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New Si 2.1 build!
http://www.fiesta-si.com/forums/viewtopic.php?f=5&t=26564
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Author:  JoeyBoyden [ Wed Aug 12, 2015 12:18 am ]
Post subject:  New Si 2.1 build!

My short lived yet much loved Si came to an end unfortunately. Many issues with the car including it being a Cat C forced me to let t go. The car has been put to rest, stripped for parts and scrapped :(

Here's the old one, RIP :(

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But here's the new one, a quick teaser whilst we build it. Will copy the rest of the thread over tomorrow. Needs lots of welding, most of it me and my mate have done now. We've also removed the old 1.6 lump and sourced a cammed 2.1 N/A engine and ecu, so should be quite quick haha. Should have the engine in this weekend if it arrives Friday and hopefully running provided we don't run into any wiring issues. ECU is a desk item and loom is standard Si so should be plug and play right? No key changes, barrel etc?
Once it's running, we'll be removing those steelies and replacing them with some Escort GTI/Mondeo wheels ready for MOT and undersealing session Monday night. Steelies will be kept for winter and track use. Really looking forward to getting it on the road, if it;s anything like the last one, I can look forward to many roadside clutch cable changes, surprising lots of people and some track days!

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Author:  meilack [ Wed Aug 12, 2015 8:37 am ]
Post subject:  Re: New Si 2.1 build!

if it's a 2.1 with cams etc I'd be tempted to put proper management on it and made the most of the engine

Author:  JoeyBoyden [ Wed Aug 12, 2015 11:04 pm ]
Post subject:  Re: New Si 2.1 build!

At the moment it's running Kent inlet cam with standard exhaust cam. Once the engine is in and running, we'll see how it performs before looking at aftermarket management. Also Bought a set of Mondeo alloys for 80 with good tires but one, possibly two need dent removal to get it through MOT. Hopefully should be ready to go by Monday!

Author:  JoeyBoyden [ Sat Aug 15, 2015 1:05 am ]
Post subject:  Re: New Si 2.1 build!

Okay so tonight we managed to get the engine in mounted up, tomorrows job is getting starter, alternator back together, box bolted up correctly and then wiring her up. One thing we encountered though, I bought a full belt kit for peace of mind (engine was rebuilt 8k ago and tensioner loks brand new but still) and we couldn't get the crank pulley off with the engine out, we were lifting the engine before the bolt was moving. Tried my impact gun and it was still having none of it, anyone got any ideas how we remove the crank pulley bolt now the engine is back in? Last thing I want to do is snap the bolt into the engine.....

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Author:  elPaulio [ Mon Aug 17, 2015 7:48 am ]
Post subject:  Re: New Si 2.1 build!

Now the engine is in and before you put the starter on get a chisel and wedge it on one of the teeth on the flywheel.
This'll stop the crank turning while you undo the bolt.

I cut the head off an angled ring spanner and use a tube as an extension to get the leverage as it's pretty forking tight!!
Much easier with two people (one to hold chisel and one to undo) but can be done on your own ;)

Other way, which would have worked while engine was out not so much when in, is to drop the sump and place a piece of wood between the crank and block.

Paul :thumbsup:

Author:  onslack [ Sat Aug 22, 2015 9:22 pm ]
Post subject:  Re: New Si 2.1 build!

good work there buddy, like the colour too :thumbsup:

Author:  JoeyBoyden [ Tue Sep 01, 2015 10:40 pm ]
Post subject:  Re: New Si 2.1 build!

Cheers guys, has taken a lot of work and cheers for the advice on the belt! I'd forgotten to update this forum, unfortunately we didn't manage to do the belt it was that tight. Main thing was to get it MOT'd and undersealed, with the tensioner looking so new, we've decided to hold on to the belt until October (let's hope it lasts) I work with an ex Ford master tech and he says they are so tight because they don't use a woodruff key, so the timing is held together by just the tightness of the bolt! Hopefully putting foot on the brake in gear should be enough? Or try remove the starter If we have to, anyway here are some more up to date pics, the car has now been on the road for 2 weeks. It runs well however, it breathes quite heavy, a lot of oil is coming out of the cam cover breather (and I've changed pcv) currently running a catch tank but I'm unsure the best way to plumb it in?

Next plans are a 4-1/4-2-1 if anyone has one? ;) Sort the cam belt, new waterpump etc then a map I think depending on how the engine is.

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First drive with me mate, nice but considerably slower MK2 gold ;)

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Then catch tank and blacktop rocker cover on with slightly better baffle plate than the silvertop one. Catch tank is a cheapy so I want a decent one, plus It needs plumbing properly.

Then got some really sweet Mondeo wheels with brand new tires from a lad round the corner from me

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Just some of the pics I've taken, once belt and niggly stuff like ign barrel etc is sorted, I want to get it into modern hot hatch territory. I've looked into some of Burton powers S1 heads which are supposed to be good for 180bhp but for the time being decat manifold and map should see 145/150bhp I'd imagine especially with the other bits already done. It's so good to be back in an Si, I missed my old one so much even though it was a right kipper and knowing I've built this one adds to it even more. As long as nothing catastrophic goes wrong (paranoid about cambelts after my Saxo one snapped) I plan to keep this for a long time! Updates to follow!

Author:  meilack [ Mon Sep 07, 2015 8:37 am ]
Post subject:  Re: New Si 2.1 build!

by map do you mean aftermarket management? as you can't map the ford ecu's IIRC maybe get a plug in superchip?

Author:  DanDMC [ Mon Sep 07, 2015 12:05 pm ]
Post subject:  Re: New Si 2.1 build!

