1986 Ford Fiesta XR2 1.7 VVT Turbo

[jhot80]

Got the arb converted to use rose joints.

Old tabs drilled out.

Kinda looks like the same picture but thats either end.

Then welded the shouldered thread into the arb.

And all done. I have cropped the thread down to size.

Went to put it on the car and as its summer the heavens opened so left it for the day.

Also took a better pic of the outside to show the new stripes. Just need to buy the bumper stripes and stick the kit on properly and it will look spot on.

 

[.Kev.]

Epic build mate, nice to see something different.

 

[jhot80]

Had a bit more a of a play about with my Hard pipe crimper.

Came out quite well i think.

The pipes just need a lick of paint, some jubilee clips and that one item checked off the list.

Also moved the fuel as almost touching the downpipe wasnt a wise chose. lol and it will make the fuel pipe route much simpler and less hosing.

 

[jhot80]

Been a little bit since an update.
Got myself a decent work spot sorted up ready for the winter.

Then set to making some flanges with -6 connections for the fuel rail.

 

[jhot80]

A lick of paint.

Then set about making my adjustable panhard rod.

all cut up.

finished article.

Blanking plate for the idle control valve.

Now i have a good space to work i will be getting more things done. i have loads of things to be getting on with but was a pain in the arse get everything out to do some bits.

 

[Leeshez]

Amazing transformation. A job well done ,

 

[jhot80]

Had a good full day working on the car at the weekend.

Got the side skirts properly glued on.

Tiger seal is horrible stuff. Will on come off my hands.

Next i wired in most things only the alternator, fan, fuel pump and injectors left to do but i go a bit bored of wires by this point. I am if i want to power up the ECU and download the map to see what its like it has the map from a 260bhp CVH turbo engine proper be able to make it work to get it running.

I also fixed the dodge electrics as when i put power to the car the indicators were going nuts. wipers turned on side light and more in the like. Spent ages chasing the wires to see if i had cut out the wrong bits when i was removing bits that werent needed anymore...

The indicator stalk and wiper have 4 connectors 2 which can only go in the correct place and 2 that i thought could only go in the correct place but i was wrong they were the wrong way round. Proper Palm+Face moment.

Also got the new lower torque linked started the old one was made in 10mins as i needed something to hold the engine in properly.

get some more done in the week.

 

[jhot80]

Got myself a new dump valve well recirc valve. The nice fancy valve that i got off a mate has a 32mm flange and i could find a 51mm t piece silicon with a 32mm take off. So got myself a standard VAG Recirc valve total sum of £8.91 bargin.

Next on my list was wiring and there is a lot of it. Started with the mess that I hadnt had the motivation to try and sort out.

Nipped to the breaker yard found a Puma 1.7 and pinched the connector that i needed for the VVT, temp sensors, reverse switch. I need to go back and get the TPS and connector for it.

All of the wiring in the interior of the car is tided up and all attached to what it need to be.

Although in the pictures i think i need to give the dash a bit of a scrub cos it looks a bit grubby.

Ill get the enigine bay wiring tidied up and take some pictures.

 

[jhot80]

Done a bit of work on the car over the week.

Couple of goodies that have turned up.

Nearly new flywheel for 16 quid bargin.

Valves all cleaned up.

Lapped the valves in.
The exhaust valves seats were actually in a bit of a bad state.

Head all assembled i hate putting the collets in so fiddly.

Head all on and torqued down.

Timed up

Everything else on. I thought i would use the little rose joint i have lying around to support the turbo hopefully little stress on the manifold.

 

[Scottie203]

an XR2 was my first car 18 years ago and still love them now

a picture of a picture mate so not the best quality,sorry[

url=http://www.flickr.com/photos/77308677@N03/6949000961/]

[/url]
002 by scott1532, on Flickr

if i had the time,effort and garage space i'd have another in a heart one beat

 

[jhot80]

Yer defo need the effort. Was starting to loose interest in it few montha back when i wasnt getting much done.

This is my second one. I was given a red colour coded one when i was 18. Always wanted one again after i sold it for going to uni.

 

[jhot80]

Got a few packages arrive in the last week.

Only took them 3 weeks to send me out this one.

My new big end bearings that actually fit properly. The issue is now the engine is mostly built it is the fiddliest thingy i have done on the car fitting the shell in the rod.

Once my sump has had the AN-8 connector welded on to it the engine is ready to go in. It is at the welders now waiting to be TIG'd Im hoping to get the engine in over xmas.

Some oil plugs and little fiddling with the management and it will be firing up.

Stay tuned.

 

[not normal dan]

Just read through this whole thread, what an awesome project really good to see something different. Always had a soft spot for these since me next door neighbour used to have one when I was 5 years old! Your work looks good too, top marks for going at it like you have certainly staying tuned!

 

[Jon.G]

This is awesome! Can't believe the amount of rust it had, you really did save it!

Keep up the good work.

 

[jhot80]

Well it was better then some of the ones ive seen people restore.

Doesnt help when my naighbour has cut a grill off his house with a grinder showered the car in metal the other day when i was out so i didnt realise otherwise i would have jetted it off straight away. So now the car is covered in rust stains and needs a machine polish.

