1986 Ford Fiesta XR2 1.7 VVT Turbo

[jhot80]

Been of here for a little bit as i have a 172 Cup daily but this is my project car.

Had this car for a long while now and been off the road more that than i have driven it, however you will see why.

I have copy and pasted this from another forum so may make complete sense sometimes.


This is my Fiesta XR2 that was a 21st present from my parents. Its not in the best of shape but I'm working on it. Doesn't help though when someone drives into it in the snow while im at work and doesn't leave any details.
First things first the car needed a good clean. So best time to do it was when it was freezing and just snowed.

The previous owner had fitted '90 spec Escort RS Turbo Recaros best seats I have ever had in a car.

Next on my list was a set of descent of tires so went on blackcircle and got 4 Yokohama A539s for the car.
Then I realised that my rear bushes were fucked as I could rock the car back and forth about 15cm with the hand brake on. So a set of polybushes.

Comparing the new and old anti roll bar bushes. Buggered!

The old front tie bar bush or what is left of it.

I then gave the engine a full service. Rebuilt the carb and found at least 10 knacked seals and gaskets. Once I had done this I found that the idle mixture screw was shagged and leaking a bit of petrol. Also well of which would explain the horrendous fuel economy for a 1.6. I still needed to get new tappets as my car sounds like someone filled it with nails. Maybe a new cam and 4-2-1 manifold. I the far future I hope to put a 2.0 duratec turbo in it.
But before that the bodywork needs seeing to. The bonnet and drivers door are shot so if anyone has either up for sale let me know. Thankfully the shell is solid underneath. Well to start I thought I would do the easy bits which were on the back of the car. The little blisters on the boot lid and rust at the side of the spoiler where the spoiler was loose and rub the paint away.
Also got a new spoiler that I need to tart it up so got a can of satin back and sprayed the spoiler and back bumper make them look good as new.

Then painted the boot and bits on the back.
Before with no bumper or spoiler

Getting ready to spray.

Finished spraying and looking really good.

Next on to the dent on the roof

Finally I have fitted the new corner piece of the bumper.

Looking like its meant to be there, brand new and old.

So I painted with satin black so it now looks brand new I have done the back bumper. Need to do the rest of the kit but it'll get there.

The rust that I thought would be very very bad under the front bumper does not look as bad as I thought it would.

With the front bumper back on and need to find a set of new bumper strips. So if anyone has any got any for sale let me know.
Also when I got the car the guy told me that the brake discs were low and has been at the top of my list of things to do for 7000 miles so got some new discs and took a look that the pads and they have barely gone down. Probably because the previous owner needed new pads for the MOT so he put new ones on and bed then in by standing on the pedal as hard as he can, glazed and rippled them.

So got the file out and rubbed the pads so that they can bed to the new discs properly.

All apart.

Back together and copper greased.
I have ordered a new boot XR2 sticker and in my uncles garage I found a
set of spots that the he bought when he got his XR2i brand new and never fitted them. They have been sat in the ford box in his garage for 19 years. Spotless so that's the crappy spots sorted. Cant wait to get the rust and bodywork sorted but gonna have to wait til after uni when im earning a bit more.



Finally bought a few bits for the car.
Ashley exhaust and manifold

Ported and polished Head, single 40 DCNF on a ported manifold bit better then the 28/32 TDLM carb and a head gasket set to put the new head on once its been skimmed a lot. But first the exhaust goes on.

New vs old

Manifold on

and the rest of it on

For the last month or so i have been having trouble with getting the car in gear. It was fine when the engine was off but once the engine was on it was impossible. So fed up of it i have decided to pull the box off to find the problem.
Box off

Problem found

The nut that holds the release fork to the arm had snapped. Did hear a massive ding one day but didnt think anything of it cos it still kinda went in gear. It was just catching i was lucky that the clutch came off at all i think.
I drilled out the the rest of the bolt and widened the hole out and put a nut and bolt in. I wasnt sure if it was going to work.
Got it all back together about 1am.

and it hasnt fixed it. The clutch doesnt come off at all. So a friend has come up trumps with a new arm and the release fork is still good just got to wait for him to bring it by.


