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Thread: Duratec Turbo Fiesta 4x4 (Quattro) Project

  1. #81
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    WOW! Simply awesome!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    The new adaptor plate looks a bit of a bodge but with luck it just might work

    Mark

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Quote Originally Posted by Mark V8 View Post
    The new adaptor plate looks a bit of a bodge but with luck it just might work

    Mark
    Ha! Simply awesome, mate

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    Spanner Monkey rich_frst's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    quality marky!!!!!
    My 3 door Cossie and Mk3 Escort Pick up Project...

    http://www.turbosport.co.uk/showthread.php?t=113630

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    awsome work, cant wait to see it all come together.

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    I´m deeply impress...

    Love to see creative people...!!!!!!!!
    load up soon, more info about your Fiesta...
    and of course picts too..!!
    and I think you are ingenious with Cad-program at your computer..!!

    //Håkan-swe

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    Pit Crew Decade Plus User Snickers's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    any updates? awesome how you got the box to work I actually have a Friend in the USA that did a 4x4 on his Focus but he said he used the lancer Evo 8 box and theres a place in miami that does bell housings the only real problem he had was the rear Diff he didnt know what to do there he almost put a mustang back end on it i think they sorted it out now tho ill see if i can get some shots and post them


    awesome keep us posted


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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Just spotted your project. Gonna be watching this one closely now. Well done so far!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    ENGINE MOUNTS

    O/S
    I've taken the opportunity to join the chassis rail to the inner wing for increased strength around the turret area.


    The existing turret was cut and then filled in with plate which was seam welded behind in the wheel arch.



    N/S
    This was considerably more time consuming.
    I had to remove a lot of metal from the turret and 5mm from the top of the chassis rail so I could mount a plate to sit the new mount on. No less than 5 pieces of sheet metal join inside the chassis leg (it's a Mk3.5 with the internal steel saftey cage!). The area underneath the new plate is all gusseted and welded to the chassis leg itself (I drilled holes in the top and plug welded them)


    All boxed in at the back.


    Access hole for a socket to bolt up the engine mount. I cut some tube in to quarters and welded it to the sheet to put the radius on the edge, looks a bit neater than a 90 degree join I think.


    Finished:
    Last edited by excursion; 01-07-2007 at 21:07.

  10. #90
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Nice!

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    Part of the furniture Decade Plus User Tone's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    excellent work again

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    keep them up dates coming

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    any gen on the txb and what car it comes from?
    Audi 02M Quattro 6 speed gearbox & transfer box:.

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    cracking as ever m8

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    How are you getting on mate ?

    I've been a lazy git and the V8 Escort is a loooong way from being done.

    Mark

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    hows the car comming on ???

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Forgot about this one.

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    popcorn:

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    my friend, you are truely a freak of nature and i mean that in the nicest possible way.... where do you get your info from... thats flawless workmanship, just one question,what happens where the driveshaft hits the oil filter?

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Quote Originally Posted by sunboy View Post
    my friend, you are truely a freak of nature and i mean that in the nicest possible way.... where do you get your info from... thats flawless workmanship, just one question,what happens where the driveshaft hits the oil filter?
    I noticed that the oil filter was gonna give some grief too! Could be resolved with a remote oil filter kit?

    I totally forgot about this thread, cant imagine the amount of thought and hours that has gone into this amazing project. Would be nice to see an update!

    Cheers Reian

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Hello guys, been really busy so I've not done much. The engine has got a twin scavenge dry sump kit to go on so there won't be anything but a blanking plate where the standard filter goes. I've had the sump milled to suit my adapter plate and due to how shallow it is, I've been able to drop the engine a further 2" in the bay, lowering the CoG even further.



    This about sums up where I am:


    Engine is in with new mounts made,
    Tunnel from S3 in place.

    I've had a change of plan, I've ordered the front end of a Mk5 new from Ford, along with a lot of the floor pan and chassis rails. I'm going to utilise the best bits of the Mk5 (chassis from front seats forward) and keep the looks of the Mk3 - which I prefer.

    I'm in the middle of making a jig at the moment to ensure the new front end is all in place where it should be.

    Shell will be going off to these people in the summer: http://www.surfaceprocessing.co.uk/for-cars.html for a full acid/alkaline dip and new coat of electro statically applied primer. It's the only way to go, my shell was new in 99 but there is still surface rust in the seams - and there's no way a normal resto will cure that.

    Small update, picked up a Mk5 front end this weekend with the help of my Dad:







    Got a Mk5 floor pan and chassis rails on order. Solves a few problems for me:

    Hydraulic clutch master cylinder access hole;
    Mk4/5 blower motor/ pollen filter aperture;
    Bracing to brake pedal and master cylinder;
    Strengthen front end;
    Loose the Mk3 suspension;
    Fabricate sub frame.

    The Mk5 front end is considerably stronger, so are the floor pan and chassis legs. I'll loose 20mm width in the engine bay by using the Mk5 front end, so I'll need to do some modifications. The front chassis legs also need shortening and the inner wings modifying to suit Mk3 wings. All pretty straight forward bar the actual fitment of the front end.


    cut and shut reference
    This is not going to be a cut and shut: A cut and shut is a weld straight across the front/rear end of a car which misses critical chassis seams and areas hidden within box sections. I'm going to recreate the front of my car in exactly the same way it was built - only using Mk5 parts.

    1) The entire front end is available, in separate pieces, from Ford - in fact this is the route I was going to take but I've saved £400 and hours of measuring by buying the front end complete
    2) I will be un-picking all Mk5 seams and joining to my car in exactly the place they fit on the Mk5 - the Mk5 after all is simply a Mk3 with revisions.

  22. #102
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Been waiting a long time for an update but it was worth it.

    Fair play to you for taking on this eppick project.

  23. #103
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Unreal!

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    me to trig,that tunnel looks awesome m8.well done

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    more pics m8

    MY MK1 ESCORT (Now turbo'd)

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Nice work - this will be a real nice car when its done Keep the updates coming....

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    I've spent most of this weekend preparing the Mk5 front end. It's now just about ready to be fitted to my Mk3.

    Supplies!


    It was mostly plain sailing, the trickiest part is where the inner sill joins to the front inner wing gussets (behind the sill in this photo):


    I've removed the wings, inner wing outer sections (not shown here - I'm keeping them for trial fitment), A Pillars, Scuttle (New one on order) and Floor:


    The Mk5 slam panel and supports will be coming off (10 spot welds) as a unit but for now its providing rigidity at the front. The Mk5 front end cosmetics are also completely different to the Mk3 - I'm going to modify the inner wings to accept Mk3 outers, also also the slam panel mounts to accept a Mk3 slam panel:


    As it stands, exposed seams ready for a clean up and coat of weld-through primer:


  28. #108
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Looking good as alway bud.

  29. #109
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Fantastic work

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Oh well in for a penny in for a pound, good work and keep the updates coming
    old fool Frank

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Nothing particularly exciting to post pictures of this weekend. All I've done is strip off the sealer from the Mk5 front end, seam weld it and prepare all exposed seams for welding to my car.

    I've also located some 909 items for the build in the shape of Racing Puma parts. For those that don't know the Puma is based on the Mk4/5 Fiesta, and the Mk5 front I'm fitting means I can use FRP lower arms and hubs (machined with a -1.5 degree strut angle) to extend my front track by 90mm (total) without compromising geometry.

    If you've been following my thread you'll know I bought Sport Ka lower arms, hubs and steering rack to extend my track on my existing front end- as the Ka is based on the Mk3.5 Fiesta like mine. However, just like the FRST, the track 20mm extra track on the Ka was made up by a longer lower arms alone, therefore you can only go so far on these parts before camber is compromised.

    I had a trial fit of an M3 front wing extension, I've had these for a year now! After a few minutes re-shaping I managed to get it to fit well.




  32. #112
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    very good,you have a very good talent there m8.this will be awesome imo

  33. #113
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    yes very nice,keep the updates coming

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Brilliant i thought you had given up on this it had been so long.
    Fiesta ST.

  35. #115
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Hello all!

    I added bracing to the front area so the shell retains its integrity when I remove the front end. I also made a frame for the shell to sit on once the front is removed:


    Removed my outer wings and seam sealer around A pillar:


    Removed the inner wing outer sections (I'm keeping these to help me align the Mk3 bonnet on to the Mk5 inner wings):


    Going:


    Going...:


    Gone!:




    I'vr booked tomorrow off so I'll get all the new seams cleaned up ready for the new front end. I've got to find a reasonably cheap Mk5 now to make a jig from

  36. #116
    Bodger

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    good lord! Top work!

  37. #117
    Spanner Monkey james1088's Avatar

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    reasonably cheep Mk5. Sweet Jesus you have some seious money and dedication.

    Mind a mk4 would work. as thats the same inner wings bulkhead e.t.c.
    Fiesta ST.

  38. #118
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    were do you get your motivation from ,its fantastic,a rebuild like this would of led me to suicide, keep up the top work

  39. #119
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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    this threas is awesome!

    it look beautifully built and very well thought out!

    keep the pictures coming im hooked on this thread!

    well done

  40. #120
    Bodger

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    Re: Duratec Turbo Fiesta 4x4 (Quattro) Project

    Haha thanks all, I must admit it felt a bit funny cutting up a perfectly good shell.

    A lot of my motivation comes from these forums, and seeing the amazing projects and the problems that get solved

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