500+bhp Mk3 Fiesta Project
Discussion
Thanks everyone! 
Cheers
olly22n said:
Love the project, I maybe have an idea for the future, my E34 had the seat belts sockets built into the seats..maybe something the you could incorporate?
Ahh! I'd forgotten about that. I think some of my previous BMWs had it too, a recess in the rear seats which housed the buckles when they aren't in use. It's a neat idea.RenPug said:
Send me an email and let me know what year the mirror casing and sensor is for and I'll try and source a bracket for you. When we replace a screen with one on I'll cut it off the old glass and put it in the post.
Thank you! That's really appreciated.Lampredi said:
Hi mate ... i've been following this topic for months now... you're having new job proposals for sure
I've just registered to ask you ... wouldn't it be easier to achieve that amount of power using LPG instead of petrol? LPG is a less dense fuel, allowing higher boost!
Greetings from Portugal
Thanks. LPG isn't a consideration at the moment as I'm not sure what availability is like around some of the quieter areas of Europe, as I intend to take the car on a big Euro Trip once it's complete. 500+ on the Zetec is a fairly well trodden path so I'll stick to petrol for now as I know it works I've just registered to ask you ... wouldn't it be easier to achieve that amount of power using LPG instead of petrol? LPG is a less dense fuel, allowing higher boost!
Greetings from Portugal
pthelazyjourno said:
How much do you think it will weigh??
Amazing watching all the rattle proofing you've done - but then again the later dashboard you've installed really is quite decent anyway. Our Fiesta 1.25 has done 90,000 miles and it genuinely doesn't make a squeak, rattle or noise.
Surprised the hell out of me - feels really solid considering.
Richard Parry-Jones had a hand in the later Fiestas (the ones based on the chassis I'm using) and lots of things were over-engineered to aid handling and increase perceived quality in the model. Weight wise, I'm not sure, but I view the added weight as a benefit as with the power I'm going for it will help with traction.Amazing watching all the rattle proofing you've done - but then again the later dashboard you've installed really is quite decent anyway. Our Fiesta 1.25 has done 90,000 miles and it genuinely doesn't make a squeak, rattle or noise.
Surprised the hell out of me - feels really solid considering.
Cheers
Bugger.
I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
Echoing what most others have said, absolutely in love with this. The attention to detail is unreal and I love the modernisation of the car.
Thank you for sharing it with us in such detail and I can't wait to see it finished!
I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
Echoing what most others have said, absolutely in love with this. The attention to detail is unreal and I love the modernisation of the car.
Thank you for sharing it with us in such detail and I can't wait to see it finished!
morgs_ said:
Bugger.
I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
Yeah, I understand fully what you're saying, it's pain in the ass waiting for the finished car! But, I've no doubt, just like everyone else it will be the business. A really great project. I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
k sake, you did it as well! 
morgs_ said:
Bugger.
I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
Echoing what most others have said, absolutely in love with this. The attention to detail is unreal and I love the modernisation of the car.
Thank you for sharing it with us in such detail and I can't wait to see it finished!
I agree with all of this. What a brilliant project and a superb thread.I've spread reading this thread over as long a time as possible, in the hope that I would get to the end and it would be finished. Now I'm going to have to suffer the same suspense as the rest of you waiting for each update!
Echoing what most others have said, absolutely in love with this. The attention to detail is unreal and I love the modernisation of the car.
Thank you for sharing it with us in such detail and I can't wait to see it finished!
I also avoid reading the topic too often so that when I actually do click it, I know I'll have a good half hour or more of drinking in the details.
That said, I'm now intrigued by today's imminent update!
Focus Centre Console
The Focus console is secured by two screws under the forward cup holders and one screw under the rear cup holder. To help me determine what needed to be done I first secured the rear console fixing by installing a stainless Rivnut in the shell. Then, once the console was reasonably secure I could plan how to attack the rest.
The black powder coated object in the vice is a standard Mk4 Fiesta centre console front mount, which I had already modified my floor pan to accept as it acts as a stiffening brace for the Mk4/5/Puma dashboard by securing it to the floor. I modified the Fiesta bracket in order to create something that would be compatible with my dashboard, my floor pan, and also the Focus console.
After a couple of test fits of the console I wasn't happy with how far it encroached into the front foot wells, so I fabricated some U sections which the edge of the console could sit into, in order to pinch the width at the base and restore foot well space.
Here's the finished bracket. I added a strengthening rib on the lower edge.
The bracket was finished in etch primer and satin black. It clears everything it needs to and is a lot sturdier than a standard Focus bracket. The two out of focus white objects in the foreground are plastic captive fittings I installed to take the securing screws.
Next I made holes in the console for the Bosch Park Pilot display and buzzer, and the Fiesta tailgate release button.
I used some trim clips from ebay to secure the Parkpilot display harness. I was a bit sceptical about them but the adhesive is very good.
Here's how far the console encroached into the passenger foot well:
When clipped in to my edge brackets, the console is pulled in and its base width becomes close to that of the original console:
This photo shows where I have cut the Focus console to suit the Fiesta floor pan.
Here's the finished result. Incidentally it is mounted far more securely than in the Focus
Illuminated Cigarette Lighter Rings
A lot of Ford models came with illuminated Cigarette lighter sockets, so I ordered a pair and fitted them to my HVAC controls and the Focus centre console. I appreciate that most people hate the fake wood, but it works for me in the context of this build
Focus RS Gear Lever Adjustment
Following a test fit I decided that I wasn't happy with the position of the new gear lever: it was too far forward. The lever assembly was already as far back on the floor pan as it could go, so I stripped down the mechanism to see what could be done; it soon became evident that the RS lever has a very shallow rake compared to the original Fiesta lever.
I bent the RS lever to match the original Fiesta lever, and the gear knob now sits perfectly to hand.
Passenger Airbag Retrofit
The passenger Airbag is a straight forward fit now the wiring is in place.
I used adhesive felt pads around the circumference of the Airbag cover, to minimise any trim noise. They can just about be made out in the above photo.
Cover in place.
B-Pillar Trim Fitted
New B Pillar trims fitted with Sound Absorber 15 pads and new trim clips.
Front Passenger Seat Fitted
I'm using a pair of front seat belt pre-tensioners from a later Ford to compliment the new Airbag and restraints system that is now wired in. A quick test fit showed that the tensioners would bolt in place of the original buckles, but the gas chamber shroud fouled the seat runner.
So, I notched both inside seat runners to allow the pre-tensioners to fit.
The affected area on each seat runner was refinished in gloss black, and the pre-tensioners fitted perfectly into place.
I drilled three small holes in the seat cross brace to allow fitment of some cable clips to keep the pre-tensioner and heating element cables away from the runners.
Here's the passenger seat fitted.
Rear Speakers and Amplifier - Sinfoni
I decided that I couldn't live without some rear speakers, or 'fill' as its known. New components are Sinfoni 90.2x Amplifier and some S100 speakers, which are the same side as the Ford originals.
Sinfoni build quality certainly matches the sound.
One Touch Window Relays Fitted
I stripped down the Mondeo relay connectors to their component parts, as that way I could solder my new wires directly to the pins in order to maintain the correct wiring colour scheme.
Completed. The Orange, Black and Blue wires are for the Audi puddle and door handle lights I mentioned in a previous update.
Mondeo Instrument Cluster
I have always planned to upgrade the instrument cluster in the car, the criteria being something that offered increased features but at the same time wouldn't require drastic loom changes. I settled on the 2004-2008 Mondeo cluster which in visual terms it's not a huge step up from the Mk5 Fiesta cluster, but it is back lit and comes with a trip/fuel computer, temperature display, and ice warning, which definitely are an upgrade over the front lit and relatively simple Fiesta cluster.
