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PostPosted: Sun Aug 08, 2010 9:45 pm 
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The Sherminator!
The Sherminator!

Joined: Sun Mar 06, 2005 6:10 pm
Posts: 22211
Location: Somewhere
well then i can finally do a thread for this :lol:

its been hard keeping this a secret from most :P :lol:

Pistonheads Ad Pic's :-

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Pic's i took for my insurance :-

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swapped from Clears to Ambers :D , jst need to swap the side repeaters to ambers too now

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then on my way to see baz my exhaust fell off, i knew it was blowing but thought it would at least stay on for a little longer :lol:

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with a spot on genius baz decided now was the perfect time to have a side exit... :halo:

up on the ramps it goes... we check the under side and it looked pretty clean :D :thumbsup:

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it was given a lick of black paint and this is how it looks now :D , sounds pretty good, lots of popping when i change down through the gears :chill: :lol:

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i decided i wanted to paint the floor so out came the carpet, only to find 2 small rust holes in the passenger foot well :cry: , deffo not as bad as i thought, will be sorted out soon hopefully so i start again with the painting :D

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stripped..only have the seat belts in the back which are coming out soon and my f2 front seats :lol:

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after we dropped my cossie off, i gathered a few bits from my garage that will be needed for the zetec conversion..

Si Fan

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Bit of Bling i bought of matt years ago now..

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Si Rad

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New Gaskets

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RS1800 Inlet and TB

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Si Fuel Lines

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Near New HT Leads

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Pink CVH Alt Bracket :teehheee:

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Spare Clutch and speedo Cable

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2 Random Poly Bushes for the Exhaust

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Header Tank and Piping

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Desk ECU and MAF

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Si Engine loom

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and my 2.0 Zetec Engine, strategically camo'd in the garden so my dad doesnt spot it while is strip bits off that i dont need :teehheee:

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Bits Removed

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Bits fitted.. well only one bit :lol: , pink Alt Bracket.. :teehheee:

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while up the workshop on saturday i got my mate baz to switch my zetec pulley off my zetec alt onto a spare cvh alt he had

Zetec Alt :-

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CVH Alt :-

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CVH Alt with Zetec Pulley :-

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a trip to halfords on sunday saw me walk out with these bits -

Fuel Filter :-

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Oil Filter :-
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i then ordered a new non pas alt rs1800 belt :-

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i then test fitted the alt o make sure the swing arm that tensions the belt fitted :-

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it fitted a treat so i test fitted my new alt belt,fits spot on juts need to tension it up when its in the car :D :-

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i then had a root round in my box of goddies that i had stored away when i had my fez and found this, a stainless steel water hose which i bought off matt years ago! :-

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this this eve i went to collect my last remaining bits for my conversion

Stage 2 S2 CTS Box :chill: :-

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Modified CVH Engine Mount :-

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4 Branch Zetec Manifold :-

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MK2 XR2 Exhaust which needs a little tlc :-

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XR2 Tie Bars and Brackets :-

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i then let the car cool down and begun stripping it, its now at the stage where the 1.1 engine is ready to drop out tomorrow eve, i'm waiting till i have a few more hands to help me :D

Started stripping :-

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Ready to drop out :-

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the engine was ready to drop out on thursday eve -

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my crew of missfits :lol: -

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1.1 out and me in the empty hole :lol: -

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zetec ready to have the box and inlet bolted on -

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zetec in -

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snug as a bug -

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i then fitted the alt and tensioned the belt up -

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then it was time for the 4 branch to be fitted, but i had to remove the alt and the alt bracket to get it on :rolleyes: :lol: , so with that done the branch was in and resting in place -

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pic's of the engine with bits fitted -

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then it was onto the part that would make or break this conversion :lol: , the fuel tank!!

mk2 and mk3 tanks next to each other -

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mk3 tank cut in half to show the swirl pot and the pump and sender -

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swirl pot and pump/sender plate -

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pump/sender -

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mk2 tank cut -

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i was making up some blanking plate for the holes that weren't needed anymore -

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baz, the man who was going to do the welding for me :D -

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the welding starts

swirl pot spot and blanking plates welded in place -

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mk3 pump/sender plate getting welded in -

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all done -

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sneaky little sticker on my boot ;) -

