500+bhp Mk3 Fiesta Project
Discussion
I have the RS accessory version of the Cosworth style wheels which have a unique centre cap and badge. I did not like the look of the original blue badge against my paintwork, the FRST green strip, and the interior & brake bell colour. I scanned an original badge and made three alternative colour schemes: one to suit the FRST green strips, one to match the interior, and a third, more subtle option.
I chose DMB Graphics to produce the reproductions - initially two of each as a test - and Dave was excellent to work with sharing his colour palette to help make my electronic design production ready. There is a small tweak required to the green version should I decide to go that way.
OEM Fastenings
I've started to go through my box of Ford clips and fastenings to refresh my mind on what I have, which thankfully is enough to finish the car. The price these parts sell for now is significantly higher than the original retail. There were some interesting little nic-nacs available.
Fuel and Rear Brake Lines
The original fuel lines are AN6 sized which is perfectly adequate for my needs so I've been through my parts store and chosen some perfect original lines: fuel feed (AN6), fuel return (AN6), and evap (AN3) hard lines. The rear brakes lines are AN3 PVC coated braided hose rather than the OEM steel lines.
I found the original Ford fuel and brake pipe clips which I'm modifying to suit the two AN3 braided hoses in place of the original AN3 hard lines.
I have replaced the original metal fastenings with nylon types from a later model.
Misc
New OEM heat shield modified to suit my unique exhaust route.
The handbrake cable is galvanised but they normally end up rusty, so I have etched primed & painted it silver.
Engine Installation
I now have a third MTX75 gearbox this time a Focus Mk2 TDCi version, and thanks to Ian/Area Six a block to go along with it.
For some reason - packaging, possibly - the 'Black Top' Zetec is mounted tilted forwards by several degrees which is not ideal for weight distribution and, hence handling. It is something that always bugged me so I've been in touch with my friend Mark who has agreed to produce a bespoke bell-housing that tilts the engine back to my specification. It will be a bolt in part meaning that there won't be further changes to my shell.
Mark built the adapter plate for my previous project: a dry sumped ST170 engine mated to a VAG 4x4 02M gearbox.
I chose DMB Graphics to produce the reproductions - initially two of each as a test - and Dave was excellent to work with sharing his colour palette to help make my electronic design production ready. There is a small tweak required to the green version should I decide to go that way.
OEM Fastenings
I've started to go through my box of Ford clips and fastenings to refresh my mind on what I have, which thankfully is enough to finish the car. The price these parts sell for now is significantly higher than the original retail. There were some interesting little nic-nacs available.
Fuel and Rear Brake Lines
The original fuel lines are AN6 sized which is perfectly adequate for my needs so I've been through my parts store and chosen some perfect original lines: fuel feed (AN6), fuel return (AN6), and evap (AN3) hard lines. The rear brakes lines are AN3 PVC coated braided hose rather than the OEM steel lines.
I found the original Ford fuel and brake pipe clips which I'm modifying to suit the two AN3 braided hoses in place of the original AN3 hard lines.
I have replaced the original metal fastenings with nylon types from a later model.
Misc
New OEM heat shield modified to suit my unique exhaust route.
The handbrake cable is galvanised but they normally end up rusty, so I have etched primed & painted it silver.
Engine Installation
I now have a third MTX75 gearbox this time a Focus Mk2 TDCi version, and thanks to Ian/Area Six a block to go along with it.
For some reason - packaging, possibly - the 'Black Top' Zetec is mounted tilted forwards by several degrees which is not ideal for weight distribution and, hence handling. It is something that always bugged me so I've been in touch with my friend Mark who has agreed to produce a bespoke bell-housing that tilts the engine back to my specification. It will be a bolt in part meaning that there won't be further changes to my shell.
Mark built the adapter plate for my previous project: a dry sumped ST170 engine mated to a VAG 4x4 02M gearbox.
The project mentioned was also Mk3 Fiesta based: a turbocharged ST170 engine with a VAG 02M gearbox and S3/TT Haldex based 4WD system. I completed all of the complex work but as time went on I became increasingly unhappy with the excess weight of the VAG components, and later, having owned a BAM engined S3 8L, I realised just how dire the platform was in terms of driving performance and pleasure.
The VR6 engine would fit so I bought a very low mileage R32 engine and gearbox but, again, the weight vs performance vs durability was astronomically skewed to the worse. The project started with the first generation Haldex platform, but later I bought the Haldex 2 drivetrain to study - but the same applied.
I bought a scrap Mk2 TT to use as the donor for sections of its shell, and also some parts from a later Fiesta.
Phase 1 was largely based on a later Fiesta.
Phase 2 was a small section of later Fiesta and sectioned parts of the TT floorpan and chassis legs & rails.
I'd figured out all of the load paths and integrated everything safely - though mainly my focus was on handling but safety tends to be a byproduct of a stiff shell.
I was early 20's at the time so it was a good learning exercise for fabrication etc. - I learnt to weld on this project.
The VR6 engine would fit so I bought a very low mileage R32 engine and gearbox but, again, the weight vs performance vs durability was astronomically skewed to the worse. The project started with the first generation Haldex platform, but later I bought the Haldex 2 drivetrain to study - but the same applied.
I bought a scrap Mk2 TT to use as the donor for sections of its shell, and also some parts from a later Fiesta.
Phase 1 was largely based on a later Fiesta.
Phase 2 was a small section of later Fiesta and sectioned parts of the TT floorpan and chassis legs & rails.
I'd figured out all of the load paths and integrated everything safely - though mainly my focus was on handling but safety tends to be a byproduct of a stiff shell.
I was early 20's at the time so it was a good learning exercise for fabrication etc. - I learnt to weld on this project.
Jacking Points
The Mk3 Fiesta standard jacking points are less than ideal being on the narrow lip of a very thin sill section. I already reinforced both sills with 25mm x 15mm box section and the finishing touch is four stainless steel jacking pads, which are a bit of a tricky shape due to the angle of the floor pan in that area.
The front jacking pads are dual function serving as an attachment point for part of the to-be-constructed underfloor chassis brace. The pads are riveted to the sills and bonded with methacrylate structural adhesive.
The Mk3 Fiesta standard jacking points are less than ideal being on the narrow lip of a very thin sill section. I already reinforced both sills with 25mm x 15mm box section and the finishing touch is four stainless steel jacking pads, which are a bit of a tricky shape due to the angle of the floor pan in that area.
The front jacking pads are dual function serving as an attachment point for part of the to-be-constructed underfloor chassis brace. The pads are riveted to the sills and bonded with methacrylate structural adhesive.
The jacking points are now complete and I'm very pleased with them. In my head I envisaged that these would take a couple of hours with an angle grinder and sheet metal folder but, as is usually the case, they required a little bit more time - this was mainly due to each surface being on a slight incline.
The front pads have a hole and accompanying captive nut/spreader plate for a chassis brace and the rears have a stud for the OEM handbrake cable clip.
Once fabrication was complete I used a poly wheel to smooth and then 40 grit to create a brushed finish.
Looking to the interior and I'm piecing together a period correct (for the dashboard) Ford 'universal hands free phone system'. I've chosen the Nokia 6210 version and once the handset arrives I will send its cover to paint along another couple of interior trim pieces for refinishing in the same metallic grey as the instrument cluster bezel.
The front pads have a hole and accompanying captive nut/spreader plate for a chassis brace and the rears have a stud for the OEM handbrake cable clip.
Once fabrication was complete I used a poly wheel to smooth and then 40 grit to create a brushed finish.
Looking to the interior and I'm piecing together a period correct (for the dashboard) Ford 'universal hands free phone system'. I've chosen the Nokia 6210 version and once the handset arrives I will send its cover to paint along another couple of interior trim pieces for refinishing in the same metallic grey as the instrument cluster bezel.
I’m 23, do we reckon there’s an outside chance this gets finished before I die of old age?
I love a good build and they don’t come better than this but i also like things actually getting used. It does feel a bit like complication for the sake of it at times. Sorry to be negative as your talents and knowledge far surpass my own but come on already
I love a good build and they don’t come better than this but i also like things actually getting used. It does feel a bit like complication for the sake of it at times. Sorry to be negative as your talents and knowledge far surpass my own but come on already
Stick Legs said:
I'm confused I must admit.
There was an OK Fiesta at the beginning of this thread, that had the external panels replaced, then got painted and looked very smart.
Now there is a Fiesta with no front end and it's insides removed. Surely not the same car...
The car with the front end missing is a different car I think. There was an OK Fiesta at the beginning of this thread, that had the external panels replaced, then got painted and looked very smart.
Now there is a Fiesta with no front end and it's insides removed. Surely not the same car...
trails said:
Could you convert that phone holder to support your iPhone...that would be pretty cool.
Possibly, but I quite fancy a period phone 
Drive it fix it repeat said:
I’m 23, do we reckon there’s an outside chance this gets finished before I die of old age?
I love a good build and they don’t come better than this but i also like things actually getting used. It does feel a bit like complication for the sake of it at times. Sorry to be negative as your talents and knowledge far surpass my own but come on already
I have other cars to use of course, but getting things right takes time and the beauty of doing this for myself and not a customer means that I'm completely free of constraints like time or a fixed plan.I love a good build and they don’t come better than this but i also like things actually getting used. It does feel a bit like complication for the sake of it at times. Sorry to be negative as your talents and knowledge far surpass my own but come on already
Gtom said:
The car with the front end missing is a different car I think.
Yes, that's right. Other posters asked about a previous project.mwstewart said:
trails said:
Could you convert that phone holder to support your iPhone...that would be pretty cool.
Possibly, but I quite fancy a period phone I have a mid 90s Motorola flip phone that I keep with the Cosworth, it’s of no use whatsoever but an interesting accessory that makes the youngsters laugh.
Could I request that when you have finished, you bring it along to a Sunday Service? I would love to be able to see the finished article.
bangerturner said:
mwstewart said:
Yes, that's another car. A couple of posters asked about a previous project.
If they only look at the pictures and can't bring themselves to read a few lines of text, I wouldn't bother to respond to them........keep up the mind-blowing fantastic work!I love the stuff you have done, and on the M3, something inside me keeps screaming "but it's a Fiesta!" which makes it even more brilliant really!
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff