Righto lets carry on..
We removed the bag of poo 1.1 engine and its wiring loom ecu ect.
Fixed the front panel as it previously had a bump which made the light and bumper sit funny
Old loom:
I cleaned the engine bay up and rattle can'd it white, trimmed the front bumper to fit my front mount on, and also undersealed the whole car!
Next was the fun part, paneling up with sheets of
steel, not fiberglass.. I got asked that question about 30 times at Ford Fair
Then the sides were made by box section welded in so we could weld more sheets of metal.
Then trimming down of the excess metal, made it look like a pickup!
Next was the problem of what happens if you cut off half the car? The strengh and ridgity of the car is no weak, basically it would eventually bend and the doors wouldnt be able to open or close. Sooo we got some scaffolding tube, big thick heavy ones.
We used the scaffolding tube, cut slits into them to bend them, and then weld the slits up.
We decided a dual role bar would look better so thats what we did.
The idea was to get the main structure and weight of the car to go through the bars and down to the suspention struts, as this would hold the car.. to be honest the amount of extra strengh put into this for the panels and the roll bar, this should be stronger than a normal fiesta
At the same time also we got some steel sheet with a lip on it so we could use the lip to overhang the boot lid and the rear quarters, this then helps pull in the panels as they flexed slightly due to cutting half the car off it
Looking really good now
I cut ouf the wheels arches to fit bigger wheels and stuck the bodykit onto the car, which we also smoothed in:
Completed roll bar and rear pickup area
As you can see we made little doors which have seals on, so you could access the rear lights.. otherwise if a bulb went you would be abit stuffed
All was left now was to get the engine in, filler work/prep and painting!
So the obvious idea was engine first incase we damaged anything, before the engine went in we fitted a fiesta diesel wiring loom and modded the intank pump, as it doesnt need the pump, we just extended a pipe inside the tank to prevent fuel surge:
We also stuck the 60mm shocks and springs all round, made it look like a car again!
As I refused to use the original top mount intercooler as it sits directly above the exhaust manifold and hot turbo, what the f*ck were ford thinking??
I got an escort one and fit it to the front panel behind the bumper (hense the bumper cutout), we welded some metal onto the front panel and bolted the other end to the IC to stop it from moving:
Right I'll just post the next pictures as it was just general filler and dent and get it all flat ready for paint.....
On went the primer:
Car got flatted perfect and on it went into the booth,
just over one week before Ford Fair!
results of this were poor due to a reaction.
So we spent 3 hours, to DA's and 100 pads laters and we flatted it back down!
It got sprayed again on the Saturday which got alot of runs in it, so unhappy with it we flatted it AGAIN and Mark painted it himself Monday before Ford Fair:
Then it was building it back up and doing little bits.
All the plastics and the roll bar were painted satin black, which makes polishing alot easier and now my handles etc are painted I cannot get white annoying polish marks on them!
Then on went my RS1800 wheels as they look the tits
And it went outside for us to finish fitting exhaust mirrors interior lights, and getting it running for the MOT on Thusday, 3 days before Ford Fair!!
It also got a MK5 Windscreen bonded into the car with use of a MK5 window rubber. this was due to the fact my local scrapyards dont get many mk3's in anymore
We got everything done on Tuesday and Wednesday night, until the fuel pump decided to sh*t itself rendering it useless. Mark started early on Thursday to fit another fuel pump, this time the one which the Endura DE was meant to have on, but he removed the electronic stuff as we didnt want to run any sort of ECU
Went in for test Thursday and passed. So got taxed and here it was! Getting alot of attention of course!
Saturday the day before Ford Fair we had to wet flat the paint down to get it to shine properly! then wash and polish both our cars!
And fit the biggest Fiesta-Si.com stickers possible
Just to top it all off, once we left the yard with both cars READY for Ford Fair at 9.30PM, it wouldnt turn off, seems that the spring in the solenoid in the fuel pump was keeping the engine running even when I took the keys out, so luckily we had another, swapped it over and bam!
Few hours drive to the camp site, at 80mph max as the diesel was running slow as hell, and then it was up early, Ford Fair, extra fueling from the pump for the drive home and it now goes alot quicker!
Ready for track
FUTURE PLANS!
Wire in the bumper lights and fog lights.
Better front brakes.
Boost Gauge.
Rev Gauge.
Boost controller.
More boost and fueling.
Sort out interier.
Then if the diesel engine gives up.. 2.0ltr Zetec engine with Derv gearbox
Hope you enjoy, and hope you understand how hard it was not to post up anything to give it away for the past 2 months!!
Also I have missed out alot of things, as I cant remember, if I kepy track of it on a daily basis you would see how it is much harder than it looks
Paul.
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. i wana see this beauty being built.lol
small amount of work has gone into this.
Could have filled it full of sand and used a pipe bender to make it a manderal bend! 
