the new eagle steel rods in their new home






the head back together after being acid dipped clean, skimmed, new valve guides, recut seats + valves





the block was rebored again aswell
original 2.0 zetecs have a bore of 84.8mm making them 1998cc or 2.0
then this block was rebored for the first set of forged pistons at 86mm making it 2047cc or 2.1 as most know
ian decided to have it bored out further for me to make it 87mm - 2098cc
then he ordered new forged pistons and rods with my new measurements


heres my favorite pictures showing the cp pistons, freshly decked block and bores after being bored out and then honed
i love the reflections in the bores

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Looking brilliant mate

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looks awesome mate.

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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

well i recieved the rest of my new skirts and arches kit,
also still brand new in ford packaging etc





so i have a full kit now woohoo





as i'm having new rose jointed lower arms and the rear beam bushes are powerflex,
i've been ordering more powerflex bushes
polybushes for the front and rear anti roll bar





my new steering wheel was becoming a bit of a knightmare as it use's a different steering wheel boss to the more well known
rs 3/4 spoke steering wheels
after lots of searching, i've sourced myself the right boss
so i'm mega pleased!!






fitted to the steering wheel

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well its been a busy week just gone for me,
heres a few updates

taken the rear arch kit off which was bonded on previously




the sealer still left on the rear quarter




brand new wings arrived




as the shell is going to be seam welded mainly in the front,
the decision was made for it to be taken for a proper shotblasting session as the small kit i'd bought was'nt strong enough to get the sealer out properly to avoid
weld spitting when seam welding

so on the back of the truck the night before




the missus decided to take a picture




the next early morning ready to go for a trip to be blasted

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so the car was back later the same day,
only problem being the weather was'nt on my side and was raining nicely
this made the journey back very interesting especially when the car cover kept blowing off the back letting the car get wet.
so some time with the airline and new cloth sorted that out!

the next night my fabricator decided to crack on now it was clean
so starting with the plasma cutter he cut out the problem areas of rust




heres some freshly cut holes
this is under the passenger side of the front bulkhead




this is the passenger rear turret




the nasty bits




the side showingno major signs of rust




also the start of the seam welding

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inside the shell is'nt being left out either
the top of the bulkhead





the floor





decided to weld up where the plastic plugs normally go aswell





the main support on the floor, even welded a washer to support the seat bolt points which normally fracture





how the engine bay is looking from underneath





close up of the drivers front arch





heres a clear picture showing the supports used while welding the front end,
as we did'nt want that much heat going into the shell while being held up by the front and rear of the shell





you can see from the seams we intend to seam weld as their back to bare metal





also had the sealer cut off the rear quarters, so the rest can be removed by the fudge wheel

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ok time to catch up with a few updates

bought some 1.2mm thick steel which i had bent to my spec





then shaped it to meet the floor and sill inside the shell
which will reinforce greatly





here it is seam welded in postition





on the inside of the engine bay we used it to reinforce between the chassis leg and bulkhead
and sort the hole made by plasma cutting the grot out





will look like this





on the otherside of the bulkhead its look like this,
ignore the dodgy looking colour its from the gas used for welding
it comes off and will all be sorted before its first coat of etch primer





had my bigger master cylinder painted panther black aswell
so will build that back up soon





mmm metallic flake

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Some seriously nice work going into that shell!!

Looked awesome in the first place, but that'll be minty mint when done!

Any tips on the seam welding?

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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.

awesome

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the seam welding has gone back to the rear floor





tidied the welds up a little and buzzed over them with the scotch wheel







the windscreen brackets were looking a rusty, so taken them off aswell





quickly machined the small scabs of rust around the sunroof to see the full extend of the tin worm





more welds cleaned up with the scotch wheel

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back on its side now for more welding underneath





the welds which have penetrated through when welding inside have been cleaned up





patches replaced where the metal has perforated after shot blasting





the inner fuel cap area was cleaned up but thin in a few places also
so that was cut out with the plasma cutter





the piece cut out







rear suspension turret where we cut out the rot has now had a new peice welded back on





this hole is where the bracket for the spare wheel carrier goes into the boot,
as i've taken all the other bracket off, i want this sealed up
so removed this extra support fords had over the top of it

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machined the sills back removing any chips in the previous paint etc





part of the front chassis welded up





the master cylinder back together





picked up some parts from the powdercoaters
rear beam, coilpack bracket and front mount





close up of the clean rear beam
now that its back, going to have the old man make up some spacers to make up for the width lost
when converting the rear brakes from drum to disc setup as the wheels sit further in the arch

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getting there now

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RUST IS LIGHTER THAN CARBON FIBER

http://www.fiesta-si.com
http://www.fiestaguides.co.uk/

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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.

Any chance of the running total so far?

Looks awsome as ever.

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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

stunning work!

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