fiestaturbo.com

[Simon84uk]

Few pics of new engine going in...
Monday:


Tuesday:





Have ordered some more parts last night, but should get the coolant system and IC pipework back on this weekend. Will book he back into M-Tech probably start of July. Things are looking up!


Si

[jonyb4]

nice going mate, looking very clean and fresh

I gotta say though, blue gearbox?

[Simon84uk]

Yeah it was painted by the chap I bought it from, personally not my taste, but I just want to get it working as it then will worry about painting it when it comes out for respray unless it's out any time soon for whatever reason. I chipped some of the paint off getting it in anyway, oops

Think I'll paint it silver, something simple anyway. Don't like it being dark. It's either that or leave it as is until I finally fit my MTX, we'll play it by ear anyway.

Cheers for the comment though


Si.

[jonyb4]

least its a nice colour

crack on man

[Simon84uk]

Update #1: Engine is now all in and started




All timed up and all fluids filled, she started fine, few not quite tight enough hoses tightened when they leaked then checked it over. Purred like a kitteh

Update #2: Got everything back together




Drove her down the road and all is sweet, little tiwtchy now and then on the map but wasn't expecting it to run smooth as larger head, turbo and smaller displacement (different CR too) than previous setup. Took it slow and with the wideband connected up.

Update #3: Oh dear...

I've decided I'm going to re-shell her, sucks as it's happened after getting the engine in, I've seen a very tidy one for sale and can't resist having a decent one again. My shell could be saved with a bit of work, but even then respraying it would work out more than a re-shell. Also decided against the whole track-car idea too , don't know what's come over me I've been considering it for months what to do once it's running, and I think fast road and having a nice RS Turbo suits me better, can take it to shows then. Bit worried about the loud ass 044 pump being in to boot, might have to mount under the car. Will just strip interior for the pod

So will be selling my track-oriented bits soon (Noting down for myself really, PM me if you want to reserve anything though) :

-- Off the car
Cage - Started to repaint, will finish before selling,
Poly windows,
Carbon roof,
Wilwoods,
Alloys (Fox black and chrome ones in other pics)

-- On the car
"Centre Console",
Seats,
Fibreglass bonnet

-- Other bits
EFi head with Kent cam and adj pulley
Zetec block with forged pistons (needs new water pump adapter plate, or mine straightening)
T34 Turbo (non-Garrett)
Paddle Clutch,
BC gearbox,
MTX-75 gearbox standard
MTX-75 gearbox with Quaiffe LSD and 3rd gear
RS2000 Gear Linkage
RS2000 Engine

[jonyb4]

oh my! big change of plans then?! sound s abit better though

witha wacking big turbo who needs a stripped out car anyway? will still be alot to handle on a circuit

[Simon84uk]

Ok update so far,

Original car has had the engine, gearbox, turbo, manifolds, etc removed and shell is now out on my gravel driveway out the way ready to be collected by whoever once I no longer need any bits.

New shell arrives today around midday so got 2 days off to fit all suspension, brakes, possibly engine? onto the new shell.

Will post some pics of the new shell soon, taken some of the engine coming out again lol, but that's been done so many times on this car I lose track.


Si

[Simon84uk]

Despite having 2 days off to fit bits and pieces, with the shell not finishing unloading until 3pm and the rain slowing play got a fair bit done. Not as much as I'd have hoped though

Tues:
Unloaded new car
Removed front shocks, brakes, sub-frames from old car
Fitted Front sub-frames, ARB, Shocks and Brakes to new car

Wed:
Removed rear shocks, brakes and handbrake from old car
Fitted Rear shocks, handbrake
Made spacers for rear brakes (didn't do this on previous car, cut beam instead)
Fitted rear brakes
Fitted hard fuel and brake lines
Removed swirl pot, 044 pump, filter and hoses from old car and mounted on new
Started fitting fuel hoses.

Thurs:
Put all bits that will be fitted on new car inside it, anything else in my old shell
New car now away in garage


Si

[Simon84uk]

Ok, thought I might as well update this as having a quiet morning at work...

Essentially it's all been an absolute nightmare! Got the car built on the new engine, got it trailered to Mtech where it was checked over, few changes then mapped. It made a good 267bhp and 326ft/lbs but was held back by air flow.