The majority of information used by the cluster is read over the CAN Bus, so in order to use it in something as old as my Fiesta there is a requirement for both new data lines and a suitable ECU. You may recall I already integrated new twisted pair data lines with the interior loom in anticipation for an instrument upgrade, so that just leaves the ECU.
The Mk3 Fiesta used 'EECIV' Engine management which is now basic by today's standards and doesn't offer anything of use for my project, so that system and loom was cast aside and replaced with a modified loom from a later Fiesta, which gave me 'EECV'. This is a much more advanced Powertain management system that was in use up to 2008 and is actually available in two architectures: the more basic 60pin and a more advanced 104pin, which includes CAN bus amongst other things. The problem was that to my knowledge, the Fiesta only ever came with the cheaper/simpler 60 pin version of EECV so I fully anticipated I'd have to modified the engine bay loom to suit! This however wasn't a problem to me as the engine bay loom is separate entity and I hadn't yet started work on it: if I had, I wouldn't have attempted to fit this cluster. It was by chance that I stumbled across a Mk5 Fiesta 1.8 Turbo Diesel and noticed it used the 104 pin management, so I've since purchased the engine bay loom from that model which gives me basically plug-and-play pre-wiring for the 104 pin management. There are quite a few modifications I'll do to the engine loom but that will be covered in a later post.
Physically fitting the new cluster was actually quite easy even though it is larger then the original. My aim was to keep the dashboard standard and to modify the cluster, as it can be removed very easily if required.
I first stripped the cluster to determine if I could safely remove material in the necessary areas, and also inspect the PCB which also required a slight trim. All was well and the PCB wasn't printed in the areas I had to trim. Any cut areas will be made good with new plastic glued into place and I will also bond on some new mounting lugs, as the Mondeo lugs were in the way.
The Fiesta bezel shrouds the new instruments somewhat, so it will be removed, reshaped to suit and then repainted.
Billet 7075 Rear Hubs
Here's the first of many bespoke billet components for the suspension: Billet 7075 Focus rear hubs. The hub flange and body is thicker for increased strength yet there is still an overall weight saving over the original. The finishing touches will be a machined lip to mount the standard ABS ring, a groove to allow fitment of the standard bearing dust cap, and finally gold anodising.
Later Steering Column
I'm using the steering column from a later Fiesta because it came with a three piece steering shaft, which seems like it would be far safer in frontal impact than my original two piece shaft would be. The later column is also far sturdier around the mounting point which serves to improve location of the steering wheel.
The later column (top) is an evolution of the original steering rack and isn't a million miles away from the original, the main difference is that its smaller in diameter. To get around this I'm having an aluminium spacer turned which will allow the original rack locating bush to fit the later rack, which in turn suits my steering column mount in the shell.
The Focus console is secured by two screws under the forward cup holders and one screw under the rear cup holder. To help me determine what needed to be done I first secured the rear console fixing by installing a stainless Rivnut in the shell. Then, once the console was reasonably secure I could plan how to attack the rest.
The black powder coated object in the vice is a standard Mk4 Fiesta centre console front mount, which I had already modified my floor pan to accept as it acts as a stiffening brace for the Mk4/5/Puma dashboard by securing it to the floor. I modified the Fiesta bracket in order to create something that would be compatible with my dashboard, my floor pan, and also the Focus console.
After a couple of test fits of the console I wasn't happy with how far it encroached into the front foot wells, so I fabricated some U sections which the edge of the console could sit into, in order to pinch the width at the base and restore foot well space.
Here's the finished bracket. I added a strengthening rib on the lower edge.
The bracket was finished in etch primer and satin black. It clears everything it needs to and is a lot sturdier than a standard Focus bracket. The two out of focus white objects in the foreground are plastic captive fittings I installed to take the securing screws.
Next I made holes in the console for the Bosch Park Pilot display and buzzer, and the Fiesta tailgate release button.
I used some trim clips from ebay to secure the Parkpilot display harness. I was a bit sceptical about them but the adhesive is very good.
