Right, this is to let you all know the problems I encountered fitting the ZS rear beam, focus brake set up and how i solved these problems.

ZS rear beam :- No real problems involved with fitting this. Just a direct replacement for the original. 4 screws each side, wheel off, handbrake cable off all clips.
The only problem I found with this was if you have RS2000 side skirts like me! I had to break the last rivet so that i could lower the beam down. As the skirts fit directly below the attachment of the beam to the body. Not a problem, just re-rivet it after.

Focus rear brake set up :- This is where the problems start. But they do fit perfectly to the beam!

Brake hose:- the existing brake hose of the Si is too short to reach the focus calipers. You can see this in this picture. Note the black hose is the new one, explained later:

okay this end


This is too short now:


So...i had to pop down to the local motor shop, they directed us to a helpful chap who has loads in Basildon. The fiesta Si hoses are 13 inchs, we need about 16 inches. So went to have a look in Basildon, and they had some 17 inch, Mk 3 escort 1980-83 front brake hoses that fit pretty much perfectly, as you can see from the pics above and below (black hose)

Please note that we moved the brake hose the other side of the strut after we tried the wheel!!


Hand brake cable :- after looking on FT.com for a while, XR3i handbrake cable was the cable that everyone said should work and that fit. But this wasn't the case.
We had to take the yoke off the fiesta handbrake and use that, as the yoke would not fit under the floor pan.
The outer cable is too short, but shortcuts can be taken, this is ok.
The inside cable was too long, and this was a problem. As you can see from the pic below, the cable is too long!



SO my dad had to make up some sought of spacers on the lathe.

This is what he came up with:



Now this fits here:

This is what it was like before:


After all these problems, the handbrake cable was cable tied into position (with shortcuts taken). The cable needed to be adjusted so that it was an MOT pass.

Now the brakes were bled, and the wheels were put back on. Notice the wheels stick out with the zetec s rear beam.
Here are pics of the final result:



Tom

_________________

hi when you fitted the beam did it stick out more on 1 side than they other

_________________

thread was done back in 2005! not seen the guy on here in years!

_________________

_________________
Daily isn't so Special. And it makes me sad.
Need space and time and I'll crack on with Jams si!

Catch me on Facebook as I'm rarely on here.

will the si drums/stub axles fit on the zs beam?

_________________

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