixing point looking free of rust aswell now





a few more parts came in for me, all for the fuel tank this time
including fuel pump/sender unit seal and lockring
springnut and bolts to secure the fuel tank in place
and insulators which were'nt on my car when stripping but ordered them anyway when i saw them on ECAT the fords parts system

[FRSJON]

looking great as usual rob... properly mint car when finished...

[jonyb4]

your really going to town on her mate top job as usual

cheers for that pic on the brackets, ill try my best to replicate the spacer metal piece to save finding the genuine ones


does the masking tape actually stand up to the sand blaster? id figure it just make holes or blow it off lol

[RS rob]

well if you aim directly at it, will go straight through
but theres no need to go near them

[jonyb4]

haha oh god, this one must be more powerful then the one at college, mind that used to make holes in the gloves

that was painful

[mrorange2]

looking great as always mate

[knuckles]

im gonna stop looking in here

keep getting jealous

love the car

[Max M4X WW]

You need to look again clark as I want all those fuel tank bits

[RS rob]

well i've got a spare clear gasket in the picture above
all available from fords anyway

[heeman10]

Looking good Rob! I've just realised I STILL haven't got a pic to you. I haven't tried uploading pics for a while, I assume you still need it?

[RS rob]

Looking good Rob! I've just realised I STILL haven't got a pic to you. I haven't tried uploading pics for a while, I assume you still need it?

yes please mate if you dont mind,
otherwise i'll be chancing my luck drilling it out

[RS rob]

well i've kinda made a decision to sort every little thing i was never happy with
basically i'm looking to take the sideskirts and arches off due to bad fitment/second hand bodykit,
the front wings are coming off because it will give better access to seam weld the front chassis legs completely
aswell as shot blasting every part of the legs clean,

so i've managed to source some rare parts,
i picked up the first two bits last sunday, the other remaining parts will be coming later this week from somewhere else


original ford xr2i / fiesta turbo sideskirt and arch pre-painted ford diamond white
still in the factory wrapping with part numbers etc until i took them out for pictures
they were made in 1990 going from another sticker on the kit







its really wierd having such old parts in factory condition
few more pictures for any old ford fans





studs came with covers





still like new




factory double sided tape and part numbers inside the sideskirt




so the rest of the bodykit pics to come, hopefully so more progress aswell

[Excursion]

Beautiful! I have the genuine rubber backed nuts if you have trouble getting hold of any.

[mrorange2]

where did you get them from?

[RS rob]

Beautiful! I have the genuine rubber backed nuts if you have trouble getting hold of any.

thanks mate, i'll be pm'ing you for some advice soon

:o where did you get them from?

i know off two collectors of rare ford parts now,
what you after??

[RS rob]

well to ensure the engine bay is fully seam welded,
also was'nt too happy with how the wings and front arches had been trimmed previously

so decided to take the front wings off, drilled the spot welds etc





also had some photo's from ian to show how the engine is looking,
although he's itching to finish it, but i'm not in a rush for it.

anyway i'm mega happy how things are looking

heres how the block looked before





after being acid dipped clean





new bearings to go with the polished crank





heres the block after its first coat of black paint

[RS rob]

the new eagle steel rods in their new home






the head back together after being acid dipped clean, skimmed, new valve guides, recut seats + valves





the block was rebored again aswell
original 2.0 zetecs have a bore of 84.8mm making them 1998cc or 2.0
then this block was rebored for the first set of forged pistons at 86mm making it 2047cc or 2.1 as most know
ian decided to have it bored out further for me to make it 87mm - 2098cc
then he ordered new forged pistons and rods with my new measurements


heres my favorite pictures showing the cp pistons, freshly decked block and bores after being bored out and then honed
i love the reflections in the bores

[jonyb4]

looking awesome mate very fresh

[andymcd]

looking mint rob, you hardly know where theres another new bodykit?

[FRSJON]

looks lovely rob awesome...

