500+bhp Mk3 Fiesta Project

500+bhp Mk3 Fiesta Project

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Discussion

mwstewart

Original Poster:

7,554 posts

187 months

Thursday 1st September 2011
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P.S. You'll have to insert your own punctuation marks in my response laugh

bazza1000

294 posts

151 months

Thursday 1st September 2011
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Wow - serious amount of work gone into this project! Monster power for a little fezza

mwstewart

Original Poster:

7,554 posts

187 months

Tuesday 13th September 2011
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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 smile.

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 smile

The next step is wax injection.

Edited by mwstewart on Tuesday 13th September 23:01

payner2008

269 posts

184 months

Sunday 25th September 2011
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Any updates OP?

BBS-LM

3,972 posts

223 months

Sunday 25th September 2011
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Amazing attention to detail on this project, but I just do not get the Fiesta part, sorry. But good luck with it. biggrin

hewlett

2,186 posts

220 months

Tuesday 4th October 2011
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Might it be a good idea to make a simple aluminium flat underside?

mwstewart

Original Poster:

7,554 posts

187 months

Tuesday 4th October 2011
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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 smile

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 biggrin
Thank you - totally understandable smile 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.

hewlett

2,186 posts

220 months

Thursday 27th October 2011
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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 smile

k-ink

9,070 posts

178 months

Saturday 29th October 2011
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Interesting build! Personally I'd have kept the interior 100% original as I prefer it to the newer versions.

I bought a brand new Si when I was 19. It had all the boxes ticked at the time including the Ford lowering kit. I look back with fond memories to the summer of '95.

Red16

589 posts

167 months

Saturday 29th October 2011
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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.

mwstewart

Original Poster:

7,554 posts

187 months

Tuesday 22nd November 2011
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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.

Edited by mwstewart on Tuesday 22 November 10:57

Bosshogg76

792 posts

182 months

Tuesday 22nd November 2011
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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. laugh

Edit to add it is you, and I'm now off to remove the egg getmecoat

Edited by Bosshogg76 on Tuesday 22 November 13:04


Edited by Bosshogg76 on Tuesday 22 November 13:05

k-ink

9,070 posts

178 months

Tuesday 22nd November 2011
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Can i persuade you to opt for the Si black. I had that and it looked lovely when brand new. It had loads of lovely metallics glinting in it cool

mwstewart

Original Poster:

7,554 posts

187 months

Tuesday 22nd November 2011
quotequote all
k-ink said:
Can i persuade you to opt for the Si black. I had that and it looked lovely when brand new. It had loads of lovely metallics glinting in it cool
Ash Black? I agree it's nice, but I have a soft spot for the metallic red.

k-ink

9,070 posts

178 months

Tuesday 22nd November 2011
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It was too long ago to recall. However I think you could only get three colours (red, green, black). The diamond cut finish on many of the optional Ford alloys were cool at the time as well :rosetintedspecs:

Lund

1,743 posts

209 months

Tuesday 22nd November 2011
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mwstewart said:
she did get good penetration
ETA. hehe

dom9

8,040 posts

208 months

Wednesday 23rd November 2011
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Still loving this thread - Great work as always!

Was there a thread with respect to the Quattro/ R32 project?

mwstewart

Original Poster:

7,554 posts

187 months

Thursday 1st December 2011
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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.

Edited by mwstewart on Thursday 1st December 11:23

Greg_D

6,542 posts

245 months

Thursday 1st December 2011
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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

mwstewart

Original Poster:

7,554 posts

187 months

Thursday 1st December 2011
quotequote all
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 nuts 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