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 Post subject: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:17 pm 
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FSI Poster
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
realised that i havent put up my xr2 rebuild on here
basically bought it around augest last year for £1500
on the face of it, it was a soild good little car for the money i had a good poke around etc and found very little wrong with it

did puff a bit of oil on start up but ran well
ive copied this from xrtwo.com so the dates etc will be a little out

quick current spec
engine
twin 40 carbs
kent fast road cam and vernier
ashely system

suspension
gmax kit
partly polybushed

body
colour coded body kit

interior
leather retrim

heres what i intend to do to it
polybush all around
cosworth brakes
rs2k alloys
possible lighten and balnace of bottom end
get the body work sorted

heres the current state of the car
there is some rot on the rear arches that was hidden behind the body kit
the arches have been replaced in the past but not done very well as there is a ton of filler blending them in

so they will both be replaced

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other than the rear arches the body work is in very good condition

having checked the engine number it still has the original enge with 99k on the clock

the valve stem oils seals are in need of replacing so i thought id tae the head off and have a nosey at the bores etc

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it was a lucky thing i did
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as you can see the water ways have become very gounked up with corrosion and crud with just the small holes in the head gasket letting any coolant to the head
how it didnt over heat i never know
but on the plus side all the bores seem to be good
but i will be doing a bottom end strip aswell as i want to give it a good clean and inspect
due to the crap coolant when i took the thermostat housing ou i found the stat was corroded into the housing so i had to chisel it out

hence why i now need a new stat housing ans its knackered

heres a sneeky of my rocker cover that will go on
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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:17 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
bit of an update today
took the rest of the engine in prep for it to go to the body shop and the engine rebuild
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plan for it now is hopfully it will be going to the bodyshop the next couple of weeks
the head, crank and fly wheel will be sent off to get worked on
the block will be stripped down this week
all came out very easily apart from one bolt holding on the alternator


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:18 pm 
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FSI Poster
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
stripped the engine down
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water pump has seen better days really gunked up and corroded

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next step im sending the head off for ported and polishing
and the crank and flywheel for lightening and balancing


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:18 pm 
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FSI Poster
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
little update today
stripped the interior out today for its trip to the body shop today
no major nasty suprises floor pan is all solid and the first fiesta ive had where the floor is soaking wet froma water leak
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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:19 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
not alot to report atm the car is still at the bodyshop and im still undecided on what todo with the engine
but i have got this through the post yesterday
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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:19 pm 
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FSI Poster
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
couple of little updates
the car is still in the body shop but its not far off paint now
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when they removered the o/s arch the body shop found that most of the inner sill had rotted away so that had to bereuilt which has taken the extra time
this is whats left of it
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basically in ford infinite wisdom the drains for the sunroof just go straight into the sill with no where for it to go
hense why sills rot out so quick and its not just mk2 3/4/5's are the same as are other fords of the same eara
but luckely the body shop will be modding it so the drain acctually leavse the sill



also got the engine back from the machine shop
its had a 0.5mm over bore and a new set of pistons rings and gudgon pins aswell
will get pics of that tomorrow


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:20 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
new shiney pistons
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knackered old ones
you can see the vertical scoring on them
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block bored next on the list
get it in the parts wash
new core plugs and painted
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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 9:58 pm 
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Elite FSI Poster
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Joined: Fri Sep 21, 2007 12:55 pm
Posts: 3034
Location: Blackwood, south wales
Drives: Suzuki Ignis Sport
i should have bought an xr2 a few months ago! :( i love em!!

looks good gar!

what have you bored the engine out to? 1.7?

whats the final plan for it then?