I was excited to get her back, but driving her home from M-tech middle November 2012 she got about 30 miles and packed up . It wasn't running right for the last mile as was failing to rev up, but maintained constant 3k revs so I figured I would nurse it home at that, but the RS had other ideas.

I had a quick look over her without stripping too much down and didn't see anything obvious, so I got it trailered back to Mtech middle Feb 2013.

I've linked these from M-Techs facebook album of my car:







As you can see the cam had worn through one of the followers, and cyl #4 big ends are scored. This has lead me to abandon the ZVH idea, as no longer trust 8v heads and go to a full zetec turbo. Also had to get the crank reground and new bearing shells fitted, so pretty much full rebuild.

It's still there being worked on now, slow progress as they have a lot of projects on concurrently at moment but I'd rather it was done right. While it's there we've had some other stuff done to make it better , new pedal box fitted, hydraulic clutch actuator, rover turbo inlet, 640cc injectors, 16v head port matched to inlet and exhaust, full rebuild of the bottom end bearings and a head stud kit.

Most of the work is done now, just needs plumbing and mapping. I might get them to get my arches and skirts painted and fitted (awaiting quotes) so when I get it back I don't have to worry about organising that.

I'm looking forward to getting it back, but just been a nightmare of a car for me. Still once it's done, it's done... until I decide I want more out of it


Si

[andymac]

Ahhh crap. FWIW, something very similar happened to my mates ERST - luckily turned it off the instant something sounded off (was on stands in garage). It's still in bits 6 months later, but slowly coming together.

[Simon84uk]

Ahhh crap. FWIW, something very similar happened to my mates ERST - luckily turned it off the instant something sounded off (was on stands in garage). It's still in bits 6 months later, but slowly coming together.

Did he ever find out what caused it? Still no idea what caused mine, but the new Zetec Turbo is running sweet.

Another update: MTech has informed me the car is running again, but there was a slight oil leak caused by a scratch in the head surface. This was skimmed out and now back together. Has had some mapping done hitting 275bhp and 335ft/lbs but she's running a bit too hot.



Next step is they're going to fit an oil cooler and start chasing a bit more power.

Here's a few pics of the engine bay:





Hopefully will have it back by this weekend or next super excited!


Si.

[- Danny Boy -]

Awesome stuff

[Simon84uk]

Thanks mate

They're fitting oil cooler to it to try keep temps down hopefully it does the trick. Was meant to be going up for a test drive today see if anything needed tweaking, but sadly had too much piled on at work.

Going to be fitting the cooler in O/S fog light so I'll probably cover it with some black mesh to try and hide it a bit and keep those nasty stones off the fins.

Even when I get it back I'll still be handing it straight over to local bodyshop to get the skirts and arches repainted and fitted, so will be a little while before I'm driving it about properly still.

Not going to add up what I spent until it's done so I don't freak out too early...


Si.

[Simon84uk]

Update...

M-Tech have finished mapping the Fiesta


Or link in case video doesn't work...

Making 285bhp @ 17psi! Picking it up tomorrow and hoping to take it to the pod this weekend, providing weather hold off.

I'll get some pics up of the work when I get it back, but thought I would share the video with you all as I'm just too excited!

You can see some of the pics in the album of my car at M-tech automotives facebook page link if you were interested.

Awesome!!!


Si.

[- Danny Boy -]

Awesome stuff Simon

[Simon84uk]

Finally had a chance to sift through pictures and get them organised. So here are some pictures over the last 18 months showing the Re-shell, the 3rd engine rebuild and some other bits and pieces (Some pics from M-Tech's facebook page).

===== 2012 =====
Re-Shell
Tidy new one





Interior In


Engine Fitting




Came With Lots Of Spares


Scapping Old Shell


Stainless Exhaust Manifold



Engine Failure
(See previous posts)

===== Mid-2013 =====
Rebuild Engine As Zetec Turbo (3rd engine)
New Gasket & ARP Head Studs


Port Matched To Exhaust Manifold


Port Matched Rover Inlet Manifold


Crank Reground


Knife Edged Throttlebody


Pedal Box


Reservoir Pots


Hydraulic Clutch Actuator (No more snapped cables)


