500+bhp Mk3 Fiesta Project
Discussion
Under body protection and paint
The products I have chosen for the under side will provide ultimate protection rather than a show like finish. In the past I completed another project car with a perfect underneath and I was always worried about taking it out in wet weather etc.; the goal for this project is to create something that I can enjoy in any weather without fear of it rusting or degrading. I chose 3M 08800 sealer as this is some of the best protection available, I originally ordered 11 bags which turned out to be very optimistic as in the end I ordered 20 .
In total the materials for the under side treatment have come close to £500, which is a lot given the end result is rarely seen, but I figured it's an investment in protection for all the work that has gone in to the shell.
The 3M 08800 is over-paintable within 20 mins, so once that time had elapsed I applied two pack primer, two pack base and two pack lacquer.
So in total I have 90% Zinc primer, satin black, two coats of 3M 08800, two pack primer, two pack base and two pack lacquer. It should be well protected under there
The next step is wax injection.
The products I have chosen for the under side will provide ultimate protection rather than a show like finish. In the past I completed another project car with a perfect underneath and I was always worried about taking it out in wet weather etc.; the goal for this project is to create something that I can enjoy in any weather without fear of it rusting or degrading. I chose 3M 08800 sealer as this is some of the best protection available, I originally ordered 11 bags which turned out to be very optimistic as in the end I ordered 20 .
In total the materials for the under side treatment have come close to £500, which is a lot given the end result is rarely seen, but I figured it's an investment in protection for all the work that has gone in to the shell.
The 3M 08800 is over-paintable within 20 mins, so once that time had elapsed I applied two pack primer, two pack base and two pack lacquer.
So in total I have 90% Zinc primer, satin black, two coats of 3M 08800, two pack primer, two pack base and two pack lacquer. It should be well protected under there
The next step is wax injection.
Edited by mwstewart on Tuesday 13th September 23:01
payner2008 said:
Any updates OP?
I have sent the shell to a body shop for a full bare-metal respray because there were a few areas of my prep/paint that I wasn't entirely happy with. I will have it back for November I’m also still waiting for Pace to make a dry sump pump to my spec: I’ve found the customer service to be slightly lacking so far...
BBS-LM said:
Amazing attention to detail on this project, but I just do not get the Fiesta part, sorry. But good luck with it. biggrin
Thank you - totally understandable It’s by no means the most expensive or technically capable car I’ve owned, but driving these things still puts a smile on my face.hewlett said:
Might it be a good idea to make a simple aluminium flat underside?
I’ve been thinking about this and I’ve bought some plastic under trays from a Mercedes that I hope to adapt, and I’m looking for something else suitable for the engine area.Apparently flat undersides make a big difference particularly if it goes to a diffuser at the back:
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
All good to keep the car on the ground and subtle i.e. no ungentlemanly wing at the back
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
All good to keep the car on the ground and subtle i.e. no ungentlemanly wing at the back
I'd like to say congratulations on the brilliant work gone into this car so far, I've really enjoyed reading the thread!
Are you a member of www.passionford.com? if not i think you should be, your car would be well appreciated on there.
Are you a member of www.passionford.com? if not i think you should be, your car would be well appreciated on there.
Thanks for the feedback.
Some snaps from the Bodyshop that show their progress with stripping back to bare metal. The panels look horrendous but they're not; they were all brand new.
I have decided to go for a colour change and switch from 'Dark Aubergine' to another Ford colour called 'Noveau Red'. This was the colour of the car used for one of my other projects and surprise, surprise, it was another Mk3 Fiesta.
The car was one of my first that I'd kept and had gone through various mechanical guises and engine configurations until the last project which saw me purchase a crashed 2008 Golf R32, and from this I transplanted the floor pan and drive train into the Fiesta. The Golf/Quattro car was the 'main' project and the Fiesta in this thread was always intended to be a sideline, but as time has passed I found that my priorities changed and I moved on to bigger and better (though not necessarily more fun) things.
