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Thread: Ford Fiesta ST Rally Build

  1. #1
    Spanner Monkey Arwel's Avatar

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    Ford Fiesta ST Rally Build

    Hi guys. As some of you would have seen, the Pug was sold back in April and since then we bought a house so its all been going on and causing a bit of a distraction. But we are now moved in, the house is pretty much finished inside so the time was right to start a new build.

    I opted for a Fiesta St as their pretty reliable and pretty quick in standard for and there is loads of bits available for them. We shall hopefully get cracking on the build in the next few weeks now so keep an eye on the thread. The plan is to do the same as the Peugeot, build it up in stages and develop it as we go along. It will be based as a road rally car but will be logbooked for stage events as we plan on doing a few different events next year.

    Here is the first pic having just brought it home.


    cheers
    Arwel

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    Re: Ford Fiesta ST Rally Build

    It will be good to see out on the stages again mate :-)

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    Re: Ford Fiesta ST Rally Build

    Nice choice! I look forward to watching this build.

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    Re: Ford Fiesta ST Rally Build

    Quote Originally Posted by marchy View Post
    It will be good to see out on the stages again mate :-)
    Cheers Lyndon, we'll be back next year. Hopefully we'll do a bit of forestry and tarmac aswell as night events next year so we'll have a good go at it.

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    Re: Ford Fiesta ST Rally Build

    Its been a bit quiet on the car front the last few weeks due to lack of time and the house taking priority. Last night I managed a few hours though and started stripping the interior as it'll hopefully be going in for a cage to be fitted in the next couple of weeks. I must say that coming from being used to building and prepping a Pug 205, stripping this was simply fantastic. All the panels came off without bending or breaking and none of the clips broke so its a case of so far so good with the little Fiesta. Quick pics of progress are here




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    Re: Ford Fiesta ST Rally Build

    looks a good car...watching with intrest....cheers mark

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    Re: Ford Fiesta ST Rally Build

    Little more done today. Passenger airbag removed, radio removed and some more sealer removed from the floor where the cage will be mounted. Next big update will be when the cage is fitted.

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    Re: Ford Fiesta ST Rally Build

    nice, seeing more and more of these lately, must be some goodies out there with all the msport cars

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    Re: Ford Fiesta ST Rally Build

    Quote Originally Posted by lukem30 View Post
    nice, seeing more and more of these lately, must be some goodies out there with all the msport cars
    There are some nice bits out there but with the ST Trophy gaining in popularity at the moment the nice bits aren't that available at the moment. All new stuff is out in Msport Poland too so a little difficult to get hold of however there are some alternatives that we are looking at.

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    Re: Ford Fiesta ST Rally Build

    Got sent through some photos last night from the fabricator. Its not quite finished yet but it gives you the idea of what it's going to look like.





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    Re: Ford Fiesta ST Rally Build

    Not had a little update in a while. We had the car back form the fabricator a few weeks ago but with lack of time we haven't had a chance to do much untill last weekend. We took the cage back out to paint it so thats all been done. Here is a sneak pic of the rear part of the cage.



    Next job is to weld in some seat rails for the bucket seats and make a bracket for the cylinder to convert the handbrake to a hydraulic one. Before we re fit the interior we will also fit new fuel lines and brake lines which will run inside the car so their nice and protected.

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    Re: Ford Fiesta ST Rally Build

    It's been a while since the last update but we are still plugging away at it slowly. This weekend we've put seat rails in and the roll cage is back in loosely for now but we're going in the right direction.






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    Re: Ford Fiesta ST Rally Build

    looking good! but dont you think that for rally it'd be good to extend the cage to the front schock mounts?

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    Re: Ford Fiesta ST Rally Build

    Quote Originally Posted by hfcworks@gmail.com View Post
    looking good! but dont you think that for rally it'd be good to extend the cage to the front schock mounts?
    It was an option for us but for the level that the car is going to be used for we decided against it. We had previously a bolt in cage in our old 205 which didn't go to the top mounts and that worked fine so decided to stick to that plan again.

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    Re: Ford Fiesta ST Rally Build

    Managed to get a few hours on the car this morning. Got her in the air, wheels
    Off and gave everything a check over. Few little niggles to sort on top of what is getting
    changed anyway but nothing major. Hydraulic handbrake has been put in
    Place but will be properly fitted later. Also dropped the fuel tank ready to re route the fuel lines inside the car. Progress should speed up in the new year now as we are sourcing the replacement parts required.



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    Loving this build. As I'm doing much the same but mines gona run RWD .
    One question Arwel, regarding h/handbrake. How are u piping yours up. As mk6 fiesta has twin pipes running back along car to rears. Or have u modified braking system. Thanks

    Sent from my SM-T560 using Tapatalk

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    Re: Ford Fiesta ST Rally Build

    Quote Originally Posted by scoobymike View Post
    Loving this build. As I'm doing much the same but mines gona run RWD .
    One question Arwel, regarding h/handbrake. How are u piping yours up. As mk6 fiesta has twin pipes running back along car to rears. Or have u modified braking system. Thanks

    Sent from my SM-T560 using Tapatalk
    We have a bias valve going in so we should get away with just the one line out of the handbrake and then splitting via a T piece to each rear caliper then. This is what others have done so should work fine.