Havent done anything major on the car lately as it is still out of commission due to the clutch problem. Just waiting on a new arm and fork but have been pottering around doing bit like cleaning up the head and painting the ram pipes for the carb.
Ram Pipes before a bit blurry

Part way through

Painting

and the finished product

Then on to the head. dirt and shitty.

Getting there after hours.

Then combustion chambers done

and then the inlet tracks.

The head all done for now. Just need to have it skimmed then when i get the head off the engine that is in there at the moment then i can put some valves in and to get a cam. Looking to put a XR2i cam in it if anyone has one around for sale?!
Have been thinking about doing a ZVH conversion with a 1.8 zetec.
The shopping list for this would be?
1.8 zetec bottom end
Flywheel Clutch? Which one?
Anything else and any advice anyone can give. There are a couple of people on here that have done this sort of conversion.

 

[jhot80]

Well on a trip to Worcester and back the finally clocked up to 150k.

Also on that same trip the brand new rear wheel bearing i had fitted only 50miles before the trip eat its self, sent me a bit sideways down the A41 at 70mph was fun till i realised what had happened and the car ended up looking very sorry for its self on the back of a AA van.

Well got it home thankful the stub axle wasnt damaged and i took the remains of the bearing to the motorfactor where i got it and he gave me a new one and a fiver back. Not bad. New one seems to be doing fine.
But a week later the front gearbox mount broke almost into 2 pieces and the engine moved to the point that it was touching the underneath of the bonnet and the alternator fans were touching the front cross member.

I nursed her home but in the process the alternator cooked itself. Luckily a mate from uni had a near new one floating about and gave it to us for a tenner bargain. When i got the old one off i noticed that it had a metal sticker on it say make in uk and dated 08 1986 same time as the car was made. The bushes in it were in good condition i reckon it had failed before and rather then a put a new one in the pre owner had just had new bushes instead so might be the original one?
I then went into the uni workshop nabbed a off cut of billet ally tube and knocked up a set of solid gearbox mounts to replace the absolutely knacked ones. They ended up looking like this.

And apart from it being a bit louder inside the car it is amazing. The gear changes are so much quicker and the engine is much more responsive now it doesnt swing around the engine bay.
I have also sorted out my back bumper where it sagged one side although i dont have a pic of that.


Been a while since i last posted about anything i have done to the car so thought i might add a bit. Well now have a garage so the car has come the road for the winter and i lost my mind a little bit and decided to strip to back and sort out the rust that i have been dreading doing anything about it apart from forgetting its there. So got the kit and heres the damage.

The right hand side is worse than i was expecting and the left hand side was better so all in all it is as bad as i was thought it would be.

I think i have caught the battery tray in time just need to get it out. Not going to be replace it as the battery is now in the boot.

This was a small scab till i got the wire brush on it.

Finally fitted the bigger carb and made a throttle cable bracket for it. Not ready to start it though as i need to get a new aux venturi for it. i Know where to get one it just getting around to it.
So started on the rust.

Put some rust remedy stuff over the surface rust and some paint i have lying around to protect it.

Still a lot, A LOT left to do but get there in the end.


Well im finally making some head way on getting the car ready for the summer. After moving home and towing the car 60 miles with a wing duck taped on. I had a place to work on the car with power to time to crack out the power tools and welder.
Someone had made a patch on a hole but not bothered butting out the rust so it just carried on eating its way through the patch and inner wing.

The gusset on the inner wing in rusted through. I had a good poke about and i couldnt find a anywhere selling then so it cutting out the rust and patching it up.

Next was the rear arch. Which after cutting out a some of the rust. I discovered that someone has had the rear arch repaired before and its still had it.

The rust had stretched on to the rear corner so cut that out as well.

and...

the boot floor

Repaired.

Lined up

Inner on

Outer On

Corner Repaired and the driver side of the car is now rust free. On to the passenger which doesnt look as bad as the drivers. Making good progress. At this rate i will be getting the arches and underbody bare metalled ready for under sill in the next week or so.
Pcking up a new drivers door on sautrday as well. Will be painting before i know it.

 

[jhot80]

Now one side is finished ish still needs a bit of work tarting up but the big stuff is finished. On to the passenger side.

I have cut all the rust off now and made a start on welding the bit of the boot floor however i have run out of welding wire so cant carry on with the bits of the body work till i get some more wire so made a start on stripping off the suspension and the engine bay.

Rear suspension is off and is in fairly good condition. Just waiting for pay day then get a big tin of hammerite and paint the suspension parts.
Next is the front of the car. Taken the head of the engine as i have a ported hemi head to go on.

Looking at old head gasket it looks like has gone not very badly but still knacked. Looking at the state of the block and head its no wonder the straight line speed left a lot to be desired. I think i may have to source a new bottom end as this one has a bit of a lip to the bore. Should have the front end of the car stripped by the end of the week and next weekend finish off the welding on the back end.
Well finally got hold of some wings. Only panel left to get is the front panel and that will be the last panel i need to get so starting to see the light at the end of the tunnel of body work.

Started the weekend by finishing off the rear right arch.

Stripped out the rest of the interior.

I have now taken the engine and box out, removed the front suspension and removed the passenger wing and front panel. The car is almost just a bare shell now. Not bad one days work.

Next i have moved the battery to the boot so the battery tray has come off.

The whole thing is off just forgot the get a picture of it removed. Wasnt as bad under the tray as i was expecting which is nice.
In the next couple of weeks i need to get hold of a engine. Im after a 1.6 Zetec s engine. So that once i have finished stitch welding the front end of the car i can mock it up for fitting the engine.


Well thanks to crap weather i havent got anything done on the car this weekend but i have picked up a set of solid top mounts thanks to dazzle.

Getting a bit ahead of my self as i dont have any shocks at the moment but slowing getting getting hold of the parts i need as i have just ordered a new front panel, a underseal gun and a lot of underseal.
I have managed to get a load of sheet metal for a grand total of nothing from work and at the same time i have got a Zetec S engine from a friends who dad wants him to get it out of his garage, so getting that for a drink. Been having a good week this week. Be picking that up in the next week and start mocking up for the engine mounts.
and for zetec_xr2 i got a pic of the sticker

Well the postman had a good present for me today...

Just need to get around to actually doing some work on the car. The weather is meant to improve for the weekend and i have friday off work. Hopely get a lot done in a long weekend.


Well got the day off work so decided to get ahead on the car.
Rust cut out

Patch Cut

Welded

Ground Back

And again Rust cut out

Patch cut out

Half of it Welded

The rest of it welded

My welding is starting to look like fairly good if i do say so myself. Did get my dad who was a metal worker at some point to give me some pointers.


Cut out yet more rust.

Hole filled.

Then onto getting the bits that need renewing inorder to fit the front panel

New piece to be welded on.

Got half way through welding on the new piece and i ran out of wire.
I have a couple of days off work this week. So will be going to the shops tomo to get some more wire, primer and gloss black. Im going to be doing the engine bay gloss black. I need my new engine and engine mount to turn up before i can paint the whole engine bay but i want to do the bit between the front panel and cross member as it will be difficult to to do when the panel is on.
So as progress on the shell was brought to a halt. I decided to do a bit of tidying around my workshop/bedroom.
Before

and with a bit of shelving added.

I also picked up my SNAP ON air compressor. Just need to wire it into the fuse box and get some air line and it'll be ready for me to spray the car.

Last couple of bits left to do.

Little bits on the other wing

The layer of grime was sooooo thick i needed to take a picture. Took ages to get it off.

Once i had done that i moved on to stitch welding the front end. Done the engine now. I cant actually think of anything i need to do before welding on the front panel. Cant wait for it to start looking like a car again.

Well the front panel is ready to go on but i want to leave it off till i have made up the new engine mount and put the new engine in just so i dont damage the front panel. The new engine should arrive between next wednesday and friday. So in the mean time i have...
Got my new seat fitted...

MMM Carbon
Hammerited a load of bits.