Here's how far the console encroached into the passenger foot well:
When clipped in to my edge brackets, the console is pulled in and its base width becomes close to that of the original console:
This photo shows where I have cut the Focus console to suit the Fiesta floor pan.
Here's the finished result. Incidentally it is mounted far more securely than in the Focus
Illuminated Cigarette Lighter Rings
A lot of Ford models came with illuminated Cigarette lighter sockets, so I ordered a pair and fitted them to my HVAC controls and the Focus centre console. I appreciate that most people hate the fake wood, but it works for me in the context of this build
Focus RS Gear Lever Adjustment
Following a test fit I decided that I wasn't happy with the position of the new gear lever: it was too far forward. The lever assembly was already as far back on the floor pan as it could go, so I stripped down the mechanism to see what could be done; it soon became evident that the RS lever has a very shallow rake compared to the original Fiesta lever.
I bent the RS lever to match the original Fiesta lever, and the gear knob now sits perfectly to hand.
Passenger Airbag Retrofit
The passenger Airbag is a straight forward fit now the wiring is in place.
I used adhesive felt pads around the circumference of the Airbag cover, to minimise any trim noise. They can just about be made out in the above photo.
Cover in place.
B-Pillar Trim Fitted
New B Pillar trims fitted with Sound Absorber 15 pads and new trim clips.
Front Passenger Seat Fitted
I'm using a pair of front seat belt pre-tensioners from a later Ford to compliment the new Airbag and restraints system that is now wired in. A quick test fit showed that the tensioners would bolt in place of the original buckles, but the gas chamber shroud fouled the seat runner.
So, I notched both inside seat runners to allow the pre-tensioners to fit.
The affected area on each seat runner was refinished in gloss black, and the pre-tensioners fitted perfectly into place.
I drilled three small holes in the seat cross brace to allow fitment of some cable clips to keep the pre-tensioner and heating element cables away from the runners.
Here's the passenger seat fitted.
Rear Speakers and Amplifier - Sinfoni
I decided that I couldn't live without some rear speakers, or 'fill' as its known. New components are Sinfoni 90.2x Amplifier and some S100 speakers, which are the same side as the Ford originals.
Sinfoni build quality certainly matches the sound.
One Touch Window Relays Fitted
I stripped down the Mondeo relay connectors to their component parts, as that way I could solder my new wires directly to the pins in order to maintain the correct wiring colour scheme.
Completed. The Orange, Black and Blue wires are for the Audi puddle and door handle lights I mentioned in a previous update.
Mondeo Instrument Cluster
I have always planned to upgrade the instrument cluster in the car, the criteria being something that offered increased features but at the same time wouldn't require drastic loom changes. I settled on the 2004-2008 Mondeo cluster which in visual terms it's not a huge step up from the Mk5 Fiesta cluster, but it is back lit and comes with a trip/fuel computer, temperature display, and ice warning, which definitely are an upgrade over the front lit and relatively simple Fiesta cluster.
The majority of information used by the cluster is read over the CAN Bus, so in order to use it in something as old as my Fiesta there is a requirement for both new data lines and a suitable ECU. You may recall I already integrated new twisted pair data lines with the interior loom in anticipation for an instrument upgrade, so that just leaves the ECU.
The Mk3 Fiesta used 'EECIV' Engine management which is now basic by today's standards and doesn't offer anything of use for my project, so that system and loom was cast aside and replaced with a modified loom from a later Fiesta, which gave me 'EECV'. This is a much more advanced Powertain management system that was in use up to 2008 and is actually available in two architectures: the more basic 60pin and a more advanced 104pin, which includes CAN bus amongst other things. The problem was that to my knowledge, the Fiesta only ever came with the cheaper/simpler 60 pin version of EECV so I fully anticipated I'd have to modified the engine bay loom to suit! This however wasn't a problem to me as the engine bay loom is separate entity and I hadn't yet started work on it: if I had, I wouldn't have attempted to fit this cluster. It was by chance that I stumbled across a Mk5 Fiesta 1.8 Turbo Diesel and noticed it used the 104 pin management, so I've since purchased the engine bay loom from that model which gives me basically plug-and-play pre-wiring for the 104 pin management. There are quite a few modifications I'll do to the engine loom but that will be covered in a later post.