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it started on friday where i stupidly forgot wtf half the plugs did on my si loom :lolz: :red:

so i took some pic's for rs220bhp to help me out, but before he could reply i had already worked most of them out :red: :lol:

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close ups

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1. Coil Pack correct
2. Oil Pressure Switch correct
3. Bottom Therostat Plug - Gauage correct
4. CPS Plug corect
5. Maf Plug correct
6. VSS Plug ? 6+7 possibly to do with the pats sytems
7. ? as above
8. Plug for Injector Sub Loom
9. Main Car Loom
10. ?possibly that charcoal thing for emissions/ or not neened
11. ? this connects to the inlet vacume on the back,im sure its not needed
12. Lambda Sensor Plug
13. ?possibly that charcoal thing for emissions/ or not neened
14. Earth Wire

wiring a zetec into an mk2 using a 1.6 16v si loom

http://www.xrtwo.com/forum/viewtopic.ph ... it=si+loom

my suspension and tracking have now been done,i have done a few 1st's this week! i fitted new ball joints, did the suspension swap and did the tracking on my own, i did have some help and guidance from baz and my mate steve as i was up at thier work doing all this

shitty before pic of the 1.1 suspension

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after pic of the 30/40mm drop

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some pic's to go with the last update

another hole to be welded up...

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cowboy'd shaft, can you see the flat edges??

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old drum off ready for new bearings

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right then guys some bits arrived for me in the post yesterday afternoon, nice fresh set of bright oranage poly bushes, to match my hair :cool: :pmsl:

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on wednesday after i had finished work i shot off to the post office to collect another parcel that i had missed, 2 cans of crackle black had arrived for me :top:

i got my spare rocker cover out of the shed and headed to baz's work, i gave it a clean off in the degreasing tank thing

then set about spraying it, nice and shiny

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then after 3 coats, i left it in the sun to dry out,looked really good here

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On Saturday(last week) my beam was collected for me by a mate of mine up in Yorkshire! big thanks to mattyboy for collecting it for me and another big thanks to happypaul for bringing it down to FF for me! :thumbsup: :bow:

I also had a post delivery,my gearbox mounts arrived

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after i fitted my uprated suspension one of the rear shocks burst, so i had to then set about replacing it AGAIN!!.....

On Wednesday before FF I ordered 2 brand new standard xr2 shocks! :DD: which actually turned out to be made by bilstein :top:

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got them fitted and what a transformation :content: , I love it :cool:


comments welcome, she's a work in progress so bare with me :lol: :red:

got my mot tomorrow..... :wack: :crazi:

** Big Thanks go to - Alex,Del,Baz, My 2 Brothers, Kenny, Adam(scamp), Steve(rs220bhp) for all the parts i have bought off him and helping me source some bits i couldnt get hold of!**


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PostPosted: Sun Aug 08, 2010 9:59 pm 
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looks a good project :thumbsup:

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PostPosted: Sun Aug 08, 2010 10:11 pm 
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It looks poo and is too slow :teehheee:

It's seriously quite nice and I love the sound :drool:

Also Barry looks like a pedophile with that ice cream :lol:

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PostPosted: Sun Aug 08, 2010 10:16 pm 
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The Sherminator!
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:teehheee:

as you could tell i didnt clean it today :hsugh: :lol:

it looks like shit but goes pretty well now ive sorted out 90% of the issues

even same said it sounded like a bike :lol:

poor baz i'll tell him tomorrow :lolz:


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PostPosted: Sun Aug 08, 2010 10:21 pm 
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was somewhat surprised to see you in this Terry but after looking at the above does look like it could be a nice little weapon :thumbsup:

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PostPosted: Sun Aug 08, 2010 10:23 pm 
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I was kidding :homo:

It looked cleaner today than when I last saw it :lol:

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Dave G fsi wrote:
FRST's, scaring pedestrians since 1990


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PostPosted: Sun Aug 08, 2010 10:26 pm 
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The Sherminator!
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:halo:

cheers jono :thumbsup:

its been very hard not to post anything about it, i had been sourcing parts here and there for "a mate" :lol:

i needed a runabout and this fitted the bill quite nicely!i just couldnt live with the 1.1 engine a few weeks of 1.1 4 speed godliness was enoug for me :lolz:

when ive sorted the mot then the spending begins on the saph :hsugh:

:gheeyyy:

scamp i think it was due to all the rain we've had :hsugh:

its still got alex's hand print on my wing from when we did the conversion!

i'd also like to say ive not got any pic's of the work we did over the weekend to the car, but id like to thank scamp for popping down to help :thumbsup:


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PostPosted: Sun Aug 08, 2010 10:33 pm 
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Drives: mk3 Java, Fiesta RST
Clean it god dammit :lol:

You can't class eating pizza and chips help :teehheee:

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Dave G fsi wrote:
FRST's, scaring pedestrians since 1990


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PostPosted: Sun Aug 08, 2010 10:34 pm 
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so this is the mountian bike you were on about!
i was wondering why you were so desperate for a dipstick and tube then it clicked a few weeks ago haha

sounds the tits :chill:

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PostPosted: Sun Aug 08, 2010 10:36 pm 
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The Sherminator!
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this is indeed the mountain bike i was on about :lolz:

yeah i was hoping the " for a mate" excuse would work :hsugh:

cheers, i can only hear it inside the car,it sounds raspy and a touch chavy to me :red:


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PostPosted: Sun Aug 08, 2010 11:35 pm 
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not chavy at all, more like a motcross bike!

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Dave G fsi wrote:
FRST's, scaring pedestrians since 1990


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PostPosted: Mon Aug 09, 2010 6:51 am 
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interesting project :)

bet it goes well :)

at least the welding jobs aren't major :)

good luck with it :)

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PostPosted: Mon Aug 09, 2010 7:34 am 
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i cant believe a zetec fitted in there. looks like a real real cool project. love it. :thumbsup:

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PostPosted: Tue Aug 10, 2010 12:25 am 
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I could hear this thing from behind in my cougar with music on, but window down next to it the sound is the mutts nuts :D

It goes quite well too, can't believe it when i saw it i was like wtf i totally wasn't expecting to see terry's smile behind the wheel of a white mk2 :teehheee:

Will make for a great project dude, looks like you've done loads already, look forward to seeing more on it :thumbsup:

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PostPosted: Tue Aug 10, 2010 9:16 am 
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The Sherminator!
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cheers guys :D

now ive sorted out a few of the issues and its finally stopped trying to kill me ive been able to give it a boot full and it shifts pretty nicely :halo:

MOT was yesterday and it failed, but it failed on a few little bits of rust that we found while the car was on the ramps having the side exit made :lol:

so all in all, it good and i'm happy, welding starts this weekend! :thumbsup: :D


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PostPosted: Tue Aug 10, 2010 10:13 am 
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Glad it stopped trying to throw you across the road :)

You can take me out in it now :P

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Dave G fsi wrote:
FRST's, scaring pedestrians since 1990


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PostPosted: Tue Aug 10, 2010 10:41 am 
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The Sherminator!
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i have a slight update to do when i get home this eve, as i fitted the new wheels and the fez had a tad more strippage... :chill:

indeed i can now safely take you out for a spin! :thumbsup: :halo:

need to get some measurements for my maf so i can get a reducer.. :hmm:

safe to say i'm loving the S2 box!!! :D


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PostPosted: Tue Aug 10, 2010 12:15 pm 
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Does that mean you've got some great big holes cut into it then :teehheee:

I'll have to pop round soon then :chill: or you could always venture up to mine. Unless you don't want to go too far into the ghetto :lol:

Ge the pics up of the new wheels. I'm assuming there the ones you got Saturday? :halo:

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Dave G fsi wrote:
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PostPosted: Tue Aug 10, 2010 12:22 pm 
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The Sherminator!
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:teehheee:

no holes...... yet!

when you next down my way for college? i dont mind popping up to yours, will wait till i have some fuel money ;) :thumbsup:

:lolz: @ the ghetto

will do as soon as i get home as i dont have access to photobucket and its a pain in the ass doing it on my iphone :hsugh: , but yes they are indeed the wheels i bought on sat off mr tango man :thumbsup: :D


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PostPosted: Tue Aug 10, 2010 12:48 pm 
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Love it, love the working in progress pics too, always look forward to threads like these :thumbsup:

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