I have hammerited more than just the tie bars and tcas but forgot to take pics.
My new inlet manifold has turned up as well.
All slowly coming together gonna try and get the rest of the welding done this week. Although i feel like that is all i have done to the car and it seems never ending. But i thinking im getting there. Cant be that much left to do.
Once that is done i need to get the air compressor working then make a start on undersealing the arches and underbody.
Cant wait to have it back on 4 wheels!!

 

[jhot80]

Well thought i would have a go at sorting out the dent on the roof on the car from where the previous owner drop a set of ladder on the side of the roof.
Welded a bolt to the dent.

Pulled and tugged at the bolt. Then grinded it off and i was left with something that kinda looks like what the roof is supposed to look like. With a bit of filler and after paint you will never know.

I have also got my air compressor working now so i can underseal the arches and underbody once i have bare metalled them. Once that done i can start putting bits back on the car. Like wheels be nice to have a car with wheels!

Finally got around to welding in a rear strut brace. Took me ages to get ends the right shape.

Then moved onto undersealing the rear arches.
Bare

Undersealed

The car finially has a face again!!! Although i still need to get a new bonnet.

Which meant that i could put the underseal on front arches and be done with using that horrible stuff.

Underseal being finished means that i could put some of the rear suspension on and i had to move the car so that i could weld on the drivers wings as it was rather tight to the wall. Althought there is only the bare minimum of rear suspension as i still havent hammerited some of the bits.

Well i have not done much work on the car as i am low on cash and working a lot.
But just so i dont wanna leave the car sitting there having nothing done. I have put on the newly painted tie bars and tcas.

Not very exciting update but come pay day this week i will be getting on with painting the inside and putting bit back on the car.
I also got hold of much nicer looking and more comfortable harness for the drivers front seat. Much better aswell as it a 3" shoulder strap.

Also found out from machine mart that the 130 quid electric motor that i bought a couple months ago that s**t itself a month after i bought is not going to be repaired or replaced i got my uncle who is a electrician to wire it in. I trust he did it right. But they say he didnt and the warrenty is void w*****s.


Progress at last!!!!
Pay day has come and i have spent most of it already but i have fixed my air compressor and i have painted my interior. Which has come out ok... ish im not really happy with it but it will do til i come afford to have pro paint it for me.

Primered

Top Coat

Im sure come of the more keen eyed will spot the imperfections. Looking forward to putting bit back in the car again.
I have also finally bought a new bonnet for the car after 18months of saying i need a new one.


Been a long time since i have posted a update in my car but then again it taken a long time for me to get anything done on it as i dont get much time away from work to crack on with it. But with a week off work come progress.
Before i could do anything i needed it on all 4 wheels so needed to put in my top mounts which look awesome.

Next some work on the bonnet. I got it for a tenner so cant complain too much but it was mint, bar the worst paint i have ever seen until i dropped a spanner on it. Because of the bad paint i couldnt just key the surface needed to cut it right back.

2 and a half hours later.

Then on to the engine and gearbox mounts. Well happy with how the mounts have come out.

In the engine bay and leveled.

I was going to try and use the gearbox mount that come on the box. Think its from a focus so it was a bit too tall so needed to make something.

The difference a decent welder makes.

Meant that this came out quite well.

Then the otherside needed something that was level and something to reinforce the inner wing a bit.

Done just the lower steady to make but im gonna make a bracket that comes off the original rear creadle mounting points. So as soon as i get my engine crane back from my mate i can get the engine back out then prep and spray the engine bay at the same time as the bodywork.
I have got the body work preped and in primer just wait for a couple of days of good weather to come up and the car with get some top coat.

Bit of prep and masking.

Primered

While i was waiting for it to vapour off. I put some top coat on the bonnet needs a bit of cutting back to make it nice and shiney.

Next of the list was get rid of the patchs of rust on door.

So just need to prep the door for spraying along with the absolutely mint door i got for free off a mate. Result!

Just need to get the top coat on the car then i can start putting the car back together. Getting rather excited about it. But need the good weather to do the paint. I can't wait to get the paint over with and have a car again not just a pile of pieces.



The car has been painted. Well happy with it!

Looks so good.
I have also painted the door havent got a pic of the outside of them painted but there almost ready to go on the car.

Going well tomo will get the black around the windows done then i can start putting bit back on the car. Still needs flatting back a bit and then a bit of compounding but can do that wiith the windows and bis in.

Whats the boot originally off?
Hurry and get this spraying done, i wanna see the outcome.
What you doing on the inner rear quarters? Leaving the cards on or off?

Im gonna make some door cars to cover the rear quarters, there not very pretty. Its the original bootlid that was on the car when got it.
Well the spraying is all done im gonna re do the bonnet as im not happy with it as it hasnt come out as well as the rest of the body. but i did the black around the windows yesterday.

I also assembled the doors but i thought it would be a good idea to put some newspaper between them to protect the new paint when i put them away how ever the ink transferred im hoping that it will come out with a bit of compounding.

Also sprayed the side mounts for my seat and the gearbox mounting plate.

and then today i have taken the car from a near bare shell only had the bare minimum of rear suspension to scoot it about to this.

Doesnt have an engine but i made up for it with some realistic engine noises generated by me. lol
In a day i have...
Fitted all the windows
fitted the doors
fitted all of the front suspension
fitted the rear brakea and handbrake
fitted the petrol tank and filler
fitted the steering rack and column
Changed the track rod ends
fitted my seat with the fresh side mounts and the harness
fitted the bonnet
fitted the bootlid
fitted the sun roof
fitted the rear lights
and i still have a s**t load to be done. Namely sorting out the wiring loom, which im slightly drean mostly because im fitting stand alone management dont know what bits of the original engine loom i need to keep i can find out but it is easy to ask?
and i need to tidy up the bodykit. Has a little bit of pitting on it. I have seen threads of people asking about restoring it but i cant remember how its done. Sanding with wet and dry? but what grit?


Well been a while since I have posted up any sort of update. Haven't got anything major done. The bodykit is back on the car and most of what interior that im gonna have in there is there now and I was going to stick the engine in as it was but glad i didnt as the bearings were on the edge and the cam belt had ben rubbing against something. So now i have stripped down the engine ready for rebuild.
Some pictures to make this interesting.

The black stuff is fibre from the belt.

Still so much left to do and to buy.
Wheels still need refurbing.
Still need engine management
Still need a pedal box and to sort the brakes
clutch
gear linkage
decent suspension
make an adjustable panhard rod
reassemble engine
Change the pulley arrangement to work with a different alternator and no power steering or air con.
some sort of speedo to work with electronic pick (undecided whether to go full digi dash or just a dial with odometer)
And a mountain of little bits that i have not go to go with the puma engine ie starter.

 

[jhot80]

Well have got a few things done.
The Dudd engine is in place for be to begin putting bits in around it.

I've dropped off the rear beam to make the brake line to go on it.

and done.

I have also got my turbo a TD04L and what will be the exhaust manifold when i have done a bit of grinding and welding.

Bit by bit getting there.

Update!
Well put the rear beam back on the car and while i was at it adjusted the handbrake cable as it wasnt really doing much. Small improvement. i might have to change the shoes as its still not hugely good.
Rolled the car down made start on the exhaust manifold.
First thing i noticed. The turbo just about fits behind the engine let alone being able to mount it nicely on a manifold. The manifold i have is fairly compact and it didnt go onto the engine either.

So had a site down with a drink scratched my head for 10mins.
Came up with 2 ideas.
1st was mount the turbo above the enigne like in andrew@A.L.D's S3.

my second idea was to mount it over the gearbox like the area six zetec manifolds.
Well the over gearbox would be an expensive one either in materials to make one myself or haveing one made. I can cut and weld the current one to point the way i want it. Well since i have already started cutting up the current manifold i've got nothing to loose trying it that way.

I havent cut the manifold for it yet but im 99% sure u can cut and re weld it all once i have borrowed my mates welder and bought the flange.
Although if i wait a bigger turbo im gonna need to move it to above the gearbox as theres not much room. But this will get me by till i want to fork out the cash for the tubular over box one.