I didn't have time for everything so I decided to 'call it a day' with Quattro project and gave away the converted shell. I still have the majority of the R32 that I need to sell on - it'd only covered 1500 miles.
The closure of the Quattro/R32 project does mean I can liberate many brand new and obsolete Ford parts that I'd been saving and use them on the project car in this thread.
Some snaps from the Bodyshop that show their progress with stripping back to bare metal. The panels look horrendous but they're not; they were all brand new.
I have decided to go for a colour change and switch from 'Dark Aubergine' to another Ford colour called 'Noveau Red'. This was the colour of the car used for one of my other projects and surprise, surprise, it was another Mk3 Fiesta.
The car was one of my first that I'd kept and had gone through various mechanical guises and engine configurations until the last project which saw me purchase a crashed 2008 Golf R32, and from this I transplanted the floor pan and drive train into the Fiesta. The Golf/Quattro car was the 'main' project and the Fiesta in this thread was always intended to be a sideline, but as time has passed I found that my priorities changed and I moved on to bigger and better (though not necessarily more fun) things.
I didn't have time for everything so I decided to 'call it a day' with Quattro project and gave away the converted shell. I still have the majority of the R32 that I need to sell on - it'd only covered 1500 miles.
The closure of the Quattro/R32 project does mean I can liberate many brand new and obsolete Ford parts that I'd been saving and use them on the project car in this thread.
Edited by mwstewart on Tuesday 22 November 10:57
Always like reading this thread. I'm sure you've probably already read it, but I've added a link that might be of interest.
http://www.turbosport.co.uk/showthread.php?100672-...
This is where you say that, that project was done by you, and I end up with egg on my face.
Edit to add it is you, and I'm now off to remove the egg
http://www.turbosport.co.uk/showthread.php?100672-...
This is where you say that, that project was done by you, and I end up with egg on my face.
Edit to add it is you, and I'm now off to remove the egg
Edited by Bosshogg76 on Tuesday 22 November 13:04
Edited by Bosshogg76 on Tuesday 22 November 13:05
I think the Turbosport thread was the most comprehensive, but I stopped updating that half way in.
Some more snaps from the Bodyshop:
Lead filler work on the quarter panel join:
I've specified the 'X5' Ford colour code for Nouveau Red, it is from the 1995 model year and tends to be a richer metallic red than some of the earlier codes. The Bodyshop are spraying some paint samples for me on Friday to make sure I get the shade I'm happiest with.
I now have an inlet manifold for the engine, it is a WRC manifold with individual throttle bodies and carbon 'trumpets'. It is currently unfinished but will be complete for the new year. NB The engine below belongs to the previous owner of the manifold.
The changes I will make are to create an adapter plate with a taper which makes the most power on a Zetec, and then space the plenum to provide the necessary volume for my engine.
I've been in discussion with Specialist Car Services in Peterborough who have a Superflow-901 Engine Dyno. The result of that discussion was that I'm going for Pectel T6 engine management with wide band Lambda control, Knock sensing, EGT, multiple maps (low power, high power, high octane) and air injector based boost control. The management can be easily set to retard ignition based on EGT or knock, or cut ignition altogether based on other safety parameters.
I require the T6 because it has 'throttle multi-map multipliers' which gives it the ability to support different configurations at every 10 degrees of throttle as required by ITBs.
Some more snaps from the Bodyshop:
Lead filler work on the quarter panel join:
I've specified the 'X5' Ford colour code for Nouveau Red, it is from the 1995 model year and tends to be a richer metallic red than some of the earlier codes. The Bodyshop are spraying some paint samples for me on Friday to make sure I get the shade I'm happiest with.
I now have an inlet manifold for the engine, it is a WRC manifold with individual throttle bodies and carbon 'trumpets'. It is currently unfinished but will be complete for the new year. NB The engine below belongs to the previous owner of the manifold.
The changes I will make are to create an adapter plate with a taper which makes the most power on a Zetec, and then space the plenum to provide the necessary volume for my engine.