Physically fitting the new cluster was actually quite easy even though it is larger then the original. My aim was to keep the dashboard standard and to modify the cluster, as it can be removed very easily if required.
I first stripped the cluster to determine if I could safely remove material in the necessary areas, and also inspect the PCB which also required a slight trim. All was well and the PCB wasn't printed in the areas I had to trim. Any cut areas will be made good with new plastic glued into place and I will also bond on some new mounting lugs, as the Mondeo lugs were in the way.
The Fiesta bezel shrouds the new instruments somewhat, so it will be removed, reshaped to suit and then repainted.
Billet 7075 Rear Hubs
Here's the first of many bespoke billet components for the suspension: Billet 7075 Focus rear hubs. The hub flange and body is thicker for increased strength yet there is still an overall weight saving over the original. The finishing touches will be a machined lip to mount the standard ABS ring, a groove to allow fitment of the standard bearing dust cap, and finally gold anodising.
Later Steering Column
I'm using the steering column from a later Fiesta because it came with a three piece steering shaft, which seems like it would be far safer in frontal impact than my original two piece shaft would be. The later column is also far sturdier around the mounting point which serves to improve location of the steering wheel.
The later column (top) is an evolution of the original steering rack and isn't a million miles away from the original, the main difference is that its smaller in diameter. To get around this I'm having an aluminium spacer turned which will allow the original rack locating bush to fit the later rack, which in turn suits my steering column mount in the shell.
And yet again the attention to detail is stunning. That console brace is a piece of work in itself and it'll never be seen by anyone other than us reading the build thread.
We may need to have a serious discussion/user poll about that fake wood at some point though I'm afraid. It's not quite up to the standard of the rest of the interior really.
We may need to have a serious discussion/user poll about that fake wood at some point though I'm afraid. It's not quite up to the standard of the rest of the interior really.
Awesome, still loving this thread! amazing attention to detail!
by the way I think the topspeed record is 183.99mph in a Fiesta isnt it? Lucas 'Trolley'
You mentioned someone doing 184 earlier? who was that? Paul or Sunny never went that quick did they?
by the way I think the topspeed record is 183.99mph in a Fiesta isnt it? Lucas 'Trolley'
You mentioned someone doing 184 earlier? who was that? Paul or Sunny never went that quick did they?
Edited by Porkie on Wednesday 9th May 18:10
Thanks guys!
Porkie, Cheers! I'm not sure about 184, but on page 3 I mentioned Paul J's 179.8.
I finished another couple of small jobs tonight. The alloy spacer for the new steering column is complete. I had a lip added to the rear face to prevent the nylon bush sliding off, and the alloy spacer itself has a tapered bore to prevent it moving on the shaft. I had to sweat the spacer on to the column so it's certainly secure.
The new column fits perfectly!
A very minor job on the rear quarter trims. The plastic covers for the seat belt aperture weren't a very good fit and could have caused a small rattle, so I've put some felt tape around the aperture. The covers (not pictured here) are now a very snug fit.
Porkie, Cheers! I'm not sure about 184, but on page 3 I mentioned Paul J's 179.8.
I finished another couple of small jobs tonight. The alloy spacer for the new steering column is complete. I had a lip added to the rear face to prevent the nylon bush sliding off, and the alloy spacer itself has a tapered bore to prevent it moving on the shaft. I had to sweat the spacer on to the column so it's certainly secure.
The new column fits perfectly!
A very minor job on the rear quarter trims. The plastic covers for the seat belt aperture weren't a very good fit and could have caused a small rattle, so I've put some felt tape around the aperture. The covers (not pictured here) are now a very snug fit.
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