Time for my weekly update.
I have made a start on the flipping the manifold over to mount it above the engine.

I need to open out the flange a bit so it is a move of a taper down to the tube then a step.

Then i looked at the tube and realised that the outer tubes were unbending themselves.

Not the end of the world just means that when i weld it back together ill have to weld the inner 2 then heat up and bend the outer 2 and weld them before they move back.

As i dont have the welder atm kinda as far as i can go atm as it needs welding.
Then onto the alternator mount. As graham said bit of Cardboard aided design CAD.

Half way there.

Alternator on.

Just end to get a duratec or blacktop zetec tensioner pulley and im sorted.

Havnet done a huge amount in the last couple of weeks. Althought saturday i was only gonna do a couple of hours and was outside all day as the weather was too good not to.
I have managed to unravel the wiring loom remove whats not needed and tidy it back up and repair the damaged sections.
Only go 1 pic of it done waiting for some braided covering.

and i have also made a path for the gear linkage and hooked it all up really good position position for the stick as well. getting very excited as things are progressing.
I have got myself a duratec pulley tensioner for a fiver bargin! I have also bought another carbon fibre seat along with a clutch, turbo flanges, 440 scooby injectors. They should be arriving in the next couple of days well excited.
As i have another seat coming my RS Turbo recaros are up for sale if anyone is interested. I will get a sale thread up this week.

Havent got a great deal done in the last few weeks. Couple bits here and there and gave the car a good clean.
Been slowing buy up bits beginnning to run out of bits to buy which is nice.
Few pics of the bits bought.

Gotech Pro X Management it is a rather good ECU from the specs and the Loom is quite well made shame that i need to change the injector connectors for different ones to suit the Scooby 440cc Injectors

Couple of turbo flanges which will be coupled with some stainless tubing once bought.

5 paddle clutch which should be manly enough,

Well had myself quite productive day. Picked up the welder from a friend on mine then dragged the engine out the workshop as it was prob the only nice day we have had in a couple of weeks.

The umbrella is because i didnt trust it not to rain.

Chopped about and put in about the right place.

All MIG up.

Another piece of the puzzle.

And the flange on top. Quite proud of how it has come out!

Sits nicely in the engine bayOnly issue is it sits a bit proud.

I've got a couple of things i can do to make it sit lower. Firstly the upper drivers side engine mount needs to come down about 15mm anyway. I as it is a escort mount i can get 1 smaller. Next is chopping out a section out of the collector and re weld it. Then theres a section of the bonnet inner skin that could be cut out. Failing all that just raise the bonnet a little bit. not a fatal problem really.
The next problem with the manifold is that because of the diameter of the primaries and its just s**t design its good for getting the engine running but i doubt i could easily run more than 200bhp through it.
Going to buy a load of bend and flanges and make a equal length manifold. Done a fag packet drawing of something that will be up to that task.

Complete package.
Whilst having a think about the manifold. I thought I would have a crack at another bracket needed for the engine.

Can you tell what it is yet?

Fit for the job.
All in very happy with the days work!


Well made a start on chopping a section out of the manifold to drop the turbo down a bit in the engine bay.

The bit i have removed.

Welded back together. The keen eyed will spot it is a bit on the piss. Done that so that compressor side of the turbo is dropped down a bit.

and on the engine.

Before.

The manifold before

and after.

Havent had a chance to get it in the car as it has stopped raining all day. So once the weather is a bit better i will put it in see how much room i need to find.
An option I may have to look at if i upgrade to a VF23 is use an external wastegate that i will incorperate into the Stainless manifold im gonna make.
Had my second carbon seat for a little bit now just hadnt taken a picture to show it. The cover is a bit dodgy but gonna get new covers made for both seats so that they match. Just black I think.

Right thought i would make a start on the downpipe.
First though needed to make a little adaptor to take the 2.5 downpipe to the ashley system. Once the car is MOT'd i will be making a 2.5 system whilst i run it in. Save a bit of money to get it on the road and as it will prob take me a bit of time to get the engine run in.
Anyway on with the pictures.

Going together bit by bit.

Test Fit

Then to weld it up. My welding is getting good i just need to work on being consistant.

Just need to make a little L bracket and weld it on to support the downpipe and it will be spot on.
I have also got new engine mount which is a bit smaller then the other ones so i can shut the bonnet now with turbo on.

Also got some big end bearings for £20 from america as i could find any that actually fit in the UK. ACL ones as well so should be up to the task.

Well my ratty daily failed its MOT on welding which was a morning of work and have done it and emissions. Started looking at CATs to get it through then thought to myself can i really be bothered to faff with this car anymore.
So been out about bought myself a new daily.

£1850 good history, 64k 12months mot and 4 months tax. Got to replace a powersteering sensor and service it but i think its a bargin right there.
However this is prob gonna slow progress on the XR2 as its a bit more to run then a 1.2 fiesta but I now dont feel in such a rush to get the XR2 on the road, and will do things less on the cheap and more how i want it, as i have something interesting to drive in the meantime.

Well have done a bit of work on the car for once rather than just buying bits and stacking them on my shelf.
Made a start on the boost hoses. Just need to wait for the Julibee clips and the bit of hard pipe top turn up and i ill have them finished but thanks to the charge cooler they are quite short. Should help with keeping the lag down.

I gave the car its first proper clean in months. Was begining to look quite sorry for itself. I think that clean is what gave me enthuiasum to do the other stuff becuase it look bloody good when its clean just need to do the pin stripping to tidy up the line of the window surround.

I have honed the block and put the pistons in with the fresh rings. Just need to buy the main bearings and some gaskets and the engine will be ready to go in.

and i did make a start of wiring in the ECU and took some picks as the loom does look rather good but guess i didnt.
Picked up some aeroquip connectors for a bargin price but they were cheap and i bought them before thinking too much and they are a size too big for my swirl pot.
Got 7 and 2 can be used for my turbo oils line but other than that the rest are now for sale.

Spent my evening titing around doing little bits for the car.
Made up one of my Boost pipes.

Welds need grinding flat as i made the pipe from left overs and the end werent the tidiest to weld with. Cut the leg to length and they will be spot on.
Made a little tool to bead the end of the pipes but i made it from a small pair of mole grip i have lying around that are a bit tired.

Isse one with it being small its very hard to put a lot of force of the pipe to bead it. Secondly I need a 2.5 inch exhaust clamp not the 2 1/4 i have used. This should work on the smaller pipe i have coming for the hot boost pipe but the big one its not making a big impression.
Wasnt expecting it to be perfect firrst time but would have been nice. lol.
Gonna buy some big mole grips and a 2.5 exhaust clamp and i should be away.

 

[Ian_182]

Very good effort i'd say.

 

[Riad]

Awesome Read!

 

[Jonff]

Impressive stuff. Certainly saved it from the doom of rust.

I'll be definitely keeping an eye on the progress of this.

 

[welshname]

Mental. Looking very nice

 

[yeecup]

Fantastic work! Love xr2's, remind me of my youth, my mate had a mint f plate one in mercury grey, loved it. Nearly bought one 3 years ago will buy one at some stage I'm sure.

 

[Gaz.]

Fair play for doing everything yourself, hope it all pays off.

 

[GiT]

Would love a mint XR2. Mk1 or 2 tbh.

Love this little project.

 

[James28]

Just read the whole thing.
That is unreal the amount of work you've done.
You're only 21, how the hell do you know how to do all this stuff?!

 

[Jekyll]

Nice project and a great read

 

[Daniel]

Great read! Thanks for that.

Keep up the good work.

 

[Gally]

Fantastic work mate, dedication is noteworthy I must say and although not perfect you should be mega proud at some of that fabrication and welding!

 

[jhot80]

Just read the whole thing.
That is unreal the amount of work you've done.
You're only 21, how the hell do you know how to do all this stuff?!

Well i was 21 when i got it, closer to 24 now.

Thanks for all the messages. It is getting there not too much longer i hope till its running again.

 

[DIDITNO]

Good read and work done. I had one of these 17 years ago. God im old. Still remember the reg of it. Was a cracking car in there time.

