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Fiesta-Si.com :: View topic - XR2i "DJN" Track Car Project
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XR2i "DJN" Track Car Project
https://www.fiesta-si.com/forums/viewtopic.php?f=5&t=22375		 Page 1 of 2
Author:  SLEEMAN [ Mon May 16, 2011 10:15 pm ]
Post subject:  XR2i "DJN" Track Car Project
Hey guys right some of you know me, have dealt with me even a couple of people have maybe seen this car.

My original plan was to rebuild it to use as a daily driver but plans have changed and its going full wack track car. the car came with no engine just a box, no interior etc, so i had to start from scratch

Here is what i started off with:

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slight rust issue:

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so the strip down began:

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some dtm mirrors:

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rear bumper i bought but i sold later on:

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the front end removed including wings:

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new wings:

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and some new parts:

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more later!!!
Author:  SLEEMAN [ Mon May 16, 2011 10:27 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
now i prepped up the engine bay for a lick of paint:

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then protected the inner wings with stonechip and underseal:

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the front bumper decided to have a diet because it thought it was too fat and heavy:

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poly bush set bought and installed the front strut ones:

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rally/race washer bottle, i have placed it here but going to move it later on possibly in the cabin:

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donor 1.8 115ps escort gti engine:

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fiesta si gearbox as it was alot better than the xr2i one condition wise and it was from a car i stripped:

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add a couple of vibratechnics mounts (old mounts above):

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add a cradle:

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bish bash bosh you get some running gear:

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competition mounts these are!! nice and solid:

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4 branch manifold i had spare:

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spare sump removed from a spare engine and an added bonus it has a magnetic sump plug!!!

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new goodies:

momo pedals cheap from a mate:

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new delphi wishbones:

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more later!!
Author:  Chris [ Mon May 16, 2011 10:32 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
Looking good!

Surely those momo pedals extra unnecessary added weight??
Author:  SLEEMAN [ Mon May 16, 2011 10:36 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
engine and box in:

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front avo coilovers serviced nice and new with a lick of paint by myself as they wouldnt do it lol!

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oh and a slight hub issue:

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no worries managed to find another one at a high cost!!

and car back off axle stands and on all fours:

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fitted a nice big mondeo servo:

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lovely mocal oil cooler setup just need hoses now:

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good ridge brake hoses:

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got the dashboard flocked:

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more in a bit.............
Author:  SLEEMAN [ Mon May 16, 2011 10:37 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
latest update:

so basically now the front end is pretty much sorted, i'm gonna concentrate my efforts on the rear and rear quarters. so first things first, get the rear beam off:

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put the new bushes straight in:

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and got cutting away with me angle grinder!!!:

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also removed the fuel tank underneath as well:

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engine bay of how its looking in may:

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the recieved some ultra thin cutting discs then used them against the rotten rear arches:

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the offending arch:

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then i attacked the shoddy sound deadening:

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and i've modified the rear beam to accept st170 rear discs. i know my car hasn't got huuuuge power but then the car is prepped and ready for it plus i've had these hubs lying around for ages so might as well use em!!

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and now i'm concentrating on underneath using a cup wire brush on an angle grinder and going to strip the protective coating underneath so i can cut out part of the passenger chassis leg as it was rotting under the tow eye!

thats all for now folks!!
Author:  stuff n that [ Mon May 16, 2011 10:41 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
looks like a good project mate! your "slight hub issue" made me laugh too, did you pull the wheel and the flange came off with it lol
Author:  SLEEMAN [ Mon May 16, 2011 10:48 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
Author:  stuff n that [ Mon May 16, 2011 11:05 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
ha stuff like that adds character to the car mate! whats the spec gonna be when its finished then? also, can you use the fiesta master cylinder with the mondeo servo or does it have to be the mondeo 1?
Author:  SLEEMAN [ Mon May 16, 2011 11:51 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
has to be a mondeo mk1 master cylinder non abs but you can use a mondeo mk1 or mk2 servo as they are the same!! i followed the guide on fiestaguides

spec of current engine:

1.8 115ps gti engine with gti plastic inlet
2.0 throttle body
2.0 maf
2.0 cams
2.0 ecu
swapping the wiring loom for an si one so it can accept the 2.0 ecu
4-2-1 exhaust manifold decat with decent exhaust system, probably going to temporary use the system i have till i can get a decent custom made 2.5 inch system one.
viper pipercross carbon induction kit
mocal oil cooler kit with thermostat so will only cool the oil till it gets upto and above temp
and thats about it for now

i have two 2.0 silvertop engines as well in my garage, i know i'm greedy but they need work. one will build to have TB's, the other will be a complete rebuild maybe a 2.1 zetec turbo

the first 2.0 will go in when the 1.8 decides to go bang, if i haven't built the 2.0 by then i know where i can get another 1.8 for cheap lol!

if i had the money i would give it a full cosworth conversion 4wd! so i can catch up with other turbo'd cossies, and be a decent sleeper. and maybe go all out drifting it. this car will be with me till the day i die or till it dies by a crash or something
Author:  DALSY [ Tue May 17, 2011 12:33 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
great job youre doing there mate, ill watch this thread for updates :chill: :chill: :chill:
Author:  SLEEMAN [ Tue May 17, 2011 12:41 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
thankyou dalsy! thats really something coming from a guy i look for inspiration when building this thing lol! i wish i could have the power and setup you have in your si!! its all down to money though :( lol
Author:  DALSY [ Tue May 17, 2011 1:56 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
youve got to remember i started at the very beginning too, and built the car originally on a tight budget, but ive been doing this with the mk3 fiesta from 2004 , so ive came a long way since then

Your doing the right thing first by getting the brakes and handling right before going for power, thats where people normally get it all wrong, they go mad building a fancy all singing engine, which when the come to the first corner , cant stop in time for and cant go round, and go off the circuit, or nearly crash every corner

as i said, ill watch the progress, and enjoy the build of the car , bring back some memories for me too :thumbsup:
Author:  meilack [ Tue May 17, 2011 8:51 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
good work mate :)
Author:  SLEEMAN [ Tue May 17, 2011 5:51 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
cheers dalsy!! will keep you entertained no doubt lol!

thanks meilack!!!
Author:  The Loumiester [ Tue May 17, 2011 11:38 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
Good work!! Iv got some of those transmission mounts on mine.

I wish I had a clue how to replace arches and wings lol.

Keep up the good work!!
Author:  SLEEMAN [ Wed May 18, 2011 12:47 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
its easy once you know and have the right tools, the front wing is spot welds and a normal weld to the front panel, so need a decent drill with a spot weld drill bit and an angle grinder with an ultra thin metal cutting disc. and its basically the same for the rear arches and sills!!
Author:  The Loumiester [ Wed May 18, 2011 10:48 am ]
Post subject:  Re: XR2i "DJN" Track Car Project
Have you got any pics of the spot welds and where to put them?
Author:  SLEEMAN [ Wed May 18, 2011 12:06 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
for the front wings or rear arches??
Author:  The Loumiester [ Wed May 18, 2011 12:09 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
Front wings mainly.
Author:  SLEEMAN [ Wed May 18, 2011 3:24 pm ]
Post subject:  Re: XR2i "DJN" Track Car Project
if its the front ones you should see the small spot indentations made by the spot welder if you can see them take a wire brush cup on an angle grinder strip off the paint to show exactly where the spots are and use a spot weld drill bit and drill about 2-3mm it has to be flat so you remove all the weld then take a cutting disc on the grinder to the welds on the front panel, and two 10mm bolts under the arch holding it, and also use a metal cutting chisel to seperate the top of the wing incase them spot welds are tight lol! and that is all
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