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    Re: Ford Fiesta ST Rally Build

    There has been a fair bit of progress lately. No photos as of yet as its all been boring stuff really. Fuel and brake lines are now running inside, fuel tank guard has been made and fitted, sump guard is in the process of being made, dash panel for switches and master switch is taking shape along with all the wiring that goes with it. Windows have had the safety film applied and there has been some weight saving going on too. I bought one set of 15" wheels which will be re painted when i get round to them and we have bucket seats, belts and other rally related things on order from Nicky Grist which should be here soon. The only dilemma I have is suspension. As the car is going to be used for both tarmac and gravel I am in need of something that can cope with both. My two realistic options are some fixed Bilstein B8 shocks which are similar to what I had on my previous Peugeot 205 gti which proved to be a good all rounder on all surfaces or I go for the new Avo R1 coilover kit which has multiple damping settings as well as being height adjustable. A decision is to be made on this at the moment.
    Our first rally in the car is hopefully going to be the Tour of Epynt on 12th of March so we have a lot of work to do as I want the car finished to is phase 1 spec by the end of February so it can have some mileage put on it.

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    Re: Ford Fiesta ST Rally Build

    Plenty of work been going on the last few days. We were hoping to do Tour of Epynt but we wont be ready for that one. Progress so far is the new Bilstein suspension has gone on, the dash panel and all wiring is nearly complete, cage is all bolted in place permanently and the interior has started going back in. Sump guard mount has been fabricated and fitted to. Next job is to get the seats in place so we can see where to mount the nav foot rest and the plumbed in extinguisher.



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    Re: Ford Fiesta ST Rally Build

    Last night the car was given its competition log book. This involves it being checked over by an MSA scrutineer to ensure it complies with all the relevant regulations. With the car now log booked we are one step closer. Finishing touches are being done and it will be out of the garage at some point over the weekend ready for an MOT in the week and a few little test runs ahead of the first rally on the 9th of April. Couple of quick picks of the interior coming together and the first set of wheels that we've had done by the Wheel Specialist in Swansea



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    Re: Ford Fiesta ST Rally Build

    Competed on our first rally in the new car yesterday. After nearly 18 months away from competition we were aiming to just get around and get a finish. We managed to finish 15th overall and 3rd in our class which was fantastic. Had one or two "moments" as I started getting more confident with the car and finding its limits and finding my feet again after some time away from competing but other than that it was all good.
    Our only issue was that the engine seemed to like oil and we found ourselves topping it up after each stage so I think the engine will now come out for a freshen up and have a few tweaks made for some more power. Couple of images below of it all done and I'll hopefully get some in car footage up later on.



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    Re: Ford Fiesta ST Rally Build

    Here is SS1 from the rally at the weekend. First event in nearly 18 months and first competitive run for the car too.
    https://youtu.be/ufNdp6MVqig

    Here is SS3, I started pushing a little more and finding my feet with the car on this one
    https://youtu.be/0n6ZNWVU61w

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    Re: Ford Fiesta ST Rally Build

    Last stage from the rally on Sunday. Think this was our quickest run of the day as we properly started settling into the car.

    https://youtu.be/tTfKUTffIYE

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    Re: Ford Fiesta ST Rally Build

    The rally was a non speccy event and there have been very limited photos from the photographer who was there but here are a quick couple.



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    Re: Ford Fiesta ST Rally Build

    I haven't put much time into the little Fiesta lately but we cracked on with it on Saturday and got the engine out as it needs a rebuild. It always had a little rattle from the top and we found a loose timing chain follower which solves that. However it used a lot of oil on the rally we did in April and a compression test showed that cylinder 4 was 50psi down on the others so we decided to give it a refresh now and add a few more goodies for some more power. Im hoping for a quickish turnaround to get the car back up and running and put some miles on it before its used in competition again.
    P.s, Sorry about all the other photos, Photobucket has had a meltdown so Im starting again on Imgur.




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    Re: Ford Fiesta ST Rally Build

    Some more updates over the weekend. Engine now completely stripped down and the clean up has began. The big end bearings were toast and we were very lucky not to have a really broken engine on our hands. So new parts will be ordered this week and hopefully next weekend we can start putting it back together.




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    Re: Ford Fiesta ST Rally Build

    Following the build and have subscribed to your YouTube channel.

    The car is looking good, what tyres are you running on stage?

    I'm in the market for a decent ST at the minute and looking to do similar events up north.

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    Re: Ford Fiesta ST Rally Build

    Nice little project, these little ST's are very underrated cars...
    http://www.scooternations.com/

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    Re: Ford Fiesta ST Rally Build

    Hi guys, we ran the Nankang NS2R on the last tarmac stage we did in April. I was very impressed with them and think they were as good as Yokohama A048. Nice price on them too.

