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Whats it like under the Carpet?

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RIP Ben. Gone but not forgotten.

SportKA - I've driven one and its deffinately a Girls car

Ford Fair 2010 0-60 7.45 secs Trek 4100

Save the trees, wipe your arse with a Cosworth

Going to pull it up and have a proper look next time i work on it.After ive hoovered it out probably.

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tah dah da daaaaaaaa!

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Removed some clutter from the new shell when I was bored.




Discovered some good news today.The ecu pin setup for the 1.1 is the same as the Si so im really hoping I wont have to swap the entire interior loom

Alright it's been a while coming but I have finally had the time to start this reshell. I had the battery on charge for 3hours and in that time was fiddling with the project in the garage *see zetec turbo thread in projects section for update* Then i started the Si,which fired up first time after being stood still for few months. I moved it over into position on the paving slabs in our garden, Got it up on axel stands and started to rip it apart... Will let pics tell the story of how far I have got so far.





Soon as the engine is out of the blue Si I will push the shell backwards into the garden and move the white donor car to where the Si currently stands to fit the 1.6 Zetec. Will have to pull out the dead engine in that one first though.

First ripped off the old buggered cossie lookalike bumper that the car came with,Infact it was an **** so i decided to get out a big hammer and smash it off as it was screwed on in the arches due to having snapped off bolts! BODGE!


Placed safely on axel stands and drained the coolant.



Most of what needs to be removed for the engine to be dropped out is out but powersteering and loom etc still need to be unplugged from the pump and various connectors around the engine bay.Placed the loom wound up in a bag at the ecu end for now until I work on it next.




When the engine is out I will replace the cam belt and give the engine a good cleanup.Including spraying the cam cover and adding a plug cover. Might invest in a K&N Filter too.

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good work dude ,this projects going to be exciting

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Rip Ben Elvin (jam)

Started to remove the engine today, Removed the driveshafts then set the crane up to support the weight of the engine while I undid all the bolts on the mounts.


Lowered the engine down to the ground.


Supported the front of the car with a spare lifting strap then lifted it up and over the engine and dragged the engine out.



Will crack on with removing the white mk3's engine tomoz.

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making good progress buddy

Nice going buddy, the white shell looks like a good'un, nice find at a great price...

As for the PAS i don't think you'll need it it's a waste of time TBH....... I'll buy it off you..

looking good!! i spy the dog agen lol been helping agen has it!!

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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

Today has been a bit of a busy day. First thing i did was grind back all the rust i could see so it was back to bare metal, Then I sprayed it all with Zinc primer to protect it. It wasn't applied perfectly but I'm not bothered aslong as its protecting it for now.



Yes the dead 1.1 is now out.



Here on the left is a whole 1.6Si engine bay loom,Right is the whole interior loom and the wet patch is all over the bag containing the interior loom.Kindly applied to the bag by TC one of our dogs. :jealous:


Here is where I keep all my spare parts / interior items after removing from the cars. I call it my Ford Parts Warehouse lol aka the caravan.




The blue Si was stripped bare inside ready to be used as a main dumping ground of anything not needed like the dead engine etc.


Oh and yes Lilly is still an annoying biatch as shes now learnt that getting inside the car while im ripping it apart means its more likely I'll throw the ball lol


THE PROBLEM...

The problem I will have soon is the engine mount for the zetec in the quartz engine bay. On the si we have the mounting holes with what looks like threaded nuts welded to the inside of the boxsection.On the quartz the holes are there but no threads! Going to probably have to weld the whole mount straight onto the car as you cant get inside the box section to weld up some nuts. Well unless i cut it open to do it but i really dont want to have to do that as it might weaken the chassis leg even after putting a plate back in.

Si Chassis Leg...


Quartz Chassis Leg with mount...


Also the Si mk3.5 has an addictional brace for the engine mount but its not on the quartz although its a mk3.5 it wasnt blessed with the zetec engine so didnt need it. I will be welding this onto the quartz shell

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OH MY GOD! This is going to be a long conversion.




Right, So far from the mk3.5 Si to the mk3.5 Quartz all this needs to be changed over...

Complete steering column,
Steering rack for P/S one,
Wishbones for mk3 ones,
Hubs for mk3 ones,
Engine ofcourse,
Driveshafts,
Gearbox,
Engine bay loom,
Interior car loom.

The cam belt looks brand new so leaving that as it is but the Aux drive belt is really cracked so getting a new one.

Then i need to have the engine mount welded onto the chassis as theres no way im cutting it up to allow use of the nuts.




Today i actually hoisted the car up so i could easily stand in the bay. I gave the whole engine bay a clean and scrub down with grease and oil remover aided by a jetwasher

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Today has been busy, welded the engine mount onto the car as it cant be bolted. Also removed the petrol tank to swap for the si 1.6 item but its really really rusty. Going to look into getting the tool to swap the pumps over as the tank off the quartz is mint as feck.

Good news is the fuel lines dont need to be swapped over as they are the same.Checked that today.

The whole interior is stripped now.No loom,no dash etc. Already swapped the steering columns over as they have a larger knuckle to connect to the P/Steering rack, The rack is also now fitted just not plumbed in.

Engine cant be fitted until i source a new Aux drive belt as its knackered.



Still need to change the wishbones,hubs and fit whole new suspension before fitting the engine.Then ill fit the interior loom again and test the engine etc before fitting the dash.

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Didnt get too much done this weekend as saturday was spent working on my dads renault clio changing his driveshafts and a few other bits,Fitted a ford horn to it though lol

Sunday was spent doing minor jobs on the reshell project.



First thing I needed to do was pull the heater matrix out of the Si and fit it into the Quartz as the one on there had one connector snapped off so it was pumping fluid inside the car! Had to remove the lower box section in the below pic *breaking one of the sodding clips* and then figure out a way of pulling the **** matrix out lol Was a tough job for how easy it looks.Fitted the new one in and then started on the Powersteering piping.



The power steering rack was dirty as feck so scrubbed at it with a wire brush for a while then started on fitting up the P/S fluid cooler.It was bent as feck as looks like it was off an accident damaged car *if not from when the last owner crashed the si* So i put it into a vice and clamped it down a few times lol straight as an arrow now.



The petrol tank off the Quartz *pictured below* is in great condition compared to the picture below it that is off the si.Now as far as im aware I couldnt use the pump from the Quartz hence why ive removed the si tank.Now ive seen the condition of them both I really want to swap the Si pump into the Quartz tank lol Its in much better condition


Sprayed up the engine mount support bracket and P/S bracket too.Not bothered about a perfect job oviously but it looks better than fading paint and rusty patches.The can was running out so fired some out onto the top of the engine mount to lol its still wet.


The engine mount was welded on from behind,on top and to the front. Grinded back and then rewelded to make sure there wasnt any cracks or holes.Then sealed it with Zinc primer.

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How the si currently stands lol STORAGE.

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looking good mate! its cumin along now! it will be worth all the hard work in the end!

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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

Today didn't quite go as planned as the engine isn't fitted Went out and spent around £50 on parts and fluids etc to do a full service and get a few new gaitors etc ready for when the engine gets put back in later in the day. Got home only to find out my supplier has got hold of the wrong Auxilary drive belt :worried: Not sure how it could of happened as we ordered one for a 1.6 16v engine with P/S and no A/C. The belt was too long so im guessing its the one for A/C & P/S i have here.

Oh well not worried.Will send it back get a refund and order the right one.

What I did do today was drain the old oil out of the engine,Clean the gearbox and engine up abit with a wire brush and a blow gun then fit the new oil filter. Also removed the old fuel filter and bracket *painted up the bracket* and refitted it all with a nice shiney new filter.

Will see what i can get done tomoz...

Fitted my MK3 XR2i wishbones and MK3 XR2i Hubs today after giving them a good scrub up with a wire brush. I'm going to buy some black hammerite paint and paint the hubs next weekend. After fitting the hubs I realised the Steering racks track control arms dont fit through the hole provided in the mk3 hubs. *See pics below*

MK3 Hubs with MK3.5 TCA's

MK3 Hubs with MK3 TCA's


Picture of XR2i hubs fully scrubbed down with a wire brush.The bearings seem fine


Picture of the clean wishbone next to the other one for which it started out like.


Bought new oil and fuel filters and fitted them.Drained the engine fully of old oil before fitting the oil filter. Will fill with oil once the engine is in the car. Gave the engine abit of a cleanup aswell with degreaser and scrubbing brush. If you think its filthy now you should of seen it before lol




I also got around to getting the angle grinder and cutting disk out and cut the side front engine mount support off the old si shell.Going to tidy it up ready to be welded onto the new white shell.

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Was out working on the car at 8am this morning.Got the engine fitted,new bush fitted and hubs fitted with new track rod ends.





Lilly was helping all morning. Took quite a while removing the old bush,well the metal inner casing anyway.The rubber part pulled off easily with a pair of pliers.

I've even bought both silver and black hammerite metal paint so i could paint it all up nice. Only reason for not cleaning it up and painting it was that to do a proper job I'd have to remove the exhaust manifold and other ancillaries and I didn't want to risk having a seized bolt/stud snap on me as it would just cause a major setback.

I did degrease the block and gearbox though. Oh and I also painted the gearbox cradle black.

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coming on really well buddy

Going to attempt to fit my 280mm disk setup tomoz. Do you guys know if drilling out to 12mm is required on mk3 hubs?

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