Hello all, this is a copy of my post on Fiestaturbo.com, I figured I would post it here too seeing as I also browse this forum a lot.
I've been through phases of wanting to sell the car and wanting to keep it. I figure it's not worth anything other than to me, and as it's a fine base to start with I will be undertaking one last 'Fiesta Project'.
The rationale for this project is as follows; I've learnt quite a lot since the last Zetec turbo so the S4 project aside this will be an ideal chance to do something different. I also feel that the car could do with bringing 'up-to-date' as I enjoy learning about new technologies and I have plenty in store for the car.
As with previous incarnations I'm not looking to create the loudest, most powerful and ostentatious car. It's going to be firmly driver orientated and tastefully done. The chassis will be as strong as possible without doing anything radical such as a weld in roll cage, seam welding is a possibility. I'll be making few braces for the running gear and chassis, particularly at the front end. However, there will be a firm luxury element. No knocks, bangs or harshness. Anybody can create a rock hard & unforgiving car, but it takes more thought to create one equally as good that is still comfortable. I like to use the car in 'everyday' cirumstances.
Enough of the talk, here are some quick (read poor) preliminary photo's of the components I have amassed to date. There are lots more but I will post when Uni is finished.
SportKA PAS rack. Matched to my ST170/Focus RS PAS pump which has unique valving for sports applications. The Sport KA rack will enable me to run 20mm extra front track and provide a nicer feel on the road.
Believe it or not this is from a '53 plate car. Lots of farm tracks around here, it'll clean up fine.
Pedal box assembly from SportKA. I'm performing a hydraulic clutch conversion so that I can run a HD clutch without encroaching on pedal feel. Modifications to bulkhead and steering column required.
Master cylinder and brake booster from aforementiond KA. Temporary measure until a VAG setup is sourced.
SportKA front hubs, +20mm lower arms (cast for strength). Also hub carriers with revised gearbox mount, ideal for my gearbox conversion. The S brace is stronger and lighter than the mk3 version.
Hubs have integral ABS sensors, needed as I'm wiring in 4 wheel electronic ABS.
Puma VCT gearbox mounts, may be of some use yet. Not sure at this point.
The ST170 wiring loom, reason explained below:
The heart of any modern Ford electronics system, the General Electronics Module (GEM). I'm cutting this system from the ST170 loom to gain radio frequency locking, control of double locks and a security system. The GEM is integrated with many functions of the car including lighting and wipers. I will be utilising its functionality to the maximum to provide functions such as automatic wipe when wash, rear wipe in reverse, interior light delay etc.
The front brakes, Focus RS 330mm with 4 piston alu calipers. 16" Superleggeras to cut down unsprung weight. Billet hubs are something I'm looking in to. Front driveshafts are going to be equal length to cut down on torque steer.
The rear brakes. ST170 front 300mm discs and Brembo 2 piston calipers. Seperate handbrake caliper. A lot of people claim large rear brakes are overkill, this is horse, the rear brakes must be relavtive in size to the fronts to provide an even spread of torque across the system. A well balanced system equates to shorter stopping distances.
Porsche are a company that takes braking very seriously, look at their top steel systems and the rear calipers and discs are the same size enabling them to have powerful yet controlled brakes. An example of this is on track days,RS4's with Mov'it front 380 6's cant touch GT3's for braking unless the rears are done to compliment.
Focus, Mondeo and Golf IV A/C system's. Parts of each will be utilised to improve on the low capacity Mk5 Fiesta system. Wiring will be custom and I will be retaining the Mk3 dashboard.
Mk5 clocks with rev counter...in black (Thanks to Project for these () )
GRS EVO3 I/C and rear strut brace. IC may be changed when the front of the car has been re-worked (tubular front crossmember to give clearance for a larger radiator & cooler):
Electric & heated mirrors, heating will be controlled by the GEM:
The powerplant, ST170 turbo. It will be all steel internals which are still to come across from the states. I've comissioned a custom inlet manifold that has been made a person who works on the US Indy series. He has taken a particular interest in the Zetec. The manifold has been designed around what I want from the engine, which is driveability and effortless torque throughout the rev range.
Pics of the manifold to follow, its at a friends place in Boston along with my throttle body and injectors.
ST 6-Speed gearbox. I'm worried about it's torque capacity, Getrag don't put a very high torque rating on the box, but then neither did Ford on the B5. It's a gamble at this stage. The ST gearbox is geared for 185mph at 8krpm in 6th. It'll be flat out whenever the opportunity arises.
A little dusty..she's been in there for a few years now..Still only on 38k miles..
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