Noice, can't beat a fat engined fez

Author:  JoeyBoyden [ Mon Sep 07, 2015 8:07 pm ]
Post subject:  Re: New Si 2.1 build!

meilack wrote:
by map do you mean aftermarket management? as you can't map the ford ecu's IIRC maybe get a plug in superchip?


Yeah that's something I've discovered, are superchips worth it or they just a little light in a box to look flashy? I think the cat is a non gen item because it's huge, I have a genuine ford Cat in my shed and the one that's on the car is way different. Is it worth decatting the standard downpipe?

Author:  meilack [ Tue Sep 08, 2015 5:02 pm ]
Post subject:  Re: New Si 2.1 build!

Not really IMO - if you have a decent 2.1 I'd get proper management - expensive but makes the most of the engine :) ;)

Will free up some power - but probably lose some torque - so I'd say yeah why not :lol:

Author:  JoeyBoyden [ Thu Sep 10, 2015 3:33 pm ]
Post subject:  Re: New Si 2.1 build!

meilack wrote:
Not really IMO - if you have a decent 2.1 I'd get proper management - expensive but makes the most of the engine :) ;)

Will free up some power - but probably lose some torque - so I'd say yeah why not :lol:


Yeah thought as much, I'll be looking into a full system though. My ashley one was good on the last one before it snapped, the car sounds like it really wants to pop on overun. Ben is selling his ashley backbox so I'll be having that I think, will probably look into ported head, exhaust cam and all that and that will give me reason to go mad on management

Author:  JoeyBoyden [ Thu Sep 10, 2015 3:37 pm ]
Post subject:  Re: New Si 2.1 build!

Got a nice shot at weekend after a good clean. The car has performed faultlessly on my trip down to milton keynes, other than a completely flat tire. I checked all pressures before I left so must have run something over on the way because 2 days later when I checked (hadn't driven it since the drive down) it was totally flat and delaminated :/ new tire later and seems to be okay *touch wood*

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Author:  JoeyBoyden [ Thu Sep 10, 2015 8:16 pm ]
Post subject:  Re: New Si 2.1 build!

Terrible quality nightime shot!

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Author:  JoeyBoyden [ Wed Sep 16, 2015 9:48 pm ]
Post subject:  Re: New Si 2.1 build!

Small update again. Went to Milton keynes last week for work training and took the Fiesta down as Ford Fest was on the Sunday after. Gave me a chance to give the car a proper run, unfortunately a tire shat itself on the way down but other than that it ran spot on. Got a few pics of Ford Fest. My mate who built the car with me has also caught the Ford bug, he's bought an absolute kipper of an XR3i, more rust than actual car and bought an Xr2 with loads of spares. The 2i he's bought is 2.0 converted just not running but comes with full spare XR bumpers, steering wheel, and engine. So, looks like I'll be buying the steering wheel, bumpers and one of the engines. Either the 2.0 to build, or the CVH to eventually go ZVH turbo....Plenty of plans lined up, lets hope I can do them all this time :)

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Meet the night before the show

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Then the episode with the tire....

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Quick stop at the services. We set off from my area at 5AM to get to Pod as a convoy. Took us about 2 1/2 hours to get down, was a good drive down and also met up with a few others on the way, especially this lovely S1 ERST. I wish I'd have cleaned my engine bay up properly, mine looked a mess compared to some of the immaculate cars down there but seeing XR's and RST's really made me want the arches and kit for mine plus some RS2k wheels again.

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Creepin...That's not me using the phone either although it does look like it.

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Then we got to the show, didn't get many pics of mine was too busy getting pics of some of the other mint motors. Will upload some more when I get chance!

Author:  JoeyBoyden [ Sun Sep 20, 2015 6:35 pm ]
Post subject:  Re: New Si 2.1 build!

Got rid of my hideous rear lights and also some Lockwood dials!!

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Author:  meilack [ Tue Sep 29, 2015 8:26 am ]
Post subject:  Re: New Si 2.1 build!

nice one :D

Shame I missed ford fest :(

Author:  Seanymk2 [ Thu Nov 12, 2015 12:21 am ]
Post subject:  Re: New Si 2.1 build!

Alright pal, I believe you have been talking to my brother on Facebook, nice to see another si so close to us!!

We all need to get out sometime-

Add me on snapchat?
Sean-dh90

Author:  JoeyBoyden [ Sun Nov 15, 2015 2:30 pm ]
Post subject:  Re: New Si 2.1 build!

Seanymk2 wrote:
Alright pal, I believe you have been talking to my brother on Facebook, nice to see another si so close to us!!

We all need to get out sometime-

Add me on snapchat?
Sean-dh90


Aup mate, yes I was speaking to him the other day! Would be great to all meet up, there's a warrington meet today I think I'll be going up!

Author:  JoeyBoyden [ Thu Nov 19, 2015 10:29 pm ]
Post subject:  Re: New Si 2.1 build!

So got a bit of an update on the kipper. Finally saved the money to sort some of the bits on the car, both lower arms done, new tires all round, Toyo Proxies for £155! Can't moan there, K&N panel filter, and also some ST150 brakes! The new tires give the car the grip is deserved. The Ling Long ditchfinders that were on the wheels when I bought them were horrendous, spun even in 3rd in the wet and they were to large so scrubbed all the time! With the tires I now want to tighten the back end of the car up with some Polybushes. Anyone have any experience doing these as I hear they can be a right cock ache? Also the car has a bit of a water ingress problem in the front and rear drivers side footwells. It does seem to be tracking down from behind the dash, it's right in the centre of both footwells, not in the surrounding carpet. Any grommets that could have come loose?

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