Fiesta Mk6.5 and a half.

Fiesta Mk6.5 and a half.

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E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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Copied over from another forum thought I'd share my Fiesta and a half. (The half will make sense later)

Bought the Fiesta in November 2015 to replace my Mk4 Golf, Had the Golf 2 years and to be fair it was relatively faultless, but it was only a 1.4 so it was time to move on!




I didn't really know what to replace it with, I was looking at normal 1.4TDCI Fiestas but then found the only TDCI Zetec S for sale in Ireland at the time so jumped at the chance!

It had some random Focus alloys and the rear lights were tinted (Looked awful IMHO) Had 98k Miles and I'm the 3rd owner (First Irish owner as is a UK import) But other than that it was an original unmodified car which is exactly what I wanted.







Focus alloys got swiftly removed and sold, Replaced by a set of Borbet 16'' (Original Fiesta Alloys) Came up as new, Not bad bad considering they were about 8 years old! :detailer:






Then I added some electric colour coded mirrors and a pair of G3 Wind Deflectors,



Then had the chance to buy back some alloys I sold a few months previous to me buying the Fiesta came up, So they were quickly purchased and tyres swapped over from the 8 Spokes





Rub Strips and Door Handles got colour coded, ST150 Side Skirts were sourced and had them painted to match. (Correctly fitted by using original clips not tigersealed to death like most!)
Then a Tripple R Composites front splitter and bonnet lip and an eBay 'S' badge were fitted.









Front brakes needed replacing, So decide I'd upgrade them to ST170 300mm Front and a 280mm rear disc conversion. A simple upgrade using original Ford parts that just bolt straight on!




Wasn't a fan of the original cloth interior, Wanted full leather but they were fairly hard to come by as I specifically wanted the correct Zetec S seats, ST are the exact same with the addition of an ST logo on the backrest which I didn't like!

30th Anniversary/Celebration chequer door sills got added, Matching DMB Graphics heater rings. Replaced the original 6000 CD radio with the factory optional Sony. And an Armster II Armrest to complete it! :driver:






To carry on the chequered theme I had the the roof wrapped, Similar idea to the Anniversary/Celebration models but it's all individual squares in charcoal black rather than one piece in black/white.





Then a set of alloys came up for sale that I didn't even know they existed but a bit of Googling later told me they were a rare option and slightly wider and lower offset than my current ones. (16x6.5J ET40 compared to 16x7J ET35!)

Shown in the 1990s Rs Accessory Catalogue for the Puma and Mondeo.







Had them powdercoated and wrapped in Hankooks Ventus Prime 3,





Managed to find a 5th matching wider alloy on eBay, So got the tyres swapped over with my current spare so I now had a proper set of 5! :thumb:
7J on left, 6.5J on right


E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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From looking around online, It was an option when new to have Bluetooth and Voice Control, Mine didn't have this! frown

So I set about trying to retrofit it, First off the column stalk controls for the radio needed fitting.... Luckily Ford had all Mk6.5 pre wired with the wire being tapped to another loom so it was just a case of finding the wire and getting the stalk and column plastics and connecting it all up.

Next I bought the Nokia module and microphone from a breakers, Luckily Ford do a retrofit loom for this (Although it ain't cheap!) but it's a straight forward fit. The loom takes power from radio, Connects to Nokia module behind glove box and also extends to connect to the microphone on the drivers A pillar.




Connected it all up and it works as it should! :thumb:




Was even sad enough to rename my phone's Bluetooth so I could have this on the display!



Got some show plates made up to match the roof, Pic taken at the RS Owners Ireland show in New Ross.





eBay sent me a £15 voucher so put it against some ST150 Aluminium pedals, These are an exact fit. Clutch/Brake just being covers and the accelerator being a complete electronic unit but it all bolts in and works as it should.






Edited by E36Ross on Sunday 22 July 20:44

E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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Some current pics,














E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
quotequote all
An update with a difference, Bought this a month ago in Galway (A few miles from the coast) Guy had bought it for parts for his own.

It's a 2004 Mk6 Fiesta Van.


Tried everywhere to try get a detachable towbar for a Zetec S, Didn't want a visible cut on bumper or visible electrics!


There's about 2" cut on diffuser but it's not visible, Electrics fold up and towbar detaches. smile


I stripped what remained of the van, (Diesel tank, Interior Plastics etc..) and dropped it up to a guy in Dublin.




And a few weeks later, The van was back on the road......
Looking a bit different than before. It got LOTS of attention on the motorway! :thumb:



All orginal Fiesta rear axle/suspension in place. Working factory handbrake and all lights wired, jockey wheel etc..

More for show use than anything but it will be used when needed, Ideal for tip use. smile

Will be painted Moondust Silver with Zetec S Bumper/Spoiler and ST Skirts to match, Factory van interior in place with all plastics/carpet trimmed to fit and lowered.

I'm also half way through a Mk6.5 rear light conversion.

Edited by E36Ross on Sunday 22 July 20:18

E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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Collected it from bodywork this evening, Really happy with how it has turned out! :thumb:


Before, Front had just been tacked on in places,



It's now fully welded and cleaned down to a nice smooth finish, A few other imperfections including a dent on the arch was also done. smile





Side Skirts modified to fit and mould around the front, Stapled together and plastic welded. These are genuine ST skirts!




And a quick few pics on the way home, Mk6.5 mouldings fitted and ST Spoiler fitted.










Have some LED marker lights ordered for the front of it, So will have those fitted and then it's off for paint!


Trailer has been fitted with a set of adjustable springs so I can change height, Took me ages to try find someone willing to sell just the rears... These had only previously been tested fitted so were as new. biggrin




And it's been finally painted in Moondust, Boot door was removed and all the inner boot shut was painted to match so no obvious signs of its original colour. :thumb:




]






Was only painted last week so havnt even washed it yet, Few little bits to tidy but nearly there. wink


My badges arrived, Not cheap at €80+ even after discount redface
Few things to still match on the rear but nearly there. :thumb:





Edited by E36Ross on Sunday 22 July 20:14

E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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poing said:
Do you work for Ford? If not, that is some proper geek stuff managing to use Ford parts almost everywhere. Impressive stuff regardless.

The trailer is rather brilliant!

On the trailer the rear window needs to be painted black to pretend it's a window.
No, I drive a bus. smile

Just use as much Ford parts as possible where i can, a lot of it isn't noticeable but it's the little touches that I enjoy doing most.

Yeah iv thought about it but a wrap/paint wouldn't look original up close so if I were to match it'd be van panels on the car.

E36Ross

Original Poster:

502 posts

113 months

Sunday 22nd July 2018
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Ordered a KAP Industries Fire extinguisher mount, Advertised as a Mk6/Mk7 bracket. Turns out it was made just for a Mk7, But a quick message to the UK supplier and a few measurements later and they've custom made and sent me the correct one all the way from head office in Australia at no cost! :thumb:







Also fitted my Mk3 Mondeo interior light, Direct replacement for the Fiesta unit so it means I now have individual map lights.





Spent ages looking for a factory parking sensor kit (Or Reverse Proximety Sensors as Ford call them) to keep the OEM+ theme going.
Couldn't find anyone willing to sell seperate from a bumper and I didn't fancy my chances of finding an individual sensor should one ever go wrong without paying €€€ to Ford.

It's a Dolphin D400 kit, Came pre painted and matched to Moondust. Lifetime warranty!



Sensors fitted in factoryish positions, Also showing off my detachable Witter and foldable electrics. cool





They give a solid beep when about 12" away from a wall etc... Towbar doesn't interfere with them either. Don't need them but it's another one ticked off the options list. smile


Trailer roof has been wrapped to match so that's pretty much finished now, :thumb:




Another OEM+ mod that's not noticeable to the majority, Mk6 Fiestas have a key slot on the drivers door as standard, I used a blank from the rear door of a 5 door.
Needs slight trimming inside to clear the barrel but once done fits 100% :thumb:






And pics of a clean car for once, TRC Side Skirt Splitters fitted to match the front splitter. biggrin










E36Ross

Original Poster:

502 posts

113 months

Tuesday 24th July 2018
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Muzzer79 said:
I'm loving the trailer, but doesn't the bluff front of it make it rather like towing a sail or a parachute?
Nothing different to a normal box trailer, It weighs 300kg and has about 30kg noseweight. I know it's a cliche but you don't know it's there when towing.

Ideally I'd have made it a bit bigger, (There is a Fiesta trailer done from the A pillar out there) but it'd mess about with noseweights and be a pig to tow. As it is, it's perfect. smile



Appreciate all the positive comments. smile


Edited by E36Ross on Tuesday 24th July 09:34

E36Ross

Original Poster:

502 posts

113 months

Friday 27th July 2018
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No not local, Just attended the Ford show in Bolands Ford. smile


Anyway,
Slight change of theme for the inside, Seen an ST500 for breaking on FB (ST500 was a limited edition of the ST150 with only 500 made in 2008)

Cheeky offer later I was the owner of the 'Carbon Fibre' trim that was limited to the ST500 model only.

Complete set with heater dial surround, radio surround, gear gaiter ring and 4x heater vents.



Quick reminder of the standard interior,



And now,




ST500 limited edition badge removed and replaced with the custom S badge.

Also if anyone is breaking a pre facelift Mk3 Mondeo, PM please as there's a small few interior bits I need. wink

E36Ross

Original Poster:

502 posts

113 months

Sunday 29th July 2018
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poing said:
Is that a mobile phone holder to the left of the hazard switch? If that's very neat!
Yes, Lad on the Mk6 Fiesta owners posted up looking for ideas of what he could 3D print to replace the original coin holder..... I suggested the phone holder so he started making them and sent me a freebie. smile It's spring loaded so adjustable for 99% of modern phones.

trails said:
Looks cracking, massive lift on the interior over standard....that S plaque is a very nice touch. Black wing mirrors?
Few small bits still to add to give it a bit more luxury..... Just need to find the parts!

Not sure what you mean by black mirrors, but there's a plastic unpainted edge around them so they look black in the above pics. smile

E36Ross

Original Poster:

502 posts

113 months

Tuesday 23rd October 2018
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My car originally came with manual adjustment non colour coded mirrors, I had replaced these with the colour coded / electric adjustment a while back.... But my car never had the wiring so I just adjusted by pushing the glass for the last 2 years laugh

Decided it was time to finally sort the wiring, So purchased 2 complete door looms and 2 interior covers with the switch.




To change them the complete door needs stripping, So door card off, Glass out, Inner door card containing the window reg/motor all need removing.




All that sorted it was time to plug the mirrors in, To discover Ford changed the loom connection in very late 2005 and my mirrors were the early ones. spin

So a quick message to Mark at MS Fiesta dismantlers and had the correct set sent over,



And in typical fashion, the coloured covers although look identical have different clips so I now have black mirrors which was suggested by someone above. laugh

Insert the 2 missing fuses (Adjustment and heating) and your done.




Looms I have fitted also do 'Powerfolding' so that's another thing to figure out eventually as it's not plug and play. rolleyes

E36Ross

Original Poster:

502 posts

113 months

Tuesday 23rd October 2018
quotequote all
Have been after a set of ST seats for ages, non existent in Ireland but I was in the UK in August so brought a set home with me. wink

Now ST seats are the exact same as a Zetec S seat except for 2 differences.... The obvious ST logo AND the fact they are heated! wink



Most would just bolt these straight in and be happy, I did this laugh




Heated bases with wiring, side plastics and switchs removed.





My existing leather was marginally better condition, So I had an upholsterer swap my current leather onto the new bases. Leather I'm using is on the left of pic. wink




Add my existing seats and new heated bases together, and you end up with heated Zetec S leather. Ford never offered it as an option for some unknown reason considering they had all the bits to do it.




Added an ST gearknob, Leather finish instead of Zetec S hard plastic Feels much nicer in the hand.




Also added silver interior grab handles from an ST, Mine were just standard black plastic.



Interior is pretty much done now, Just need an interior mirror from an early Mk3 Mondeo if anyone has one.

E36Ross

Original Poster:

502 posts

113 months

Wednesday 28th August 2019
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larkm said:
Sweet setup man, the trailer looks smart!!

Couple of Qs
What's the model number of the Stereo? Do the Steering column controls still work?
Where did you find the cup holder tub? i can't find one short enough to look as neat as yours.

Cheers
Only seeing the latest comments now, Thanks! smile

Not sure of the model, But Its a factory option on the later 2007/2008 Mk6.5

Direct replacement for the original radio. Steering column controls work as they should (Including phone and radio voice commands)

It's also possible to make a hybrid version using the Mondeo Sony, To have DAB.


The cup holder insert is the factory ash tray / smokers pack. Ideal as a coin holder! smile


Edited by E36Ross on Wednesday 28th August 13:51

E36Ross

Original Poster:

502 posts

113 months

Wednesday 28th August 2019
quotequote all
Podie said:
Any updates on this?
Have a few bits ordered, So will have an update in a few weeks......




biggrin

E36Ross

Original Poster:

502 posts

113 months

Wednesday 18th December 2019
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My EGR decided to start sticking AGAIN so decided to blank it..... These have a flow sensor so would need blanking aswell as mapping out.

Now if I was to get it mapped, Made sense to do a few more upgrades didn't it? rofl

The 1.6TDCI / HDI is also fitted to the Mk2 Focus and came as a 110bhp rather than a 90 like the Fiesta.

Same engine, difference being the turbo is larger and a VNT and the injectors are also different.


So genuine Garrett GT1544v with new feed pipes/banjo bolts etc.... And Focus 259 injectors with new genuine Ford seals. (Bascally Focus 110 Turbo/Injectors)



NB Styling do a EGR blank, Catch Can and RamAir filter kit so decided to just get the lot.



Then got it all mapped by HDI Tuning to 145bhp / 290nm. A Mk6 ST150 is 150bhp / 190nm by comparison. hehe


I was hoping naively my clutch would last until I done a bit more research on a 6 speed conversion...... It started to 'just' slip on full boost in 3rd.

A 6 speed conversion needs custom mounts and shafts so just decided to go for an upgraded clutch for now.

Billet pressure plate, Organic full clutch and an upgraded slave cylinder. These are rated to 400nm so should be fine. cool



While browsing I noticed they also do an intercooler piping kit to fit a Mk2 Focus RS Intercooler...... Then seen an intercooler for £40 on eBay off a low mileage RS so that also got ordered. rofl




Just need to get a free weekend to fit the clutch and intercooler and give the engine bay a clean but the rest is done and it's back on the road. cool




E36Ross

Original Poster:

502 posts

113 months

Friday 20th December 2019
quotequote all
Alfa Pete said:
This is brilliant . Amazing attention to detail.
Must be a lot of research into what you can retro fit.
Yeah, Iv researched a good bit over the years.... Most has just been trial and error.

Currently have Auto Lights / Wipers fitted with all wiring aswel. Not plug and play so need to find a way of coding it to my GEM.


MC Bodge said:
Brilliant. How does it drive?
Brilliantly, Comes on boost nicely at about 1800/1900ish (Same as standard) So no extra lag. Very useable and really comes alive in 3rd gear so plenty power for merging onto motorways, overtaking etc... Which is exactly what I was hoping for.

Ideally I'd love a 6 speed to knock the revs down when on a motorway but that's down the list.

DevonLad said:
OP, I don't suppose you still have the early silver electric mirrors do you?
Always keep the old parts so there here somewhere. smile



a11y_m said:
love that it's all Ford with nothing obviously aftermarket. It could easily have come from Ford like that.
Exactly the look I'm after, trying to use as many Ford parts as possible. cool






Edited by E36Ross on Friday 20th December 09:20

E36Ross

Original Poster:

502 posts

113 months

Friday 20th December 2019
quotequote all
JakeT said:
It's got parking sensors, auto lights and wipers, sunroof and the 'rare' ESP, too.
Sunroof is verrrry rare in the UK for some reason, Most of these in Ireland have a Sunroof though.

ESP is probably rarer as very very few have it. The blank switch alongside it is for the passenger airbag deactivation which was a dealer fit option. smile

Nickbrapp said:
Looks mega, I lusted after one of these in red for my first car and still think the mk6.5 is the best looking fiesta they made, have you thought about the original zetec S wheels? They look smart
They were the last good looking Fiesta IMHO. I also have a Mk2 and 2 Mk3s. biggrin

They are a very soft wheel and buckle easily, I like them and have a few but would need spacers to sit right IMHO.

16x6.5J ET52.5mm and my Mondeo are 16x7J ET35 so sit nearly an inch further out.

E36Ross

Original Poster:

502 posts

113 months

Wednesday 29th January 2020
quotequote all
So browsing Facebook I seen another Zetec S for sale...... 2008 TDCI, 203k miles leaks coolant and goes into limp mode and it was over 200km away.

So I bought it. rofl



Standard enough spec, Only options are a Sunroof and a "Coral" dash.





E36Ross

Original Poster:

502 posts

113 months

Wednesday 29th January 2020
quotequote all
It's more or less a driving parts car, So first was to swap over the dash into the silver one.

Started with the black car to figure it out, Loooooots of screws and torx but fairly straight forward.



Dash removed,




Old "Pewter" dash removed,




And all screwed back together, Also fitted an auto dim rear view mirror from a Mk3 Mondeo...... Only the 2001/2 and early 2003 Mondeos have this mirror as an option so took me ages to track one down!

The reason I wanted this specific one is because it fits directly to the original Fiesta mount and is also very easy to wire in.



Needs a proper cleaning but it's all in and working. cool

E36Ross

Original Poster:

502 posts

113 months

Wednesday 1st April 2020
quotequote all
Been off work the last few weeks due to some virus or something? confused So spent a bit of time on the Fiesta.


Fitted my Focus RS intercooler, 56% increase in air volume and 70% bigger overall compared to standard with no increase in turbo lag.



Rad cradle needs trimming and it literally just about fits. (Most people remove the lower grill to fit them)

I'v also done away with the original bonnet stay and have fitted gas struts. thumbup

Still need to tidy a few bits and also have a stainless decat to fit but it's nearly there.







Edited by E36Ross on Wednesday 1st April 22:33