I've been in discussion with Specialist Car Services in Peterborough who have a Superflow-901 Engine Dyno. The result of that discussion was that I'm going for Pectel T6 engine management with wide band Lambda control, Knock sensing, EGT, multiple maps (low power, high power, high octane) and air injector based boost control. The management can be easily set to retard ignition based on EGT or knock, or cut ignition altogether based on other safety parameters.
I require the T6 because it has 'throttle multi-map multipliers' which gives it the ability to support different configurations at every 10 degrees of throttle as required by ITBs.
Edited by mwstewart on Thursday 1st December 11:23
phwoar, engine porn
Keep it coming. No detail is too nerdy, let us have it
loving the ITBs with a turbo setup. From a (relative) laymans PoV isn't the point of ITBs to allow the smoothest intake of air into the engine, thus giving the best power. How does this square with FI - surely the air being forced into a plenum with lots of weird edges (the trumpets) results in lots of tumbling air and general untidyness, hence less power
it is likely i have got this totally wrong, but it would be interested to hear your thoughts
i remember seeing a cutout of an intake for a supra that had been 'optimised' for equal flow into each cylinder and it was like a bucket of spagetti inside, mental
Keep it coming. No detail is too nerdy, let us have it
loving the ITBs with a turbo setup. From a (relative) laymans PoV isn't the point of ITBs to allow the smoothest intake of air into the engine, thus giving the best power. How does this square with FI - surely the air being forced into a plenum with lots of weird edges (the trumpets) results in lots of tumbling air and general untidyness, hence less power
it is likely i have got this totally wrong, but it would be interested to hear your thoughts
i remember seeing a cutout of an intake for a supra that had been 'optimised' for equal flow into each cylinder and it was like a bucket of spagetti inside, mental
Hi Greg,
ITBs in a forced induction application offer much less of a gain than those in an NA application. What I can expect is slightly more power at the top of the rev range and sharper throttle response off-boost. My goal for the engine is driveability, within reason, so the ITBs will definitely help. I also chose a step down from the most extreme set of Cams that Ian offers though the head casting still had to be machined in order to provide clearance for the lobes I must take some photos of the engine.
The next challenge will be the clutch; I'd like to avoid a paddle but may end up going that route. I've seen that the TVR Speed Six engined cars use a 1" x 23 splined triple plate organic clutch that may provide what I'm looking for.
I forgot to add that I finally have a pair of APs that are suitable for the rear. It's hard to find a set which are sized sensibly for something as light as the Mk3, but I finally did. I got a set of four calipers from an F3 car complete with Discs, bells and pads. The discs measure 268x16mm.
If you're familiar with Ap you'll know that a gold anodised caliper means they are made from a billet. This supposedly offer better braking performance and feedback due to increased rigidity, so I'd really like a set for the front now to replace the cast CP5555.
I'll replace the pads but they will suffice for mocking up.
Mark
ITBs in a forced induction application offer much less of a gain than those in an NA application. What I can expect is slightly more power at the top of the rev range and sharper throttle response off-boost. My goal for the engine is driveability, within reason, so the ITBs will definitely help. I also chose a step down from the most extreme set of Cams that Ian offers though the head casting still had to be machined in order to provide clearance for the lobes I must take some photos of the engine.
The next challenge will be the clutch; I'd like to avoid a paddle but may end up going that route. I've seen that the TVR Speed Six engined cars use a 1" x 23 splined triple plate organic clutch that may provide what I'm looking for.
I forgot to add that I finally have a pair of APs that are suitable for the rear. It's hard to find a set which are sized sensibly for something as light as the Mk3, but I finally did. I got a set of four calipers from an F3 car complete with Discs, bells and pads. The discs measure 268x16mm.
If you're familiar with Ap you'll know that a gold anodised caliper means they are made from a billet. This supposedly offer better braking performance and feedback due to increased rigidity, so I'd really like a set for the front now to replace the cast CP5555.
I'll replace the pads but they will suffice for mocking up.
Mark
Edited by mwstewart on Thursday 1st December 13:27
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff