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Thread: Fiesta mk3 2.0 zetec from Czech republic

  1. #1
    Bodger milos's Avatar

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    Fiesta mk3 2.0 zetec from Czech republic

    Hello, this is my first post here, I read this forum for years and its very informative for me, but never wrote anythink. Now i like to show you my cars.

    I bought my first RS1800 in 2006 and than decided to built another one for race days, slaloms, hillclimbs and maybe rallying.

    So from the beginning:

    My first RS1800, standart car bought in germany on Ebay


    Than I found really good shell without sunroof. Complete 1,1 car for 150euro...


    And other RS1800, only little scratches


    Standart RS1800 engine out
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    All stripped out, soundproof cleaned


    Rollcage is the only one think made by professional... 21meters, aprox 35kilos




    Detail
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Fuel tank is my design, but not really good, there have to be aprox 5-8litres left everywhen. Foam filled.


    Place for fuel tank and baterry


    Im really big, so need a big seat


    Underside cleaned


    and painted
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    My fathers work:


    Dont know why red, but I hope it looks good. First think was black color.


    Waiting for engine
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  5. #5
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    I cant reccomend it, but it works


    Yellow Konis works well, but "tuning" springs were weak point


    Cleaned and greased halfshafts
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Really standart 130hp engine, temporary, so didnt paint it, nothink, only new filters and oil. Gerbox was Escort RST S2




    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  7. #7
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Interior... steering wheel in std position, now I have it lover and back.


    Dont like these photos, it looks crazy... but maybe good sleeper.


    no fuel filler


    first slalom


    and first trackday... Most circuit
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  8. #8
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    few shots from slalom






    an autoslalom at the old russian army airport: http://www.youtube.com/watch?v=NWDUrCtbtzIYouTube - autoslalom Ford Fiesta.

    and a boring onboard from Brno circuit
    http://www.youtube.com/watch?v=DWb7L39AfZcYouTube - fiesta xr2i a impreza GT 4x4 turbo.

    That time I changed final drive ratio, there were std 240 front brakes with Ferodo DS2500 and rear drums.
    Last edited by milos; 06-06-2009 at 22:17.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    With our company van - Brno circuit




    and my "new" ex. manifold... modified RS2000 escort (maybe called GTi in UK? 2litre 150k, but not zetec)


    water cutted flange


    zetec have different spacing between cylinders, so its modified too




    Underside wiev
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Bought an Audi wheels - only the centre hole is small, few minutes in lathe... cheap and light, but now i can say soft...


    Front 260 brakes from escort, rears 253 from mondeo


    16mm home made spacers


    to solve this problem


    new discs and pads, front pads are Ferodo DS3000 - perfect, much better than 2500
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  11. #11
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    manifold + thermotec


    sand blasted wheels


    brakes blasted and zinc plated


    all needed


    and together


    rear adaptor prototype... laser cuted from plexiglass


    front brakes on
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  12. #12
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    modified axle... it was too hard, now I got it welded aprox in the half, so the profile looks like A, the closed triangle is smaller


    difference between brakes


    new steering (2,6 turn to turn), Tilton and hydraulic handbrake


    master cylinder from any ABS version


    here it is


    handbrake


    and steering wheel in better position


    actual weight was 870kgs with full fuel tank, front to rear 65:35
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  13. #13
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    gears and uprated case from RS1800, final drive from an mk4 1,6 escort (4,29) and LSD from ERST S2


    impossible to buy there, so from UK...


    dont know how this graph is called in english

    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  14. #14
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    and few shots of my small toy




    with stickers...




    to be continued... this was year 2007
    hope you like it
    Last edited by milos; 06-06-2009 at 22:59.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    I was looking for 2litre, and like a management for that. So ordered Megasquirt to try it with the old 1,8 and play with...

    Arrived like this:


    "EEC-IV" board to use std loom


    and wideband lambda



    Put it together myslelf... and it works




    two screens how it looks on pc




    I was surprised that the engine started first time with a map from internet without any problems. We tune it on the airport for two hours and it was ready to drive - without rollers.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    I tried to replace rear beam mountings. It was made of polyamid, not polyurethan, and it was really hard - useless.


    random picture from workshop


    new jack... never used it under a weighty car, but they write there 1500kg max. For fiesta its fine, drive by drilling machine.




    Than I was thinking about converting yellow konis to coilovers


    But bought this set:


    compare


    first test




    and a winter picture


    new custom made engine and gearbox mounts
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  17. #17
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    my first hillclimb:
    http://www.youtube.com/watch?v=g6IiTxn1fF4YouTube - Berounský vrch.

    Fibreglass bonnet


    Its white because there was a white car in the paintshop But I left it, it looks good.


    Older pictures but I like them










    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    new battery


    lightweight doors




    new blacktop 2.0, but its still in the garage and there is another silvertop in the car


    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  19. #19
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    somethink like rally..





    standart tyres...

    http://www.youtube.com/watch?gl=GB&h...&v=JY98yqOXuB0
    Last edited by milos; 10-06-2009 at 17:41.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    tried to make front arms myself...


    Maybe looks good


    but ended like this... brakes after small jump...


    another solution... cheaper, but cant setup anythink



    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  21. #21
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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Very interesting to read and see the step by step improvements
    Well done so far

  22. #22
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Thanks!

    So lets continue...

    No carbon, but looks good for that price


    I like this track
    http://uk.youtube.com/watch?v=CH_nAtoyfVohttp://uk.youtube.com/watch?v=CH_nAtoyfVo.

    And this is nice too
    http://www.youtube.com/watch?gl=GB&h...&v=XoGmF1BSEHQ

    Track day in the winter






    [/quote]

    and first spring amateur rally






    there was a stupid tree


    and ready for next event with new wheels
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    I bought used 2litre zetec - raceline 200spec from UK




    Cleaned everythink, new gaskets, oil seals and lets put it into the car

    preview

    http://www.youtube.com/watch?v=1uGE_8jabVQYouTube - dvoulitr poprvé....
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    First time with codriver

    http://www.youtube.com/watch?v=XZvvLn5b6Q4YouTube - 9.5.2009 AR B›lá p. Bezd›zem.

    I bought this one - GSXR 600 K2




    Now we have new design:








    And my best onboard I think... average speed over 120kmh

    http://www.youtube.com/watch?v=2oXY-DuRnAgYouTube - MCR UAMK Prachatice.
    Last edited by milos; 19-06-2009 at 18:29.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Decided to have bigger throttle bodies - so there are GSXR 1000 k2 next to GSXR 600 k2




    Now I have to made inlet manifold or buy ST170 one. New exhaust maybe and I hope there can be 200hp.

    I will keep this thread actual.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Tyre Kicker tekno's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    hello milos, very nice car you got there, i'm well impressed of the quality of the work done. what did you do with that new blacktop?

    PS
    i'm also a fiesta nutter, i own a mk2 and just finished my 2.0 conversion...
    Last edited by tekno; 29-06-2009 at 21:47.

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    tuk and poke me Decade Plus User mogsmex's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    good effort and some lovely fabrication work


    looks like you are having fun with it as well



    All I got for christmas was a sweater, I really wanted a moaner or a screamer......

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    well done. top work like your project

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Absolutely brilliant stuff. Its so good to see some one doing everything themselves and trying different things. Please keep posting.
    Zetec Mk 1 Escort
    Mk 2 X Pack Capri 3.0S (not a copy, the real thing)
    Mk 1 XR4i
    Mk 3a Fiesta Si

    www.zetecescorts.bravehost.com

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    looks the part mate

    those tubular wishbones look different fair play for trying. were did it break?

    this guy made some for his mk2 dont know if you have seen it yet. he is on turbosport as well.

    http://www.zetecinside.com/xr2/suspension.shtml

    were did you get other arm and parts from?

    cheers.
    Last edited by TTommy; 30-06-2009 at 13:40.

  31. #31
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    thanks for your comments!!!

    tekno: that new blacktop is for sale now, price around 1000euros for complete on that photo

    TTommy: tubular arms failed in the bend (the rear non-straight tube), it was made of std constructional steel, not CrMo. I think that the same design made of CrMo will work. I didnt like the arms so solid. Few times I had a smash tend to wheel, and its the cheapest way to damage arm. Maybe I will try it once more, still have the rod ends in garage.

    The new ones (I used them for a year now) are the best aftermarket arms I found (maybe better to use ford ones, but these are for half price). Rubber bushes out, industrial SKF spherical bearings and adaptors of my own design made on CNC. Together arms, sph. bearings and adaptors cost 200-250GBP. I can send you drawing of the adaptors and numbers of bearings if you like. Maybe I can made them for you, but dont know right price now. This works well and its safety.


    Now Im going to do the TBs, on friday arrived ST170 manifold from UK, impossible to buy used one here... Then I like to sell the car. Its 3years work now, but mk2 grp4 is waiting in garage and I have only one pair of hands :-)

    I will introduce my mk2 escort in another topic soon.

    And there is video from last weekend event.

    http://www.youtube.com/watch?v=NUIOT7bPfhEYouTube - MČR ÚAMK do vrchu Hronov.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Spanner Monkey

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    sure I would really appreciate the drawing and those numbers.

    In my road car I end up replacing rubber bushes far too often. that price looks pretty good tbh.

    if you sell the car will you break it or sell complete?

    cheers.

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    TTommy: Send me your email adress, dont know how to upload it on forum. Do you like it in autocad format (.dwg) or .pdf for print only?

    there is preview of assemble without dimensions (circlip missing there)


    I dont like to break the car, better to sell it cheaper complete... Im looking around 3500-4000GBP with TBs fitted.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

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    Spanner Monkey

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Great project. I'll have to keep an eye out for any events to come and watch next time I'm over.

    Do you have the contact details for who made the rubber engibe mounts?

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    Spanner Monkey

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    sent you an email buddy.

    cheers.

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    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    email replied, hope it can help you

    Rubber engine mounts are made by my friend who have company specialized for this. They can make any rubber mount you like from any hardness. That complete 2x engine + 2x gearbox mounts cost aprox 180GBP if I remember. Thats for one set, maybe cheaper for bigger quantities. But the company is situated there in Czech rep. There is web, but nothink interesting there now http://www.silentbloky.cz/index.html
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  37. #37
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    some progress...

    ST170 manifold arrived from UK


    TBs separated


    spacing changed... but wrong there, didnt know that the manifold have different spacing than cylinders, when it arrived I correct it


    standart on left, modified right


    throttle control lengthen


    look through...


    TBs together


    on the engine


    and with 8 injectors


    look here


    the last photo - there is a difference between ST170 and std zetec head around injectors, I will remove the edge when it will work

    maybe I will make it better without rubber hoses, but now its simplest way how to try various lengths of intake

    I install 8 injecotrs, megasquirt can run them, but for the simplicity Im going to use that ST170 ones only. I will make any plugs in place of bike injectors. (ST170 inj. are 315cc, GSXR 1000 K2 are 260cc)

    Today I made wiring loom, sensors works, it looks good. Next think to do is connect fuel rail and modify throttle pedal cable. I hope that tomorrow it will start...
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  38. #38
    Bodger milos's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    TBs works fine, after two hours of mapping at the airport it runs like this

    http://www.youtube.com/watch?v=MNTvCHF5iBwYouTube - MCR UAMK do vrchu Beroun 2009.

    and there you can see that crisis, last car in this movie

    http://www.youtube.com/watch?v=bAkbjXJPR58YouTube - Berounský vrch 2009 - závody do vrchu červenec 2009.

    Still like to sell it but its lot of fun now.
    Escort mk2 2.0 Zetec
    Sorry for my english, I speak czech far better!

  39. #39
    Pit Crew Decade Plus User turbo m's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    Loving this thread what a great car you have built i also love septerated the throttle bodys picture with the big hammer in the back ground keep up the good work

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    TURBOSPORT SPONSOR Turbosport Sponsor adolfochelle78's Avatar

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    Re: Fiesta mk3 2.0 zetec from Czech republic

    You did an excelent job!!! congratulation, I have an Escort mk2 too, and Ill mount TBs from Suzuki gsxr 42mm butterfly, Im hapy to see works fine the TBs on your zetec, my english its so bad but next week I'll post some photos of my project.
    Good work man!!

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