Oil Cooler


All Back Together & Running


===== Late-2013 =====
Seat Mount (Still need to raise front off floorpan, shown in diagram)


Bodykit Back On


Painted Mirrors


Number Plate Fitted


===== Jobs for 2014 =====
- Finish seat mount
- Tracking
- Fog Light

[russ-RST]

Awesome progress! Looks stunning all back together and a tasty zetec turbo in there too out of interest did they tell you what was holding back for pushing more power?(can pm me if you wish) I'm building a similar spec'd engine and hoping for 300bhp
Will be keeping an eye on this its a beauty!
How does it drive now? Hope that gearbox doesn't give you too many troubles
Russ

[Simon84uk]

Hi thanks, few things holding it back. First being the valve springs, over all the research I done I missed them until few weeks after getting it back where I should have uprated them. Secondly I feel the turbo exhaust housing isn't flowing well enough as it's a .48, maybe something to address when I relocate over gearbox at some point. Third thing which is probably not helping was that is wan't mapped on my EBC but using a bleed/relief valve. But for now going to fit those valve springs, my EBC and GRS intercooler and get the map tweaked.

My mates RS with very similar setup using ECU controlled boost solenoid, with valve springs ans cossie T3 hit 320bhp so spec is there for the power you're after.

Got a set coming soon from a mate who's abandoned his ZT build and have only done mapping miles on dyno.

She did drive very well for a while but has since started developing an occasional mis-fire on full boost. Haven't had time to look into it much but at the moment I'm suspecting plugs aren't cold enough at present. Will hook it up to my laptop to check sensors and run it on my LM-1 wideband to check that too.

I need to finish polishing it as only done the roof and A-pillars so far, loads of cack on the surface needing clay bar off.

Gearbox is too short IMO for this power, go into 4th within maybe 10 seconds so will look into changing final drive gears.


Cheers,
Si

[mtechautomotive]

Hi Si...

How is the little fezzy doing?

Let us know when ready for EBC mapping, have seen some really good improvements when setup correctly, stopping the tailing of of boost (and in worse cases its creep)!

Matt

[Dannyb001]

What pedal box is that that you are using

[Simon84uk]

Little update after about 5 years...

A summary would be not much, kids, not much, then a few stints here and there.

Here is a list of the changes since 2014, most being in the last 12 months:

• Replaced valve springs with uprated units
• Replaced all studs, gaskets etc on Turbo
• Built a custom dash cluster
• Replaced a failed rear wheel bearing
• Removed the Compbrake Pedal box
• Begun fitting a Mk5 Escort Servo and Master
  - All mock fitted and pipework made
• Begun modifying the Rover inlet modified
• Brand new Ford rear ARB bushes and brackets
• Sent coilovers back to AVO to be rebuilt, adjusters are seized so they wouldn't. Will be replaced soon.
• Many iterations of work on the map/ecu
  - Relocated IAT
  - Recalibrated IAT, Coolant Temp and TPS
  - Modified several setup settings which weren't quite right
  - Changed to use dual maps switching at 100kPa, then recently gone back to single lol
  - Managed to break the ignition map by pulling too much timing out
• New custom HT leads
• Changed battery for a larger one and made a new mount
• Fitted a pair of AR-1's to a pair of the wheels for test fitting clearance, arch work still in progress

Current todo:

• Modify dash cluster to use a screen with MS Shadow Dash installed
• Finish off inlet manifold work
• Modify the brake servo push rod length
• Finish arch work to fit 195/50/15's
• Source a new set of AVO's
• Fit a separate switched 12v supply to the glovebox to replace usage of always live cig lighter.
• Look to get the map revisited once everything else is up to scratch

So actually a fair few bits completed, just hoping I can get the major changes (Inlet and Brakes) completed in the next few weeks.

I'll probably update this again in another 5 years

[Simon84uk]

So... this will be the final update .

It was reaching the point where I was not getting time to finish the parts and she was rusting away as don't have a garage at my new house. A friend reached out to me and has bought the car off me to put his own engine in, fix the rust and respray it. Generally doing the old gal the justice I could not.

I've bought myself a Focus ST as a "simpler" fun car where I can just use bolt-on parts. Hopefully, once life slows down a bit I can return to Fiesta RS Turbo ownership, still love these cars.

Thanks all for the kind words along the journey.