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Suzuki Ignis Sport - ITG Maxogen - Japspeed 4-1 - Decat - 2" custom single box Scorpion exhaust 3" tip - Magnecor leads - Air con Removed - Apex 35mm springs - OMP Strut brace - Whiteline rear arb - EBC Greenstuff front pads - MTEC grooved/drilled discs - Team Dynamics Pro rally 15X6J ET28 - Toyo tyres - Rallyflapz - Black lamps - Smoked repeaters - Sparco pedals - Stripped 40kgs rear interior
125.4BHP 126.6LBFT


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 10:29 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
not sure what the total cc will be but will be over1600
well the plan was to get it up and running for the rs day at coombe but will have to wait ans see as i havent had the head crank ad fly wheel back or the car itself so im a bit behind where i want to be


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Fri Apr 08, 2011 10:49 pm 
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Joined: Tue Jul 17, 2007 9:53 pm
Posts: 8545
Location: Sheffield
Drives: Mk1 FRS and FRST
Lovely car mate, love the mk2 XR2 :thumbsup: :chill: :chill:

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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 11, 2011 8:16 am 
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Joined: Sat Apr 08, 2006 7:54 pm
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Location: Didcot, Oxfordshire
Drives: Millennium Puma
loving it :chill:

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Ford is not a decision you make to like, its a passion you grow up with.


RIP BEN ELVIN (JAM) 6.6.84 - 3.10.12 - Gone but not forgotten - The below sums you up chap
Ben Elvin "Jam" wrote:
Through serious illness you meet some inspiring and determined people. its the best we can do as human beings to inspire and drive the determination of others. Ben.


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 11, 2011 9:31 am 
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Joined: Mon Mar 19, 2007 12:29 pm
Posts: 3227
Location: Melbourne, derbyshire
Drives: Fiesta Shed mk6
Good to see another mk2 rebuild :D

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FACT wrote:
Ford is not a decision you make to like, its a passion you grow up with.

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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 11, 2011 10:27 am 
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Joined: Sat Apr 08, 2006 7:54 pm
Posts: 19046
Location: Didcot, Oxfordshire
Drives: Millennium Puma
hopefully be a 1640cc? :)

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FACT wrote:
Ford is not a decision you make to like, its a passion you grow up with.


RIP BEN ELVIN (JAM) 6.6.84 - 3.10.12 - Gone but not forgotten - The below sums you up chap
Ben Elvin "Jam" wrote:
Through serious illness you meet some inspiring and determined people. its the best we can do as human beings to inspire and drive the determination of others. Ben.


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 11, 2011 2:07 pm 
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Joined: Sun Aug 03, 2008 11:20 am
Posts: 8463
Location: Rochdale
Drives: Si 1.6 & ST170
Lovely car, cant wait to see pics when its all back together.

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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 11, 2011 7:08 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
me to lol
most involved project ive taken on and first engine rebuild aswell
well bugger all to report this week as im still waiting on pritty much the whole car
shell isstill in the body shop and im still waiting for theengine bits to be delivered
all ive done this week is cleaning of parts and painting of parts


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Tue Apr 12, 2011 2:06 pm 
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Donator? Ejaculator!
Donator? Ejaculator!

Joined: Thu Mar 30, 2006 1:23 pm
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Location: Lincoln
Drives: MK1 Focus Estate Ghia
Looks like a nice project!
Will be good to see it finished!
Only thing I don't like on XR2's is the colour coded kit

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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Wed Apr 13, 2011 8:01 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
little bit of a update
been doing alot of cleaning and painting over the last week of little parts engine block etc
got back my crank and head today
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and the head stripped back down for cleaning
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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Wed Apr 13, 2011 10:55 pm 
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Location: pimpworld
Drives: 2.0 fiesta si + mk3 1.1
:thumbsup: lookin very good
has that crank been balanced then?

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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Thu Apr 14, 2011 10:34 am 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
yup lightend and balanced


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 Post subject: Re: my mk2 xr2 rebuild
PostPosted: Mon Apr 18, 2011 8:36 pm 
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Joined: Mon Nov 17, 2008 1:56 pm
Posts: 872
Location: amesbury and south wales
Drives: mondeo st tdci
not much happening atm
got my flywheel back today
leightned and balanced
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the car should be back from the body shop tomorrow


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