500+bhp Mk3 Fiesta Project
Discussion
Ha ha 
30mm diameter spacers finished and installed. These are a better fit with the alloy bracket.
Next on to the handbrake cable, and I was pleased to find that I had a new Racing Puma cable in stock. These fit the Fiesta floor pan and suit the Lucas handbrake calipers for rear discs. I believe that this cable was discontinued a while ago.
Ford buffs will be familiar with 909 prefixed part numbers which originated in Boreham and were assigned to motorsport or special build parts. For some reason around the time of the Racing Puma production a 908 prefix was introduced.
Cable fitted and gaiter in place. I missed a trick here by not having the handbrake and gear gaiter trimmed in the seat leather. I may send them away during lockdown.
I found a couple of rare parts for the Mk3: a Ford boot liner, and an engine undertray which was fitted to the very first XR2i's to leave the factory after which it was discontinued in short order.
30mm diameter spacers finished and installed. These are a better fit with the alloy bracket.
Next on to the handbrake cable, and I was pleased to find that I had a new Racing Puma cable in stock. These fit the Fiesta floor pan and suit the Lucas handbrake calipers for rear discs. I believe that this cable was discontinued a while ago.
Ford buffs will be familiar with 909 prefixed part numbers which originated in Boreham and were assigned to motorsport or special build parts. For some reason around the time of the Racing Puma production a 908 prefix was introduced.
Cable fitted and gaiter in place. I missed a trick here by not having the handbrake and gear gaiter trimmed in the seat leather. I may send them away during lockdown.
I found a couple of rare parts for the Mk3: a Ford boot liner, and an engine undertray which was fitted to the very first XR2i's to leave the factory after which it was discontinued in short order.
ABS Module
It was decision time:
1) Fit a small frame ABS system from a later Fiesta. The benefits of this system are a compact module which is easier to package and the wiring is plug and play with the Mk5 engine bay loom that I'm using. The drawbacks are that the traction control version is not switchable and the rear Focus hubs that I've used would require machining for a different ABS sensor.
2) Fit the large frame ATE MK25 ABS system from the Mk1 Focus. The benefits are the availability of a switchable TC module (I've pre-wired for this) and the ABS sensors are more reliable, and more accurate. The drawbacks are that my wiring loom would require modification, as would the front hubs to suit a later ABS sensor, and also the gearbox mount and master cylinder to clear the larger module.
I decided to go for option 2. I had prepared a bracket for this option and I had in stock a very nice TC equipped module from a Mk1 Focus ST170.
The gearbox mount now has a couple of rounded corners and a scalloped section in order to allow more clearance.
The fastenings are from the donor ST170 but have been re-plated.
In order to fit the module the servo & master cylinder are loosed off and moved out of the way. It's interesting when working on bespoke installations not only because it's satisfying when a plan comes together, but also the learning of how to maintain it.
The servo & master cylinder refitted with the spacers to clear the larger ABS/TC module.
My measurements and mock-up during the chassis build appear to have worked; there is 5mm clearance between chassis mount, module, and servo.
Now I can move on to plumbing.
It was decision time:
1) Fit a small frame ABS system from a later Fiesta. The benefits of this system are a compact module which is easier to package and the wiring is plug and play with the Mk5 engine bay loom that I'm using. The drawbacks are that the traction control version is not switchable and the rear Focus hubs that I've used would require machining for a different ABS sensor.
2) Fit the large frame ATE MK25 ABS system from the Mk1 Focus. The benefits are the availability of a switchable TC module (I've pre-wired for this) and the ABS sensors are more reliable, and more accurate. The drawbacks are that my wiring loom would require modification, as would the front hubs to suit a later ABS sensor, and also the gearbox mount and master cylinder to clear the larger module.
I decided to go for option 2. I had prepared a bracket for this option and I had in stock a very nice TC equipped module from a Mk1 Focus ST170.
The gearbox mount now has a couple of rounded corners and a scalloped section in order to allow more clearance.
The fastenings are from the donor ST170 but have been re-plated.
In order to fit the module the servo & master cylinder are loosed off and moved out of the way. It's interesting when working on bespoke installations not only because it's satisfying when a plan comes together, but also the learning of how to maintain it.
The servo & master cylinder refitted with the spacers to clear the larger ABS/TC module.
My measurements and mock-up during the chassis build appear to have worked; there is 5mm clearance between chassis mount, module, and servo.
Now I can move on to plumbing.
Edited by mwstewart on Monday 9th November 10:22
mwstewart said:
ABS Module
It was decision time:
1) Fit a small frame ABS system from a later Fiesta. The benefits of this system are a compact module which is easier to package and the wiring is plug and play with the Mk5 engine bay loom that I'm using. The drawbacks are that the traction control version is not switchable and the rear Focus hubs that I've used would require machining for a different ABS sensor.
2) Fit the large frame ATE MK25 ABS system from the Mk1 Focus. The benefits are the availability of a switchable TC module (I've pre-wired for this) and the ABS sensors are more reliable, and more accurate. The drawbacks are that my wiring loom would require modification, as would the front hubs to suit a later ABS sensor, and also the gearbox mount and master cylinder to clear the larger module.
None of us thought for a second you'd do the easier, not quite as good, option 1....It was decision time:
1) Fit a small frame ABS system from a later Fiesta. The benefits of this system are a compact module which is easier to package and the wiring is plug and play with the Mk5 engine bay loom that I'm using. The drawbacks are that the traction control version is not switchable and the rear Focus hubs that I've used would require machining for a different ABS sensor.
2) Fit the large frame ATE MK25 ABS system from the Mk1 Focus. The benefits are the availability of a switchable TC module (I've pre-wired for this) and the ABS sensors are more reliable, and more accurate. The drawbacks are that my wiring loom would require modification, as would the front hubs to suit a later ABS sensor, and also the gearbox mount and master cylinder to clear the larger module.
I have started plumbing the brake lines. For the master cylinder I'm using AN4 hose with AN4 hose fittings then AN4 to M12x1 adapters to suit the M/C and module. The hose sent was supposed to be silver with a clear PVC sheath but it looks yellow, so I've ordered another length.
The AN3 hose was fine. I'm adding stainless rivnuts in the holes originally for the OEM plastic fittings. I always find pipe routing takes a bit of thought and time; for example a triple hose clamp drilled out to take a longer bolt in order to secure it to a hole drilled on the master cylinder bracket, over which a spire clip is mounted.
Passenger airbag warning sticker just to make things correct given that I have retrofitted one.
I addressed the faded seat belt clasps by painting with some Tamiya X-7 red paint.
Decal kit for the engine bay.
The AN3 hose was fine. I'm adding stainless rivnuts in the holes originally for the OEM plastic fittings. I always find pipe routing takes a bit of thought and time; for example a triple hose clamp drilled out to take a longer bolt in order to secure it to a hole drilled on the master cylinder bracket, over which a spire clip is mounted.
Passenger airbag warning sticker just to make things correct given that I have retrofitted one.
I addressed the faded seat belt clasps by painting with some Tamiya X-7 red paint.
Decal kit for the engine bay.
Hi Mark, hope you’re well. Have you been to the 5 Bells lately?
Do you have a photo of the exterior of the car, or is it still in bits?
I can vividly remember a Max Power magazine with a bright red Fiesta RST on the cover that was really nicely done. I think it was by Power Engineering and had Escort Cosworth wheels and a Mondeo Estate spoiler grated to the rear hatch.
Oh and to caveat, that was way before Maxy P went Pornographic and my Mum banned it!
Do you have a photo of the exterior of the car, or is it still in bits?
I can vividly remember a Max Power magazine with a bright red Fiesta RST on the cover that was really nicely done. I think it was by Power Engineering and had Escort Cosworth wheels and a Mondeo Estate spoiler grated to the rear hatch.
Oh and to caveat, that was way before Maxy P went Pornographic and my Mum banned it!
I'm surprised people are admitting to reading Max Power now. For years it was seen as a bit vulgar. Perhaps now we're all a bit older and couldn't care less what people think. The car which always got me excited was the Dimma 205. Although I'm not sure I would be too bothered about actually owning one now.
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