500+bhp Mk3 Fiesta Project
Discussion
Thanks both 
Cruise Control Sensors
The Focus CC system requires three pedal position sensors/switches: brake light; clutch pedal position; and a brake force sensor that is shared with the ESP system when fitted. The original Mk3 Fiesta pedal box comes only with provision for a brake light switch, as can be seen below (not my image):
I had already updated to a Ka pedal box with hydraulic clutch and clutch position switch to suit the later EECV engine management system that I will use to run the fuel pumps, fans, and other ancillary features. The Ka clutch switch happens to be interchangeable with the necessary Focus item, so that just leaves the brake pedal sensors. I will address this by adapting the Ka pedal box with parts from a Focus pedal box.
The Ka pedal box is on the left in the following photo, and on the right is a Focus pedal box frame and sensors that I bought from a scrap yard:
I cut out the original Ka brake light sensor mount and welded in the same section from the Focus pedal box.
There is a tab on the Ka brake pedal which actuated the brake light switch, so I extended this to cater for the dual brake pedal sensors. I created little 'bumps' out of weld to help with sensor actuation. I tested everything with a multimeter once fitted to ensure all sensors worked as required.
Pedal box painted in satin black and Focus sensors fitted. Another job ticked off of the list.
Cruise Control Sensors
The Focus CC system requires three pedal position sensors/switches: brake light; clutch pedal position; and a brake force sensor that is shared with the ESP system when fitted. The original Mk3 Fiesta pedal box comes only with provision for a brake light switch, as can be seen below (not my image):
I had already updated to a Ka pedal box with hydraulic clutch and clutch position switch to suit the later EECV engine management system that I will use to run the fuel pumps, fans, and other ancillary features. The Ka clutch switch happens to be interchangeable with the necessary Focus item, so that just leaves the brake pedal sensors. I will address this by adapting the Ka pedal box with parts from a Focus pedal box.
The Ka pedal box is on the left in the following photo, and on the right is a Focus pedal box frame and sensors that I bought from a scrap yard:
I cut out the original Ka brake light sensor mount and welded in the same section from the Focus pedal box.
There is a tab on the Ka brake pedal which actuated the brake light switch, so I extended this to cater for the dual brake pedal sensors. I created little 'bumps' out of weld to help with sensor actuation. I tested everything with a multimeter once fitted to ensure all sensors worked as required.
Pedal box painted in satin black and Focus sensors fitted. Another job ticked off of the list.
I have just read this thread from the beginning to the end.
You must be absolutely nuts!
However, it must be a brilliant hobby to have and you obviously thoroughly enjoy it - good for you.
It's been a great read and I'm looking forward to seeing the finished article.
Never has a Fiesta caused such a stir!
You must be absolutely nuts!
However, it must be a brilliant hobby to have and you obviously thoroughly enjoy it - good for you.
It's been a great read and I'm looking forward to seeing the finished article.
Never has a Fiesta caused such a stir!
A helicopter 
Thanks again for the kind words. I've managed to do a little more:
Cabin Filter
I found an activated charcoal filter is available so I ordered one and swapped it for the standard filter I'd already fitted.
Passenger Door
I've now deadened the passenger door and fitted the speakers.
I bought a product called 'Boom Mat' made by DEI. It's a closed cell foam shroud for a speaker. I cut one in half and placed it on the top edge of the speakers to form waterproof cover.
Door card on.
Alcantara Steering Wheel & Handbrake Lever
I had the steering wheel and Focus handbrake lever trimmed in Alcantara. I supplied a leather sample so that the trimmer could match my seats.
Parts fitted.
Thanks again for the kind words. I've managed to do a little more:
Cabin Filter
I found an activated charcoal filter is available so I ordered one and swapped it for the standard filter I'd already fitted.
Passenger Door
I've now deadened the passenger door and fitted the speakers.
I bought a product called 'Boom Mat' made by DEI. It's a closed cell foam shroud for a speaker. I cut one in half and placed it on the top edge of the speakers to form waterproof cover.
Door card on.
Alcantara Steering Wheel & Handbrake Lever
I had the steering wheel and Focus handbrake lever trimmed in Alcantara. I supplied a leather sample so that the trimmer could match my seats.
Parts fitted.
I think most people reading this thread have had thoughts they never could have predicted when talking about Ford Fiestas.
I for one absolutely love the OP's attitude - taking a car which is fairly basic and making it the best it possibly could be, in a lot of cases using OEM parts. There's something incredibly appealing about it and I'm fascinated (and both very humbled and jealous) to follow this thread
I for one absolutely love the OP's attitude - taking a car which is fairly basic and making it the best it possibly could be, in a lot of cases using OEM parts. There's something incredibly appealing about it and I'm fascinated (and both very humbled and jealous) to follow this thread
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