 

[Daz.]

Good effort! Always love to see a finished project!

 

[VeinAST]

Great work

 

[andywa]

Superb read mate and a great project.

 

[Adam_vxR]

I love it mate looks soo clean and tidy now I used to banger race mk1-2 fiesta along with Novas and metros and by far I loved the fiestas more just look so much nice

 

[Ash']

Hats off to you

 

[Alex H]

Awesome Makes me wish mine looked as good!

Good place for bumper strips if you're still looking: http://www.rubbertrim.co.uk/body_mouldings.htm

 

[NickMelson]

Looking really good! Nearly got one of these before my dci. Tempted to sell and get one last night after reading this... God dam you! :dapprove:

 

[Englebert]

Wish i had the ability and patience that you have! Well done.

 

[Gray]

Great write up so far!

 

[Addicted]

Fantastic so far, the amount of rust was worrying but you've taken car of it all very well!

Wish I had room/knowledge for a project

 

[Chip-mk1]

Cool car, I love the little small block 16v ford motors, would like to have a go at a 1.7 turbo one at some stage.

 

[jhot80]

Fantastic so far, the amount of rust was worrying but you've taken car of it all very well!

Wish I had room/knowledge for a project

Well it was rather depressing keep having to cut rust out and weld. Was a good 3 months solid welding. But makes you think we you see a good on the outside old car whats it like underneath. Usual as bad as mine.

But its getting there.

 

[Chip-mk1]

Well it was rather depressing keep having to cut rust out and weld. Was a good 3 months solid welding. But makes you think we you see a good on the outside old car whats it like underneath. Usual as bad as mine.

But its getting there.

older xr/rs fords are terrible for it IME, people spend ages polishing the paint keeping it mint while they slowly rot away underneath.
My rs500 shell was terrible when I took the bodykit off, loads of rust tucked away.

 

[jhot80]

Cool car, I love the little small block 16v ford motors, would like to have a go at a 1.7 turbo one at some stage.

I think their alright little engine weigh very little compared to other engine of similar capacity. Exhaust ports being quite small does limit them a bit but not massively.

Have had some flak from people that really dislike them.

 

[Chip-mk1]

I mapped an ITB one that made just over 180bhp on a standard bottom end (other than pocketed pistons for the lairy cams), I was very impressed and that was the non VVT 1.6, so nowhere near as good as the puma one really!

 

[jhot80]

I mapped an ITB one that made just over 180bhp on a standard bottom end (other than pocketed pistons for the lairy cams), I was very impressed and that was the non VVT 1.6, so nowhere near as good as the puma one really!

Well the inlet ports and the exhaust ports are both bigger on the puma head. The inlet quite a bit bigger.

And i think the puma engines have a stronger bottom end. There a few running 250 on standard bottom ends. When i have a forged engine to go in. i might be tempted to crank the boost and see what the engine can take before it pops.

 

[Chip-mk1]

250 sounds a reasonable expectation if its decompressed.

 

[jhot80]

250 sounds a reasonable expectation if its decompressed.

Yer dont think you could go more than 180 without lowering the compressison. Would prob melt very quickly.

 

[jhot80]

Bit of an update.

Took last friday off and did a few things on the fiesta.

Managed to get the bottom end mostly built up. Need to get a dash connector welded on the sump. But as i only had that day to do thing i kept forgetting to take pics. I do have some tho.

I have shorted the fuel pipes under the car because they touched the downpipe and fitted up the lift pump next to the fuel tank. Again no pics tho.

The boost pipes look nice all fitted up. Need a lick of paint and trimming to get a bit of a better fit.

Ive also done all of the pin striping which looks much better. Can see a bit of it in the pic above but need to take a better one.

On my list of to do convert my arb from the crappy ford link to rose joints and fit. Make my panhard rod adjustable. Do a bit on them tonight and tomo morning. My mate took a load of pics that day but i havent seen any yet.

Bit of a crap update...

 

[seb]

Car looks great!

 

[domsclio182]

Love xr2's great project

 

[Howell]

boys got skills!

great project