500+bhp Mk3 Fiesta Project
Discussion
Some organisation to get things moving again.
Crankshaft and Engine Build
Today I've been in conversation with Ian with regards a plan for completion of the engine, and I'm going to visit him next weekend to go over it. The bespoke crankshaft came up in conversation and the topic of dynamic balancing and lightening; I've never been particularly happy with the weight of the new crank and always planned to have it optimised then the machined areas re-nitrided. I had a flick through the IKE website and noticed that Ike has changed the design of the crank with the new ones seeming to have a lot more weight reduction machining than mine - compare the photos below
I've fired off a mail to see what was behind the change and if there's anything I need to be aware of. I also spotted a 99mm stroke crank is on offer (mine is 95mm for 2.2)...it may be a step too far for what I want but I'll seek Ian's opinion.
Clutch
I've found a clutch. This was a bit of a sticking point because the usual route for the MTX75 above ~350ft/lb dictates the use of either a Helix or AP Raching sintered paddle clutch, and I really didn't want that having years ago gone that route in another car build. I mentioned in my last update that the later TVRs used an AP Racing twin plate organic clutch with the Ford output shaft size/spline configuration so I sent out a few enquiries with regards torque capacity but alas, no answers received so I started looking elsewhere.
In the end I found what appears to the the perfect solution: TTV produce a twin plate organic clutch rated at 550 lb/ft and an adapter flywheel specifically for the Mk1 Focus RS (the gearbox I'm using). These are reasonably new to the market, so that and given I haven't been close to the Ford scene for a while means I don't know of anyone using them. I was in conversation with Ian today with regards starting the engine build again, and he happens to know the owners and will have a chat with them.
The only consideration is the price: they are more than the expensive (twin plate) clutch in the 430.
Wheels
I've decided to go with the (rare) 7J ET35 Mondeo option wheels. I did buy a set of these earlier on in the project knowing that I always liked them:
Unfortunately one of those is buckled and I'm not particularly keen on having it repaired, so I managed to find a straight replacement which is now on its way
I also purchased one brand new centre cap. Next week I'm going to send the wheels for a blast and good refurb i.e. fine media blast, powder undercoat, powder colour, and paint/lacquer finish -I'll supply one new centre cap so the re-furbishers can match the exact original factory colour.
PetrolTank
I have a friend building a high spec Mk4 Escort RST who would like my WRC Inconel manifold for his build, which is based on a largely WRC spec Zetec. I happen to be taking a different route with the exhaust manifold on my car so it is surplus to requirements. He happens to be a motorsport alloy fabricator for a well-respected company so today we agreed exchange of the manifold for a neatened up alloy version of the mock-up tank I have made. The plan is for two Bosch 044 pumps in the tank, mounted within two collector 'cubes' to prevent surge, in addition to internal baffling. The exhaust cut out will be a diagonal in order to simply the fabrication.
I'll send off my mock-up tank next week.
Crankshaft and Engine Build
Today I've been in conversation with Ian with regards a plan for completion of the engine, and I'm going to visit him next weekend to go over it. The bespoke crankshaft came up in conversation and the topic of dynamic balancing and lightening; I've never been particularly happy with the weight of the new crank and always planned to have it optimised then the machined areas re-nitrided. I had a flick through the IKE website and noticed that Ike has changed the design of the crank with the new ones seeming to have a lot more weight reduction machining than mine - compare the photos below
I've fired off a mail to see what was behind the change and if there's anything I need to be aware of. I also spotted a 99mm stroke crank is on offer (mine is 95mm for 2.2)...it may be a step too far for what I want but I'll seek Ian's opinion.
Clutch
I've found a clutch. This was a bit of a sticking point because the usual route for the MTX75 above ~350ft/lb dictates the use of either a Helix or AP Raching sintered paddle clutch, and I really didn't want that having years ago gone that route in another car build. I mentioned in my last update that the later TVRs used an AP Racing twin plate organic clutch with the Ford output shaft size/spline configuration so I sent out a few enquiries with regards torque capacity but alas, no answers received so I started looking elsewhere.
In the end I found what appears to the the perfect solution: TTV produce a twin plate organic clutch rated at 550 lb/ft and an adapter flywheel specifically for the Mk1 Focus RS (the gearbox I'm using). These are reasonably new to the market, so that and given I haven't been close to the Ford scene for a while means I don't know of anyone using them. I was in conversation with Ian today with regards starting the engine build again, and he happens to know the owners and will have a chat with them.
The only consideration is the price: they are more than the expensive (twin plate) clutch in the 430.
Wheels
I've decided to go with the (rare) 7J ET35 Mondeo option wheels. I did buy a set of these earlier on in the project knowing that I always liked them:
Unfortunately one of those is buckled and I'm not particularly keen on having it repaired, so I managed to find a straight replacement which is now on its way
I also purchased one brand new centre cap. Next week I'm going to send the wheels for a blast and good refurb i.e. fine media blast, powder undercoat, powder colour, and paint/lacquer finish -I'll supply one new centre cap so the re-furbishers can match the exact original factory colour.
PetrolTank
I have a friend building a high spec Mk4 Escort RST who would like my WRC Inconel manifold for his build, which is based on a largely WRC spec Zetec. I happen to be taking a different route with the exhaust manifold on my car so it is surplus to requirements. He happens to be a motorsport alloy fabricator for a well-respected company so today we agreed exchange of the manifold for a neatened up alloy version of the mock-up tank I have made. The plan is for two Bosch 044 pumps in the tank, mounted within two collector 'cubes' to prevent surge, in addition to internal baffling. The exhaust cut out will be a diagonal in order to simply the fabrication.
I'll send off my mock-up tank next week.
Edited by mwstewart on Wednesday 10th April 13:36
That's more like it! Great to see the project gaining momentum again.
I recognise that there's rather more significant engineering work to be done and you're a very long way away from putting the interior into the car but be aware that the edge of the Recaro seat base can rub against the mk4/mk5 door cards. Whilst only making slight contact it can make an annoying noise and has marked the leather on mine. I just put up with it but given that you strive for perfection and have rather nicer leather on your seats than I do on mine you may want to add it and a solution somewhere towards the very bottom of your 'to do' list.
I recognise that there's rather more significant engineering work to be done and you're a very long way away from putting the interior into the car but be aware that the edge of the Recaro seat base can rub against the mk4/mk5 door cards. Whilst only making slight contact it can make an annoying noise and has marked the leather on mine. I just put up with it but given that you strive for perfection and have rather nicer leather on your seats than I do on mine you may want to add it and a solution somewhere towards the very bottom of your 'to do' list.
Edited by JonJon2015 on Monday 28th January 09:51
JonJon2015 said:
That's more like it! Great to see the project gaining momentum again.
I recognise that there's rather more significant engineering work to be done and you're a very long way away from putting the interior into the car but be aware that the edge of the Recaro seat base can rub against the mk4/mk5 door cards. Whilst only making slight contact it can make an annoying noise and has marked the leather on mine. I just put up with it but given that you strive for perfection and have rather nicer leather on your seats than I do on mine you may want to add it and a solution somewhere towards the very bottom of your 'to do' list.
Thanks for the tip – I don’t remember any contact but I will double check.I recognise that there's rather more significant engineering work to be done and you're a very long way away from putting the interior into the car but be aware that the edge of the Recaro seat base can rub against the mk4/mk5 door cards. Whilst only making slight contact it can make an annoying noise and has marked the leather on mine. I just put up with it but given that you strive for perfection and have rather nicer leather on your seats than I do on mine you may want to add it and a solution somewhere towards the very bottom of your 'to do' list.
Edited by JonJon2015 on Monday 28th January 09:51
With Recaros there are a are few things to be aware of:
1) Whilst looking identical except for the velour the ERST and FRST Recaros are actually different: the FRST has a narrower profile and slimmer lower bolsters to suit the confines of a Fiesta;
2) There are very few Recaros of this vintage that are their original shape because over time the internal metal frame spreads outwards, and of course as the cars got cheaper the owners generally became less careful which exacerbated the problem;
3) The foam degrades over time and if people have been sliding in it tends to become rounder in shape rather than flat.
I ended up buying three nice interiors to get a pair of good seats, and even then I think both of those were actually passenger seats (they aren't handed). I checked the frames were straight by looking down at the top of the seat to ensure the lower bolsters were vertical with the outside edge being straight. I went with new foam inserts as well.
A lot of seats I looked out were out by anything up to 1” or sometimes more! It is still possible to manipulate the bolster by hand if fully trimmed.
A few pics from a visit to Ian's over the weekend.
My crank, rod, and piston package. I'm sticking with it - the counterweights will be machined when sent for balancing.
Ian's own 700+bhp TT RS engine.
Lanica Delta Integrale engine (front) in for a rebuild, and a ~500bhp Honda VTEC build (back).
Zetec heads with oversize valves etc.
A new ~400 spec Zetec that's back in for a clean up (it has been stored by the customer in a damp environment since Ian built it.)
My crank, rod, and piston package. I'm sticking with it - the counterweights will be machined when sent for balancing.
Ian's own 700+bhp TT RS engine.
Lanica Delta Integrale engine (front) in for a rebuild, and a ~500bhp Honda VTEC build (back).
Zetec heads with oversize valves etc.
A new ~400 spec Zetec that's back in for a clean up (it has been stored by the customer in a damp environment since Ian built it.)
Steeversturbo said:
I want to install caliper front of focus rs mk1. with mondeo Wheels 16p ET40
I'm afraid they won't fit under the Mondeo 16" wheels. The conversion brackets that are most readily available are to suit the FRS 325mm discs but I seem to remember the largest discs that'll go under the Mondeo wheels are from the ST170, and that's with a sliding caliper.Edited by Steeversturbo on Wednesday 24th April 22:31
If you need to keep your wheels then you'll be better off with a smaller caliper - possibly something from Wilwood or a smaller AP caliper.
Davie_GLA said:
masterman said:
I was watching the fiesta build some time ago - did it ever get finished??? Ive seen Jan this and Feb that but without the year being entered. This question is therefore dated this day 25th July
2019.
f2019.
k SAKE!!!leglessAlex said:
There needs to be an autoban system for anyone bumping threads like this.
Actually, the ideal solution would be for @mwstewart to request that his thread is locked until he is ready to continue with updates, as it's a bit ridiculous that we have to endure this every few months or so.
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