fiestaturbo.com

[knuckles]

sorry didnt look on edix today for your cable. I had a bit of a Knock in my rs this morning and it kinda ruined my day

will give ya a text tomorrow if i can trace one

clark

[Dazza]

Lookin good, love the colour!

[RS rob]

sorry didnt look on edix today for your cable. I had a bit of a Knock in my rs this morning and it kinda ruined my day

will give ya a text tomorrow if i can trace one

clark

hope everything is alrite mate,

no rush with the cable, thanks again for having a look when you have time

[RS rob]

Lookin good, love the colour!

thanks mate

[RS rob]

been trial fitting the ends of the car spit
the front end is lovely and solid as its basically on the chassis leg ends


but the rear is bolted to the rear panel and had alot of movement when bolted up
so tried bigger washers which made an improvement





so looking to strengthen the back as i dont want to damage anything,
noticed the hole below the bumper mount





looking underneath, the hole is part of the rear chassis leg





so i opened up the hole with a belt sander and trial fitted a piece of boxed steel bar





so the plan is to use an existing hole in the rear chassis leg to bolt the metal bare securely
and weld another piece of box section steel to make it all secure
i've used red lines to show where the other piece of steel would go
this should really firm it up





as i plan to seam weld the most of the front end of the car,
the factory sound proofing inside the shell needs to be removed, lucky with the cold wether its coming off quite easy with a hammer and chisel





and i've come across a problem,
ordered a brand new fords crankshaft pulley as everything else on the engine is brand new

it arrived in a horrible primer, as all the other pulleys come in a smooth black finish i wanted them to be all the same.
so after ringing around other dealers to find out theirs are the same
even a good mate clark the other side of the country searched his dealership to find them with the same primer finish

so i'll probably have to paint it myself




been buying more lately so will have some more updates very soon..........................

[Dave G fsi]

Doing a really good job there mate, keep it up

[RS rob]

thanks mate
cant wait to be at the stage you are with yours!!

[jonyb4]

looking good mate

thanks mate
cant wait to be at the stage you are with yours!!

oo looks like i have another project to read

[RS rob]

tonight with the good help of a work mate adrian,
the jig was sorted at the rear of the car to make it more secure and solid,


as we started before





after the hole being opened up with a belt sander to reveal the inside of the rear chassis leg





dimensions were taken, metal cut to size, and placed fire mat's over the car appropriately as we're about to weld





a close up of eveything ready to weld





job done, nothing pretty to look at but does the job we want!!






a nut was tacked inside the new tube before welding to the jig,
so that the metal tube is tight inside the chassis leg,
using existing factory holes in the rear leg the nut and bolt work well





heres the jig connected to the front, which did'nt need any modifications

[RS rob]

stripped back alot more sound deadening and even the seam sealer (will go more into that another time)





heres a close up of the floor plug i've removed, as one was a little loose when removing the factory sound deadening, so i plan to remove them all and weld them up!






my last engine had a small oil leak which i never got around to sorting, but it had blown all over the engine bay
so alot of things are quite dirty,

using a parts sink cleaner i cleaned up my vibratechnic uprated gearbox mounts, gave them a good clean
will probably rub the metal surfaces back and give a lick of paint to freshen up





also cleaned up the coilpack bracket, not sure why its gone a funny colour, but its clean and one of the many things i plan to have shot blasted and then powder coated





my vernier pulleys arrived, which accurately allow the cams to be advanced or retarded
and also look nice ha





got hold of an msd coilpack (has a higher voltage and not supposed to be used with standard leads)
so on the search for a set of them, unfortunately its an american product so the seach is'nt going to be easy





got myself a new header tank aswell





my new crank pulley which i'm going to have painted black to match the water pump pulley

[jonyb4]

nice little list mate, specially the coilpack

wont them ford racing plugs work with it then??

[RS rob]

nice little list mate, specially the coilpack

wont them ford racing plugs work with it then??

i'm not sure, so not gonna take a chance either

[pjdj1989]

Looks good buddy!
Been following your progress over on zsoc, Should be lovely when done!

Do you have a timescale for getting it done?

[andymcd]

its getting there anyway
pulleys look where did you get those from mate?

[knuckles]

nice progress rob
this will be a minter once you finish. mine will be going in for a complete strip down soon too by the looks of things

Not sure the uprated coilpack is really nessasary tbh - last thing you want to do is melt the leads onto the plugs

bit of a bummer about the crank pulley.
thats fords way of cost cutting i guess

[RS rob]

nice progress rob
this will be a minter once you finish. mine will be going in for a complete strip down soon too by the looks of things

Not sure the uprated coilpack is really nessasary tbh - last thing you want to do is melt the leads onto the plugs

bit of a bummer about the crank pulley.
thats fords way of cost cutting i guess

looking forward to some bodyshop pics from you clark,
i'm in two minds about the coilpack, sad to admit but its looks nice and different
the fact i've gotta chase up the matching msd spark leads is putting me off

i'm just going to prep the pully myself and have it painted matt black to try and match the other pulley

[RS rob]

Looks good buddy!
Been following your progress over on zsoc, Should be lovely when done!

Do you have a timescale for getting it done?

hehe thanks mate, no timescale as i keep thinking of more things to be done

its getting there anyway
pulleys look where did you get those from mate?

just obx pulleys mate, google them!