[Pastieman]

just been reading this all the way through.... good work my man.

wish i had the space and time to do this..... love it

[RS rob]

thanks for the comments again


well i recieved the rest of my new skirts and arches kit,
also still brand new in ford packaging etc





so i have a full kit now woohoo





as i'm having new rose jointed lower arms and the rear beam bushes are powerflex,
i've been ordering more powerflex bushes
polybushes for the front and rear anti roll bar





my new steering wheel was becoming a bit of a knightmare as it use's a different steering wheel boss to the more well known
rs 3/4 spoke steering wheels
after lots of searching, i've sourced myself the right boss
so i'm mega pleased!!






fitted to the steering wheel

[jonyb4]

nice the horn built into the middle of the wheel then?

since im using a mk3 wheel i have to use a after market horn button for my mk4, need it more than ever now its back on the road

[Excursion]

Awesome stuff Put plenty of grease on those arch studs when it all goes back on

The original nuts have been replaced now, they are no longer metal with a red rubber backing. The new version is all plastic, which should make removal in years to come a bit easier than the metal ones.

[HCS PIMP]

WOW iVE just spent an hour instead of planning for my road trip to france reading this thread my god you've put alot of time and effort into this car
really shows dedication
Nice one

[Jur]

Just found this post ...

omfg.. this is going to be better then new.

Me too bought some stuff from german ebay a while ago (Rs1800 steeringwheel in good condition.. for less then 10 pounds, incl postage)

A new RS 4 spoke was recentrly sold here in holland (for just 80 euros)

Some parts are more easy to come by in the UK, others are easier to come by in Holland/germany

Good luck (-:

[RS rob]

WOW iVE just spent an hour instead of planning for my road trip to france reading this thread my god you've put alot of time and effort into this car
really shows dedication
Nice one

lol that made me laugh, done that a few times myself

[RS rob]

Just found this post ...

omfg.. this is going to be better then new.

Me too bought some stuff from german ebay a while ago (Rs1800 steeringwheel in good condition.. for less then 10 pounds, incl postage)

A new RS 4 spoke was recentrly sold here in holland (for just 80 euros)

Some parts are more easy to come by in the UK, others are easier to come by in Holland/germany

Good luck (-:

thanks jur, its worth keeping an eye out these days for bargains

[RS rob]

well its been a busy week just gone for me,
heres a few updates

taken the rear arch kit off which was bonded on previously




the sealer still left on the rear quarter




brand new wings arrived




as the shell is going to be seam welded mainly in the front,
the decision was made for it to be taken for a proper shotblasting session as the small kit i'd bought was'nt strong enough to get the sealer out properly to avoid
weld spitting when seam welding

so on the back of the truck the night before




the missus decided to take a picture




the next early morning ready to go for a trip to be blasted

[RS rob]

so the car was back later the same day,
only problem being the weather was'nt on my side and was raining nicely
this made the journey back very interesting especially when the car cover kept blowing off the back letting the car get wet.
so some time with the airline and new cloth sorted that out!

the next night my fabricator decided to crack on now it was clean
so starting with the plasma cutter he cut out the problem areas of rust



heres some freshly cut holes
this is under the passenger side of the front bulkhead



this is the passenger rear turret



the nasty bits



the side showingno major signs of rust



also the start of the seam welding

[RS rob]

inside the shell is'nt being left out either
the top of the bulkhead





the floor





decided to weld up where the plastic plugs normally go aswell





the main support on the floor, even welded a washer to support the seat bolt points which normally fracture





how the engine bay is looking from underneath





close up of the drivers front arch





heres a clear picture showing the supports used while welding the front end,
as we did'nt want that much heat going into the shell while being held up by the front and rear of the shell





you can see from the seams we intend to seam weld as their back to bare metal





also had the sealer cut off the rear quarters, so the rest can be removed by the fudge wheel

[jonboisescort]

looking great mate

love the look of a seam welded shell

[jonyb4]

amasing job so far, looking really professional, like its only a few days old, hard to believe its been ont he roads for last 15 or so years

gonna be regid as when its done


love the pic of the bay and underside

[Smo]

So much time and effort being put into your car, Rob, and everything looks like it's being done properly too Pretty refreshing to see!

[FRSJON]

your doing such a great job of this rob