The Build P16

jimmyesh on Thu Dec 31, 2009 4:40 pm

Right chaps I'm well and truly back in the saddle! :Q

Had a busy couple of days in the workshop and things have progressed a little. ๐Ÿ™‚

Firstly, a pair of new Toyos have been fitted on the front rims to replace the knackered Yokos that were on there.

From my previous updates you'll remember my stroke of luck with the "scrapyard special" Focus TDDi hard boost pipes ๐Ÿ˜• Basically they fitted my setup almost perfectly and I was happy with that. I did try joining them together with coupling hose and jubilee clips but it made things look too cluttered and unprofessional for my liking ๐Ÿ™

I decided to weld them together instead and here's the results;

Boost/induction pipes welded together and dummy-fitted;

01 filter
Removed and sprayed with black lacquer;

Re-fitted once paint dry;

Finally got around to removing the old standard (HUGE!) fuel filter and fitting my nice little Sytec "bullet" anodised filter;

As I just want to get the car running and on the road ASAP I renewed my knackered MK3 lower arms with some new MK 3.5 items - (I will buy some fany adjustable rose-jointed items but I just can't justify shelling out ยฃ2-300 right now). I needed MK3.5 ones as I'm using hubs from a 1995 Fiesta Si and I had filed down the original MK3 ball-ends to fit the later hubs when I dummy-fitted the driveshafts etc and didn't want to run the risk of forgetting I'd done it and venturing out on the road! :aaah:

After what seemed like an age, I managed to find an original rubber bumper splitter on ebay for a couple of quid (mine was wrecked). This was fitted and my smaller number plate is now below the FMIC. ( I will be getting a different FMIC or re-manufacturing that one to make it more central once I've got the car running).

06 new splitter

07 front end
This last job was one of those boring, tedious affairs that you never really feel any reward for doing :rolleyes: The original cradle that goes under the gearbox was useless with the MK3 Mondeo rear gearbox mount in place and although I no longer required the cradle for gearbox mounting purposes I still need it for the front towing-eye and to keep much-needed strength/rigidity in the car. I chopped the original cradle and modified it to clear the gearbox mount, whilst still retaining ample strengh/rigidity.


10 cradle

11 cradle
Apologies if anyone has tried to read through this topic and noticed that all the old pics have gone! Basically I made separate photobucket albums for each car I've had to avoid confusion/clutter. When/if I'm ever bored enough I'll go back thorough and re-post all the pic links ๐Ÿ˜›

Happy new year all of you, have a top 2010! :Q ๐Ÿ˜€

jimmyesh on Thu Dec 31, 2009 5:32 pm


dangerousdave wrote:

looking good pal whats left now just the ecu?? ๐Ÿ™‚

Yeah pretty much ๐Ÿ˜€

Had to take the o/s driveshaft off today as it's just a tad too long and butts into the back of the "socket" part that the tripod slides into, need to get 15mm taken off it to allow it to move freely and not suffer a catastrophic failure on the road! :aaah: Still need to get the N/S one shortened too...

ECU should be bought soon - had to postpone my original purchase due to Christmas spending, I won't put a car before my family and I won't get in debt (probably why this project's taking so long! :rolleyes: ).

Other than that, just ecu + wiring, 255LPH fuel pump, dash wiring and some power steering plumbing. Oh yeah the gear lever mechanism needs moving back about 10-15mm to allow all gears to be selected without it fouling the trim. We're getting there eventually... :

jimmyesh on Fri Jan 01, 2010 8:27 pm

After recovering from the mother of all hangovers, I got in touch with a very helpful guy (Eddie) who maps/builds Megasquirt V3's in Colchester :Q I'm collecting the V3 from a mate in Kent this week and Eddie is going to change it from the VW/Audi 20V Turbo map to a map that will hopefully get my Duratec burning and turning! ๐Ÿ˜€ I know there's some brand-name snobbery in the car modifying world and some people sniff at using Megasquirt but at the end of the day, if it's mapped properly and set up correctly there's no reason it can't run an engine as well as Omex, Gotech etc... I'm saving a hell of a lot of money going down this route too, which is never a bad thing! :aviator:

jimmyesh on Tue Jan 05, 2010 7:08 pm

Had a busy couple of days on the car with it up on the ramps ๐Ÿ™‚ I've been doing all the horrible "forgotten jobs" that crop up in a project such as this - you have a lovely idea of how your conversion will pan-out but you forget all the fiddly, crappy jobs that need doing that are unrewarding and mundane! :rolleyes:

Firstly, I sorted the gearshift issues by moving the whole assembly back about 10mm which now allows gearchanges without the lever mech hitting the trim!

After that I made a heatshield/cover for the exposed mechanism. (Was all sealed around the edges later on).

12 underside

13 underside
The MK5 Fez PAS cooler was mounted somewhere where there's still actually some space! :oooh: It's all plumbed in now and all pipes suitably P-Clipped out of harm's way.

14 pas cooler
Both driveshafts were sent off to Recoprop to be shortened today - they should be back with me within a couple of weeks and fitted ๐Ÿ™‚

14 shafts to be snet
I also took delivery of a Focus RS MAP sensor today but still sren't sure what boost-control solenoid to use ๐Ÿ˜•

I collect the ECU from my mate, Si in Kent this weekend and have already begun sorting connectors etc for all the sensors etc to be connected and for the loom to be made.

I still need to work out where to site the PAS reservoir and fab a take-off plate for the feed to the pump (using Fiesta ST MK6 Pump which uses a reservoir that bolts on top of the pump but my bonnet won't clear it that way! ๐Ÿ˜ฅ )

Also need to get hold of a Focus MK1 2.0 loom/Ecu to drive my Dash (fun, fun, fun! :aaah: )

Still need to buy an uprated 255lph fuel pump (save that till next payday now...)

We're moving towards the home-straight now and things are looking good :aviator: