500+bhp Mk3 Fiesta Project

[mwstewart]

Brown00 said:

Hi, I know this is a long shot. But do you have any more information on the brembo 2 pot rear conversion you carried out on your fiesta project back in 2011?

I am looking to run a set of brembo 2 pots on the rear of my 4x100 platform VW Vento. If you could point me in the right direction as to how I might go about this that would be great.

Thanks

They were two piston rear calipers from an Evo. I don't have any more information because in the end I went with some AP Racing formula calipers.

[mwstewart]

samster1 said:

Hi Mark did you used to own J630cgp fiesta RS turbo

That did ring a bell, so I checked, and yes - I did. Diamond White and one of the later cars with window switches in the door bins. I bought two of them at the same time as I fancied a restoration project but in the end I went ahead with the red car, so I tidied up J630 and sold it.

It came down to colour preference really: J630 was a solid car requiring just the filler cap and one seat mount.

Edited by mwstewart on Wednesday 13th February 15:40

[mwstewart]

I've started to think about the Fiesta again. I've decided to change the wheels to the Mondeo Cosworth type in 7j.

I found a set of the rare RS centre caps on eBay so I now have two sets from which I can make one really good set, and have a couple spare.


The body kit is sprayed and ready to fit so that will be the next task. No further movement until around May because I have other things to finish on the 430 ready for our wedding in June.

Edited by mwstewart on Wednesday 13th February 15:40

[mwstewart]

Thanks all.

leglessAlex said:

Oh mah gawd, an update to one of the most legendary build threads ever! I'm very very much looking forward to further updates.

What stage is the engine currently in, did it ever actually get built?

It is built but I've held it up; Ian is waiting for me to choose a clutch type then all of the rotating assemblies will be sent to https://vibrationfree.co.uk/ to be balanced. The catch is I'd need a paddle clutch from the off the shelf items for the kind of torque the engine will produce, but based on past experience they are a bit of a pain in stop/start traffic and I want to take the car on road trips across Europe.

TVR fitted a double plate clutch in some of their cars that would work in mine (1" 24 spline input shaft IIRC) which may provide the required torque handling whilst keeping an organic disc. I will pick up the research again!

[mwstewart]

ATM said:

I understand you need a stronger clutch for a more powerful engine but surely if the tyres have limited grip then the clutch just needs enough grip to overcome the grip from the tyres - assuming this will run little 195 tyres maybe?

The clutch will be the limiting factor when accelerating from higher speeds or at low RPM in higher gears.

[mwstewart]

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.

Edited by mwstewart on Wednesday 10th April 13:36

[mwstewart]

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.

Edited by JonJon2015 on Monday 28th January 09:51

Thanks for the tip – I don’t remember any contact but I will double check.

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.

[mwstewart]

Excellent - good to see it is around!

[mwstewart]

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.)

[mwstewart]

Thank you. Is it the front or rear calipers that you'd like to fit? Also, what size wheels do you have and what make/model?

[mwstewart]

Steeversturbo said:

I want to install caliper front of focus rs mk1. with mondeo Wheels 16p ET40

Edited by Steeversturbo on Wednesday 24th April 22:31

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.

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.

[mwstewart]

The bottom end was built up with the new clutch and it went away at the end of last week for balancing. I'll ask Ian how it went.

[mwstewart]

I must have missed the memo about PH turning into a paid subscription forum

The Fiesta will be finished - but I shall not start any new projects at this time.

[mwstewart]

On a road trip a few years ago we were in Italy staying at an agriturismo with an access road that I'd pre-determined with the help of Google maps as being a nice gravel track. It wasn't. We arrived late one night in the 430 and had in given up half way along after lots of swearing and nearly beaching it a few times, and had resigned to sleeping in it when the owners appeared out of the dark in an early Panda. I have driven off-road/4x4 in the past but the way that little (FWD!) thing coped with the significant ruts and appalling surfaces was genuinely impressive.

The owners kindly gave us use of this farm Panda for a week so that we could park the 430 somewhere accessible. It was really a worn out old tin can - an absolute shed with holes in the seats, and gearbox return springs long gone which meant finding a gear was s bit of pot luck, but the simplicity of the thing and its go-anywhere ability - much like an old French car - meant that it was a very loveable little thing.

After driving it off road each day for a week or so I came back from the trip really wanting a nice Panda 4x4! I looked around but even then they were like hens teeth, so I gave up.

Probably a good thing really as that would have turned into another project - imagine a Hartley V8 in an otherwise standard looking car.

[mwstewart]

Ha ha that's mad. I bet its fun! It's not the right time for another project but ATM's post had me browing eBay for a 4x4, and it seems that they are out there!

[mwstewart]

Ian is back from holiday and now has the balanced rotating assembly back with him. The pistons and rods were done at the same time but aren't photographed.






Results:



Ian will now reassemble the engine and I can start to decide on a turbo and manifold.

[mwstewart]

Slowly but surely; the next stage is a custom oil system to bypass the standard oil pump that has a propensity to shatter its gears.

I have a decision to make for turbo choice; today I spoke with Ian who thinks that this is a 700bhp capable engine, which is impressive, but I see endless drive train problems with that kind of power and torque so I'll have to reign it in a bit!

[mwstewart]

Davie_GLA said:

I was all set to get angry after this was bumped by someone else asking for an update. Thanks man.

700 to the front wheels will be hilarious. Do it

It would be funny. I'm going for gear-mapped boost so the full power wouldn't be available until 5th gear

470bhp in a Mk3 Fiesta sees 184 MPH at (I think) Bruntingthorpe https://www.fiestaturbo.com/feature-cars/luca-184m...

I'd like to crack 200 in this car - which would put it on-par with the 430.

[mwstewart]

Life-affirmingly exciting

[mwstewart]

I'm very behind with car project updates but here's the Fiesta powertrain that I'm fitting over this weekend.

After we some more changes the max power figure has been revised to nigh on 700bhp at the flywheel depending on how far I want to stress things.





I'll come back and edit the post later with more photos to show the other things that have been going on.