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Discussion Starter · #41 ·
Stock everything powertrain to start with. Curious how I'm going to fight through dealing with the ABS / stabliity control system, but want to at least get it roadworthy again and then figure it out.

I know they building the cars with steering stops, some kind of insert for the front subframes, and other strengthening measures. Haven't made any headway there.


down the road, I'm kicking around doing a wavetrac, and a 4.3 final drive or similar from Pumaspeed. The stock 6 speed is silly.
 

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same here. i guess we'll be dealing with problems once they arise lol.
now i got this huge question: i took the whole car apart and now putting it back together.
pretty much all the wires are in place
BUT!
spent hours looking where to hook up this connector:
one end plugs into this ring where ignition "lock" is but the other end which looks like round optical connector is nowhere to be plugged!
looks like it has to be connected somewhere in the middle where the stereo wires are but i just don't freaking see anything!
i have two sets of wiring's: one off n/a Fiesta and one off my ST.
they both have the same connectors for ignition (recognition of the right keys i think?)
two ends as i mentioned and two sort of optical sensors embedded into dashboard on driver's and passenger's sides.
I'm sure You have those as well.
would You please help?

Stock everything powertrain to start with. Curious how I'm going to fight through dealing with the ABS / stabliity control system, but want to at least get it roadworthy again and then figure it out.

I know they building the cars with steering stops, some kind of insert for the front subframes, and other strengthening measures. Haven't made any headway there.


down the road, I'm kicking around doing a wavetrac, and a 4.3 final drive or similar from Pumaspeed. The stock 6 speed is silly.
 

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Discussion Starter · #43 ·
Was there a photo? I'm a bit confused as to what you are referring to.

I PM'd you an email address you can contact me at to help you through it.

There was an ambient light controller in some of the cars that you don't have to use.

Did your NA Fiesta also use push button start?
 

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i'm building the ST. n/a Fiesta has regular ignition but was bought with front end damage for couple hundred bucks because i needed some body parts, that's all.
though it has the same wiring part and i just mentioned it for referral.
Now
the ST has this sort of ignition lock which is not a real lock, because there's no key hole, no cylinder and such. it's just a housing for it.
but still there's a ring around it for what i think is a receptor with a chip that recognizes a key.
i don't think it's for ambient light because there are no power wires connected to it.
that piece of wire i'm talking about is plugged into it with one end then wires split and two ends go to tiny sensors that are in dashboard itself
(i think they're tiny motion sensors and can"t be removed, they're kinda glued)
and in between them there's a plug with three wires but output is optical and it's a small round one
and for that particular one i can not find corresponding plug =o(
will take pictures later but if You trace the wires coming from the ignition housing i'm sure You'll find where the other end plugs.
 

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Discussion Starter · #45 ·
Shoot me the photo. I'll look at it and get you some info.

I'm studying up on the car electrics a bit to understand what can go and what needs to stay.
 

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You must be right, i just went to Ford to buy an oil filter and took those wires with me.
parts guy run the part number and we looked at pictures so it might be just the ambient light
one end plugs into something under center console and the round side plugs into the light rail on passenger's side.
Edited:
sorted everything out. both plugs fit.
too bad i concentrated on one of them w/o checking fitments of others.
half a day lost!
 

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Would it be easier to use an aftermarket engine control system? Cars are certainly different than when I ripped ever bit of factory wiring out of my SAAB 99 and put all new of my design in.
 

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Discussion Starter · #48 ·
Would it be easier to use an aftermarket engine control system? Cars are certainly different than when I ripped ever bit of factory wiring out of my SAAB 99 and put all new of my design in.

I don't think so, at least right now.

The goal for this build was going as low effort as possible to get ~200hp in a FWD car with parts readily available off the shelf.



I'd like the restraints module to not be in the car, if possible. I don't know if it acts to enable the fuel pump, or if it just disables it after it detects some collision. That will be fairly easy to check once it's back together.

The ABS module creates the vehicle speed signal by reading the wheel pulses. It'd be easier, for me, to take those pulses into an arduino or similar and send out that speed signal on the canbus than it would be to re-tune a standalone ECU.

But first things first, I need to get the mechanical bits all stuffed back into the car, and then lay in some wiring and see what I have.
 

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I don't think so, at least right now.




I'd like the restraints module to not be in the car, if possible. I don't know if it acts to enable the fuel pump, or if it just disables it after it detects some collision. That will be fairly easy to check once it's back together.

.
as i said before i bought two fiestas. n/a for parts and ST for the build
ST was rear - ended but no blown airbags
n/a had a relatively small damage on the front end but driver's airbag was blown along with a seat belt retractor
but the car started and run and was drivable.
well onto and from the trailer =o)
i think impact sensors can be played with/removed leaving circuit open but with required resistance so after hitting bumps hard or hard landings airbag module wouldn't act.
 

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Discussion Starter · #50 ·



Finally got around to getting the holes for the seat inserts punched out and welded into the seat tubes.

Managed to break an endmill trying to hamfist it through the tubing - was using 4 flute instead of 2 and should have known better.
 

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confirmed: car starts (yeah, started it today!) and runs with airbag module unplugged.
PS i used threaded inserts from Home Depo for my seat mounts.
 

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nope. just service needed (wrench), ABS, tire pressure and stability control along with airbag.
will see what happens when it's back on the road though.
PS. i don't know what You're going to do about evap system in the back. i was going to get rid of it first and didn't get it inside. but it'd surely set off CEL
so after long consideration i pulled evap pipe through the left rail underneath.
since it's made of steel i cut it near the exit and connected two pieces with flexible pipe.
it exits where the long oval hole is in the very front of the rail right behind the bracket connecting rail to front crossmember.
had to struggle a bit with the front piece of it bending so it'd enter that hole smoothly.
 

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Discussion Starter · #54 ·
Good question. Haven't figured that out, either.

I futzed with trimming the dash more to get it around the cage, but I really need to buckle down and fix up the firewall where I brought the cage through. I'm just not feeling like making myself into a little ball of a human to work inside the car today.

With the Custom Cages kit, I can't reuse the HVAC case. I haven't looked to see if I can modify any of it, but I'm not too hopeful.
 

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OEM HVAC sucks and weights a ton not mentioning it has about a hundred sensors and electric motors and solenoids.
my buddy is building turbo AWD Fiesta with Cosworth drivetrain and for heating he's using WRC style heater with engine oil running through it.
i'd love to do the same but in production it has to be original and i'm too poor to go open.
Now
back to rear brakes: i think i mentioned swapping ST rear axle for n/a one which i parted out but surely don't like drum brakes much
(though when i started rallying we had drums on all four corners and somehow managed to survive lol)
anyway i found this kit, emailed the guys and they said with this i can bolt on calipers and rotors off my ST to n/a beam
i think it can be bought relatively cheap off of autowreckers
http://goldcoastautomotive.com/cgi-bin/p/awtp-product.cgi?d=gold-coast-automotive&item=64912
 

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Discussion Starter · #56 ·
That certainly looks simpler than the mess I've made for myself trying to adapt the beam itself to use the ST hubs that include the mounting ears.

Price seems a bit steep for what appears to be two flat chunks of metal, though.
 

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Price seems a bit steep for what appears to be two flat chunks of metal, though.
i was thinking of making them myself lol
but one day (most likely two) would be lost with all the measurements. manufacturing, fitting (frustration because it won't fit lol) correcting and such.
so either spend $175 and do something useful that day instead or losing time ....and time= money
for now i'm having drums in the back and if i have time and 175 bux i'll buy those
 

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not sure if You're going to relocate battery to the back but if You do i just want to share how i pulled my "+" cable through firewall.
where wiring harness from engine compartment goes inside there's a sound symposer flexible pipe in it.
but there's some sort of restrictor right in the middle of it though and i used a long drill bit (fairly big diameter) to get rid of it and drilled through by hand
and pulled positive cable through it alone with those two (extended) wires from negative post.
cheers!
 

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Discussion Starter · #60 ·
I am blessed with having the car completely torn down, so I have a lot of access to everything.

I spent a bit more time fitting up the stock HVAC case. It's a bit heavy, but it will work and I already bought it with the car :D

Turns out that the fact you can take it apart with the screws was pretty useful for figuring out how to snake it around the cage, and work on the parts that needed trimmed and cut to fit.

I need to get the mounting nailed down very soon. It's starting to drag my energy level down messing around with it.


I got approval for my cage certificate yesterday, so once that comes in the mail, I'll work on getting the car logbooked. Minor victory there :)
 
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