Took me 3-4 hours to get all the metal off the car and just need to borrow my friends machine polisher and cut it back a bit to get rid of some of the scratch that i made getting the metal off. Least the rust stains arent going to get worse now.

 

[jhot80]

The final piece of the puzzle.

The sump has had the drain welded in. While they were welding it for me in the workshop they had this just come in from the painters.

Aston martin DB2 body shell. The paint is amazing they are doing a full restoration on it.

Couldnt wait when i got home to fit the sump and last little bits.

Fitted lovely

Finally all assembled and ready to go in. Which i am going to do today as it meant to be the only dry day. Well excited.

 

[jhot80]

The weather was quite good today so i cracked and got the engine in.

One hole

One engine and box

Almost together.

Then i got carried away and all excited as it was the last time i needed to put the engine in and forgot to take pictures. Most of the inlet side is in put alternator and starter and charge cooler.

Although the saxo rad is being a right pain to fit. I cant get it low enough that it doesnt hit the bottom of the bonnet. Might have to think a bit and be creative.

 

[Keyser Soze]

Get some Iron X to remove that grinder fallout. Doesn't need machine polishing.

 

[Scottie203]

coming on a treat now mate,great stuff

 

[jayxx83]

Wonderful project. Love it!

 

[jhot80]

Small update. Took some pictures of how much i got into the engine bay so far.

Fitted a bit of nimbus heat shief to protect the electricals behind the turbo.

The shorted the turbo drain pipe and fitted the turbo and manifold. Also fitted the new injector plugs which is so fiddly. Looks nice so far if i do say so myself.

Drilled the hole in the downpipe for my lambda sensors to fit in. First hole with the holesaw went through like butter. The second did this to the pilot drillbit

Dont know what grade stainless i bought but it proper fucked that up.

 

[MarcoB]

Did you keep it lubricated?

 

[jhot80]

Did you keep it lubricated?

Nope prob should have lol

 

[Richyy182]

What a project!!!! brilliant

 

[ABOO]

Love this pal. Love the car, and the fact looking through this thread makes me feel 17 again!!

Keep up the good work..

 

[Zmaster2k]

Wow just devoured this entire build love it!!!

 

[N90 GAT]

Well that was one way of spending my morning at work. Pure class mate, Unreal amount of effort.

 

[chris-182]

great read! subscribed..

 

[Mr R.]

You must be the lad who worked with my mate joe?

Scott.

 

[jhot80]

You must be the lad who worked with my mate joe?

Scott.

Yer thats me.

 

[jhot80]

I havent had much time to do anything on the car much but that hasnt stopped me buying bits for it.

SPA water and oil temp gauge
Simple boost switch/controller
air filter
bias pedal box
vts rad
slim fan
load of pipe work

Pedal box

Air filter

Which inside looks pretty pimp

I managed to find some time to get something done on the car today fixing my sisters puma for numtenth time.
Change the connector on the turbo to stop the pipe rubbing on the bonnet

Before

After

Got all the pipework for the recirc valve and the airfilter sorted althought the area where the air filter is maybe a bit tight. I think i may relocate it to be under the scuttle panel.

I also finished off the plumbing for the charge cooler rad and the coolant system.

 

[jhot80]

I am hoping to be driving it to the MOT station in april. Selling the clio is making that whole lot easier. Isnt that much left for me to buy now.

Shopping list
Stack speedo
Passenger seat sub frame and side mounts
fuel lines and connectors
engine consumables
new battery
few odd and sods

To do
Fit pedal box and plumb in the brake lines
plug the leak from the sunroof. was sure that i have sorted it but there was another puddle in the drivers side
finish up that engine bay parts
turnkey and start
sort MOT bits i.e. handbrake and one of the indictors
wont be too long now.

 

[Perry]

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?!

This.

 

[Perry]

Love these since my cousin had a B reg one when I was 16. Then my best mate at the time bought an E reg one with 18k on the clock in 1991 when we were 17. I eventually got one about 10 years later, but mine was a bit tired. Still sold it to a mate, then bought it back for a short while though. I'd love to have a garage and some space to attempt something like this, with either a Xr2 or another Mk2 Gti.

 

[jamier27]

Good work and great little car, I also remember having one of these when I was 17.... Such a unique exhaust note that I recall too...

what kind of budget have you managed to stick too?

 

[vRS LIL]

Awesome cars and an excellent thread.
Only recently sold my MK2 XR2 much to my disgust!
The amount of people that would come up to me and say "I used to have one of those" or have a story about a mate wrapping theirs around something.
will keep following this with interest.

 

[Gally]

Lil is it simple age that harms reliability?

 

[vRS LIL]

The beauty of them is their simplicity and ability to be able to work on them.
most reliability issues on mine were down to parts ageing such as the alternator etc.
Carb issues due to perished parts, standard was a must but service kits were cheap, fiddly though.
Bar that simple maintenance and changing of the obvious, plugs, leads, dizzy cap, rotor arm.
Paintwork was a beauty to get red again after three years of being stood outside!

 

[Gally]

The fixing is the easy part. My Dad was building them before I was sperm but parts are the major issue or is everything readily available?

 

[B16DOE]

Love it will keep my eye on this thread