[knuckles]

looking forward to some bodyshop pics from you clark,
i'm in two minds about the coilpack, sad to admit but its looks nice and different
the fact i've gotta chase up the matching msd spark leads is putting me off

i'm just going to prep the pully myself and have it painted matt black to try and match the other pulley

cheers rob
if the leads are hard to come by you may want to just use a normal coil incase you have problems in future.

have you thought about powdercoating the pulley but asking them not to coat the ribbed bit and where it slides on crank ?

[jonyb4]

what sorta prices do most ask for doing small things like that?

id like me wheels done in the future, but dunno if i can justify the cost, i could get some better wheels for a similar price

ive hard to knocks on my wheels sicne ive used them once was at about 50 but only took a little bit out of it, epoxied it back in lol

anyway drifting a bit

[andymcd]

what rad/intercooler you using mate?

[RS rob]

what rad/intercooler you using mate?

have a look back through the thread a bit, last page i think
GRS cooler and rad

[RS rob]

more progress

ok so had to remove the remains of the rear towing eye to be able to tighten the bolt which holds the spit in the rear chassis leg,
the towing eye was chopped to be able to fit the zetec s rear bumper years ago





hour and a half later of grinding as the welds are all the way through
but allows me to bolt up tight now





been cracking on with stripping the sound proofing





suprising how heavy that lot is





bulkhead panel now soundproofing free aswell,
so when seam welding underneath i dont have to worry about anything melting,
also with the age of the car it could be hiding rust





alot of the seam sealer has looked like this





until you strip it back to find small scabby bits like this

[RS rob]

ok so all the soundproofing is gone but some remains left to get rid of

bang and the dirt is gone........................





also made a start on the engine bay
heres the old rusty battery tray





and where it used to live, to tidy things up i planned to trim the metal back to the red line





also decided to remove the bracket which holds the wheel jack





where it used to live





and after a bit of tidying will all come together soon hopefully





i plan to have alot of parts sand blasted and powdercoated
noticed the lower crossmemeber had alot of deep scratches etc
so spent a small amount of time with the DA to smooth it all out for a better finish later on





few more bits i've been buying
- fiesta turbo throttle cable as the one specific for my car is no longer available from fords
so with the helpfull advice of people on fiestaturbo.com i found out theres a small difference in size but would be fine
- the rear timing belt cover which bolts to the block and main bottom pulley with guide as ian had trouble getting my lower pulley off

[RS rob]

well some bad news

well the fuel tank was'nt looking brilliant as it had alot of rust





so decided to see if it could be saved, DA'd the top surface and alot of rust went and started to look good





but the rust on the sides was going nowhere
so i've decided to look for a new fuel tank





once again fords have come up top trumps again and its no longer available
so going to have to do some research as i dont fancy a patent copy fuel tank as i've heard a few bad stories

[knuckles]

Fiesta XR2i EFI and RS EFI tanks are still availible ?
i checked early last week when you done your post in general

its pretty pricey though

[Max M4X WW]

I'm hoping my 50k tank is ok, As the FRST one I have in the shed isn't great!

[RS rob]

Fiesta XR2i EFI and RS EFI tanks are still availible ?
i checked early last week when you done your post in general

its pretty pricey though

yeah basically their £259 inc vat retail
but by the time i have a custom fuel tank made to copy the factory tank
then all the extra bits to go with it, will be easier to just a new one from factory

[RS rob]

I'm hoping my 50k tank is ok, As the FRST one I have in the shed isn't great!

strange thing is i've noticed a few FRST fuel tanks on ebay
and their all in better condition than mine

must of been parked in a field most of its life

[jonyb4]

nice update mate, i love the colour in the close up shots of the seam sealers, nice glimmer to it

expensive tanks considering its basicly a steel box

[RS rob]

nothings ever cheap when you need it lol

[jonyb4]

remembered the other day we forgot to get a aux belt lol

not to worry picked one upto day at my local factors for 10.95, made by HQ ford in neath wanted 21quid!!

whats going on

[RS rob]

ok so as i've been stripping either sound proofing or seam sealer off
the obvious has happened and i've come across rusty sections
the plan is to cut it out, new steel plate welded in with a finish that does'nt look out of place
regardless if its covered by carpet


so the first obvious hole is the passenger front inner arch




the passenger top of the bulkhead, normally hidden by the dash




been stripping more seams in the engine bay




on this support inside the shell, just under the windscreen was two supports
just incase they were hiding any signs of rust they were taken off




support taken off, more access to strip seam sealer and prepare panel joins for seam welding




rear beam stripped down as i want this shot blasted clean and powder coated black




i gave the rear beam plates which bolt to the shell a quick sanding with the DA
as there was a few layers of paint, so wanted to make sure its clean
before and after




heres the top bulkhead support with seams back to bare metal for seam welding

[RS rob]

how the inside is looking now, with nearly every seam i plan to weld back to bear metal






been stripping the rear arches back aswell




new clutch cable and speedo cable




my new FRST fuel tank arrived
heres the underneath, seems to be zinc plated or something
anyway i plan to have it all silver




the top of it, the ford label shows it was made in 2008




and next to the old rusty tank

[dangerousdave]

have you found a difrence in the tanks mate, they look the same! except for the rust! lol

[jonyb4]

brilliant work mate, coming along nicely, alot of grinding work done, that arch looks mint, do it satin black