    The engine has now been fully rebuilt and is back in the car. We've done some modifications to the head and exhaust so we are hoping for a little bit more power. Initial start up was fine with no nasty noises any more so its a case of so far so good. There's a few jobs left to do before its ready for the running in period but all being well it will be on the road by the weekend.
    My plan is to break it back in gently for a few hundred miles and then begin testing as we are doing a road rally on the 4th of November.

    Last edited by Arwel; 19-10-2017 at 07:31.

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    Re: Ford Fiesta ST Rally Build

    Quick little update. Did a very gentle 10 miles on Sunday afternoon and on return to the garage we had a little oil leak. More concerning however was a rattle coming from the head. We are hoping its a clearance issue with the valve buckets but will need investigating to find out what it is. Not ideal but rather it happen now than in 2 weeks when the rally is. More updates to follow once we've got to the bottom of the problem.

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    Re: Ford Fiesta ST Rally Build

    Problem solved last night, turned out the noise wasn't coming from the head but was actually coming from the waterpump. A bolt had worked its way loose and was allowing it to rattle when warming up. A quick adjustment and re tighten everything and all is well again. Couldn't find any signs of an oil leak so it could just be some old oil dripping off the bottom of the engine. Everything was cleaned up and we shall keep an eye on it. But now I can carry on with some running in and then some testing.

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    World Champion Decade Plus User alladdin's Avatar

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    Ford Fiesta ST Rally Build

    Good news 👍


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    Re: Ford Fiesta ST Rally Build

    Had a bit of a productive week so far. Put some good mileage on the car and done some testing in the local lanes ahead of the road rally this weekend. All is well so just an oil change, swap wheels and a wash and a check over and we shall be all set to go. We've been seeded car 50 on this weekends Powys Lanes road rally and we are first away in class. Quick snap below of it in standing out in the works car park.

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    Re: Ford Fiesta ST Rally Build

    So the weekend didn't quite go to plan. Started off very well in what were very challenging conditions. I've never driven on surfaces so slip as they were covered in hail stoned, leaves, mud and water. Despite this we set a decent pace and caught the car ahead of us during the first section.
    Unfortunately the second section didn't go so well. We got the car stuck in a ditch which cost us 10 minutes in trying to escape it. In an effort to try and claw back some time we pushed on hard over the next few miles which included going through a farm yard and down a farm track. The farm track was to be our undoing as it proved to be quite rough, combined with my extra enthusiasm behind the wheel trying to claw back time, we hit a large rock or a step in the track which bent the suspension arm. With one wheel pointing in the wrong direction we limped to the end of the section and retired.
    Not the way it was planned to go but that is rallying for you. We shall replace the damaged parts and some strength to the new ones to prevent it happening again and we are aiming to compete in December on Jaffa Stages in Pembrey.

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    Re: Ford Fiesta ST Rally Build

    Had a quick clean and check over the weekend. Found the culprit so will get some replacement parts this week now and get it all sorted. One or two little jobs to do as well so it'll all be sorted before the next rally. Will be possibly doing a test day with a friend of mine next month to get some more seat time as im still a little low on mileage in the car at the moment.


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    Re: Ford Fiesta ST Rally Build

    We have now hosted over 30 rallies worldwide! Take a look at our recent testimonial from one of our customers, Kevin.
    “I haven’t attended other rallies before but I thoroughly enjoyed the two I have attended with Pure Rally. The rallies are well organised, value for money and great fun as they get everyone in involved. It was great to meet new people and the WhatsApp group we had is still going a year from the first rally I attended. I would say to anyone looking at attending a rally to definitely give it ago. I will forward to attending yet another rally again next year.”
    For more information visit our website purerally.co.uk

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    Re: Ford Fiesta ST Rally Build

    We have now hosted over 30 rallies worldwide! Take a look at our recent testimonial from one of our customers, Kevin.
    “I haven’t attended other rallies before but I thoroughly enjoyed the two I have attended with Pure Rally. The rallies are well organised, value for money and great fun as they get everyone in involved. It was great to meet new people and the WhatsApp group we had is still going a year from the first rally I attended. I would say to anyone looking at attending a rally to definitely give it ago. I will forward to attending yet another rally again next year.”
    For more information visit our website purerally.co.uk

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    Re: Ford Fiesta ST Rally Build

    I’ve got a spare rack if you want foc
    Hexham and District Motorclub

  45. #39
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    Re: Ford Fiesta ST Rally Build

    Quote Originally Posted by mexicotait View Post
    I’ve got a spare rack if you want foc
    Ahh mate, that would be brilliant, always handy to have a spare. If your willing to ship it, PM me your pay pal and ill cover the cost of shipping. Thanks

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    Re: Ford Fiesta ST Rally Build

    No problem sent you a pm
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