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lol, didnt even realise you were a member!

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sweet thread

lush car love it

been watching this on FT, such a lovely car

getting the power it deserves

wow that is lovely just sat and read all previous pages and glad i did mk3 fez to be proud off

this is just proof that lads from wales know how to make truly awesome fiestas!!! lol

do you do any of the shows in south wales mate??

ive never seen your car before and always wanted to see it in the flesh!

you should pop up to the www.southwalesfords.net meet sometime and show it off!

gona be an animal with that engine in there!

glad your changing the bonnet aswel. rst 1 will look 100x better!

Cars the bollocks thou mate! keep up the good work!!

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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

that is such abeautifull car mate love the detailing that has gone into it theres one thing i would change & that would be the name on the log book!

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Ford Fiesta 1.6si 5Door Mods Sony flip down cd player,Alpine Type s compent speakers Tweeters in colour coded mirror bases Kenwood 17cm speakers In Rear shelf,Splx 10inch Sub In boot 600watt Splx on passanger footwell in custom Bulid,Richbrook Ford Gear Knob,Green Cotton Air Panel Filter,Tom brown hat on rear shelf,clear side repeaters,ripspeed car mats,rear head rests rear small ford badage,ditgal volt gauge in front heater vent,Escort gti rims

Coming soon
mk4 wiper arm,laguna spilter,grey centres in the wheels 35mm drop,screen bulit into dash dvd player in glove box,stanless steel back box Mondeo dics and calipers,Rear disc conversation,Black roof lining with bulit in leds,Blue limation on dials,white dials & heater vents,graphti bonnet

thanks for all the great comments,
nice to read as all projects have ups and downs!!

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as the engine is going to have a full revamp
ian / area six gave me a list of things to get
so i can take them when i drop the engine in for inspection and to discuss a plan of action

also i've bought bits which will help the engine to look new

all i can say i'm very thankfull for employee discount
some pics


sump bolts,
stem seals (inlet red - exhaust green)
flywheel dowels x3
focus rs spark plugs x4
zetec headbolts x10
flywheel bolts x6




sump gasket
camshaft seals
rocker cover gasket
oil pump seal and gasket




inlet manifold gasket
and then two head gaskets
one being a focus rs headgasket as i read this would be needed about a year ago
only to learn once speaking to area six its no good for my engine




water pump and gasket
water pump pulley
oil pressure switch
cps sensor




middle and bottom parts of the timing belt cover, as i have a clear top section




ford timing belt kit

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heres some parts i have ready for the new engine aswell

my spare cam cover sprayed the same colour as the car, with the letters polished then laquer'd over



fiesta turbo ofab ecu



wiring loom, looks scary



S2 escort turbo T3 manifold



rover turbo M16 inlet manfold,
adapted to fit the zetec by area six
fiesta turbo throttle body
fiesta turbo iscv
ahmed bayjoo spec injectors




area six spec cams



area six modified zetec head
head taped to fit S2 escort manifold
ported by area six

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heres some pics of the block, excuse the colours, not my choice at all

heres the block upside down on the engine stand (front breather blocked off)



standard zetec rods with arp bolts



the forged pistons



sump back on, you can see the oil return from the turbo on the sump



the back of the block, showing the breather pipe relocated here also the oil feed for the turbo



heres the van packed for the trip up to area six
you can also see the flywheel on its own

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well the trip to see ian howell or AREA SIX as he might be known
went really well, stripped the engine further and discussed plans
confirmed if parts were what i was told they were, such as cams being his spec etc



The overall plan is to freshen the engine up to a very standard
heres some of the things being done to the engine

- new valve guides as some of the originals had wear meaning the valve had play in the head
- new tappets , again signs of wear
- clean the valves up
- rehone the bores, possibly a rebore if needed depending on what ian's machine shop say
- crank is being polished
- all new bearings for the bottom end
- head having a fresh skim
- block is also having a fresh skim
- acid dipping the block
- adding an oil drain to the sump
- putting the whole engine back together with all new seals, gaskets, water pump etc
- also timing it up


decided to build the bottom end to a good spec incase i want more power in the future
so i'm having new forged pistons and steel rods with arp bolts (ian's spec of course)
so awaiting what happens with the bores first before the pistons and rods can be oredered

discovered the head has been machined for cossie plugs which is a good thing as they have a much wider range of spark plugs for the cossie lump, which means we can choose a better suited plug which runs at a certain temperatures which is suited to certain boost/power.

ian also had a look at my loom which i was dreading as it looked a nightmare, much to my suprise he disconnected the bits i did'nt need and helped me lable all the connectors

the loom went from this



to this, much happier
the parts with the green and yellow tape are not needed as their either diagnostic ports
or parts from the fiesta turbo loom which basically just are not used
i plan to tidy the loom up later on, but before i cut anything i want to make sure the engine runs first



also my car spit arrived in work, which will allow me to have my car on its side
making it easier to prep the underneath

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right so my plans are to have the fiesta bay stripped and painted
also got a few other plans aswell such as relocating the battery to the boot to make more room in the engine bay

so the old engine
originally a 1.8 16v 105 ps engine
rs1800 130ps spec throttle body, cams, ecu, maf sensor
only thing i was missing from the rs1800 was the 'HO' inlet manifold (high output - stamped on the back)
but still made 129bhp the last time it was on the rollers, i think it could of been more with the proper inlet

heres a pic




so the stripping began




beefy cossie wheels




inlet off, rear firewall out, engine loom out




rad out, thermo stat off, power steering rad out

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so the engine was ready to come out,
was very happy to see this come out, its been a good engine to me but
its time to move on to better things




always wanted to have the legendary photo in the engine bay





my old man was helping me at times, so had to get a picture with him haha



alot more room, but still lots to take out, but wanted to leave it so that i can still steer etc
as i have to move the car for the next stage






wiper linkage and motor out, heater fan unit out
taped up the hole so nothing falls inside the heater unit for now

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so i was up early to make room at work for the fiesta
was bloody cold as you can see my breathe

while i'm on the subject of the weather, i definutely did'nt pick the best week to take the engine out
as its been freezing everynight this week and even started snowing at one point.



new home for a while



later on i had the car picked up from the house



much better with more space, warmth, tools etc




cover over the top as its a dusty place





more parts including the following
-cossie spark plugs (ian told me which ones to get)
-thermostat housing bolts
-thermostat gasket
-crank pulley bolt (still waiting on a new crank pulley)
-waterpump pulley bolts
-timing belt cover bolts

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i love the car and all the work that has gone into her

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Ford Fiesta 1.6si 5Door Mods Sony flip down cd player,Alpine Type s compent speakers Tweeters in colour coded mirror bases Kenwood 17cm speakers In Rear shelf,Splx 10inch Sub In boot 600watt Splx on passanger footwell in custom Bulid,Richbrook Ford Gear Knob,Green Cotton Air Panel Filter,Tom brown hat on rear shelf,clear side repeaters,ripspeed car mats,rear head rests rear small ford badage,ditgal volt gauge in front heater vent,Escort gti rims

Coming soon
mk4 wiper arm,laguna spilter,grey centres in the wheels 35mm drop,screen bulit into dash dvd player in glove box,stanless steel back box Mondeo dics and calipers,Rear disc conversation,Black roof lining with bulit in leds,Blue limation on dials,white dials & heater vents,graphti bonnet

Keep up the updates, looking forward to see the finished article.

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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

looks good

keep the updates flowing

thanks again, more updates

right i've got quite alot of parts ready for this new engine
aswell as the engine itself,

so let the pics begin

Cossie group A airfilter ( bulb was the only thing i could find, to help show the size)




brand new ford rear engine mount




series two escort turbo lower boost pipe (samco)
new fords loom for between the alternator/starter/battery




clear zetec top timing belt cover to go with the other new timing belt covers
(to show my vernier pulleys)




gauges, oil temp, oil pressure, water temp, boost, air/fuel ratio and volts




newly refurbed starter motor




fiesta turbo GRS intercooler
planning to have this pressure checked and re-polished

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grs alloy rad with kenlowe slim fans




when i bought the engine i had a few extra bits aswell, silicone hose, metal pipework etc
(custom pipework from the throttlebody to the intercooler is at the bottom middle)




13 row mocal oil cooler





front strut brace with bracket holding the edis module and map sensor




rear strut brace with bracket holding a battery kill switch as i plan to move the battery to the boot




close up of the kill switch




false floor with ford battery tray to hold the battery in the boot securely

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