JDG Build Thread (S280 Turbo, Full E85, Custom Parts & Rallycross Discussion)

[JDG]

I've decided to finally put together a build thread; so here it is! Lots of detail with plenty of SCCA RallyCross content and all of the custom parts I have built for my car.

2016 Ford Fiesta ST
White Platinum Tri-Coat
Base Model (Ford Racing Recaros Added w/ OEM Airbags)

Current Mileage & Fuel Economy (Updated 11/22/2020)
83,645 Miles
23.5 MPG (Fuelly Data, Mix of Pump Gas and Ethanol Fill Ups)



Current Setup

Powertrain
Stock, Unopened Engine **knocks on wood**
Amsoil Signature Series 5W-30 Synthetic Engine Oil

Turbo Technics S280 Turbo w/ Turbosmart Wastegate Actuator (~15PSIG Spring Pressure)
GoFastBits DV+ Diverter Valve
AET Vudu Ported OEM Exhaust Manifold
Whoosh Motorsports 3" Catted Downpipe
Thermal R&D Full 3" Catback Exhaust
Cobb Exhaust Hangers

Stratified 4-port Auxiliary Fuel Rail (X4TRA) with Split Second controller (95 lb/hr injectors)
Bravo Alpha Low Pressure Fuel Pump (AEM 320-E)
K&N 81-1000 Inline Fuel Filter

ST200 Airbox, whoosh motorsports crossover pipe (cerakoted) & induction hose
Velossa Tech Big Mouth Snorkel (white)
CP-E Front Mount Intercooler
Turbo Technics Hotside Charge Pipe

Zeitronix ECA-2 Ethanol Content Analyzer w/ Gauge
Brisk Racing 2-Step Colder Spark Plugs

Mountune Radiator
Motorcraft 180F Thermostat
Mishimoto Aluminum Coolant Tank (Black)

Tuning & Fuel
Cobb Accessport V3 w/ ProClip Mount
CP-E Custom Tune (Mitch Levy) for TT S280 Turbo w/ Aux Fuel
- Full E85
- 93 Octane
Bosch 3.5 Bar TIP Sensor
AEM 3.5 Bar MAP Sensor w/ CP-E MapTap and JDG Cutom MAP Plug

Drivetrain
CoolerWorx Pro Short Throw Shifter
JDG CoolerWorx Custom Linkage (Carbon Steel, 5/16" Ball Studs)
Raceseng Weighted Shift Knob (Circuit 100 Series)
NoPistons Gas Pedal Spacer (3/8")

CP-E Rear Motor Mount
Vibratechnics Fast Road Engine Mount
Vibratechnics Fast Road Upper Transmission Mount

Wavetrac Limited Slip Differential (To Be Installed)
OEM Clutch
Ravenol 75W-80 Manual Transmission Fluid

Brakes
Motorcraft Front & Rear Brake Pads
Stoptech Front Slotted Rotors (OEM, 280mm)
Ford Focus SVT Rear Brake Caliper Brackets
Stoptech Cryogenically Treated Rear Brake Rotors (Focus SVT, 280mm)
Motul RBF600 Dot 4 Synthetic Brake Fluid

Suspension
Bilstein B6 Front & Rear Struts
JDG Front & Rear 1/4" Spacer Lift (Stainless Steel, 5/8" Overall Lift F/R)
Powerflex Rear Spring Pads
Whiteline Camber Bolts
Dpro Rear Camber Plates

Pierce Motorsports Front Chassis Brace (2-point)

Wheels
Summer: Konig Dekagram 16x8 (Bronze)
All Season: Sport Edition 16x7.5 (Graphite)
Winter: Steelies 15x6 (Black)
Rallycross: Method MR501 VT Spec 15x7 (2), Sparco Terra 15x7 (Bronze, 2)

Current Tires
Summer: Dunlop Direzza ZIII 225/45R16 (24" Tall)
All Season: BF Goodrich Sport Comp 2 A/S Plus 205/55R16 (25" Tall)
Winter: Michelin X-Ice XI3 175/65R15 (24" Tall)
Rallycross: Maxsport RB3D2 185/65R15 (2), Federal G10 Gravel Tire 185/65R15 (2) (24.5" Tall)

Protection
Skid Plate Guy (SPG) Aluminum Engine Skid Plate
NoPistons Evap Canister Skid Plate
Sparco Mud Flaps
Sabelt Front Tow Strap (Yellow)

Lighting
Rally Innovations Light Plate (Black) with Custom Rear Mounting Brackets
Baja Design Squadron Sport Fog Lights (Amber)
Baja Design Squadron Pro Driving Lights (Amber)
Hella Halogen Driving Lights (55w)
Diode Dyanmics LED Reverse Lights
Diode Dynamics LED License Plate Lights
Diode Dynamics LED Interior Lighting
Contura Switch Panel (Cubby Area, 5 Switches) (WIP)
Otrattw Custom Contura Switches (WIP)
JDG Custom Relay Panel (WIP)

Other
JDG Custom Traction Control Auto-Off Module
Mele Design Firm Lightweight Battery Box
XS Power D680 Lightweight Battery
Shaved Grill (ST Logo Painted Semi-Gloss Black)
Semi-Gloss Black Painted Crash Beam (Duplicolor)
Drawtite Trailer Hitch
Lightweight/compact Spare Tire
ST Floor and Cargo Mats
Dark Ice Designs Hood Lift

Interior
Ford Racing Recaro Front Seats
JDG Custom Drift Button (Handbrake Modification)
RAM Ball Phone Mount mounted to ProClip Base
Valentine 1 Gen2 Radar Detector w/ Ram Magnet Mount
Dedicated Android Samsung Phone for V1G2 JBV1 Radar Detector Integration
NoPistons Dead Pedal
Dragy GPS Performance Meter
Ford Focus Leather Adjustable Headrests

Exterior Cosmetic
VelossaTech Wing Risers
2011 Fiesta Tail Lights
Third Brake Light Flasher

Past Setup

Engine
Revo RT330 Turbo
Garrett GTX2860R Gen2 Turbo

Cobb Catback Exhaust (2.5")
CP-E Intake (3")
Cobb Front Mount Intecooler

NGK 6510 1-Step Colder Spark Plugs

Tuning
Stratified Flash Tune for Stock Turbo (93 Octane & E30)
Stratified Custom Tune for Revo RT330 and Garrett GTX2860R Gen2 (93 Octane & E50)

Wheels
Sparco Assetto Gara 16x7 (Graphite)

Tires
General G-Max AS05 205/50R16
BF Goodrich Sport Comp 2 A/S 205/50R16
Firestone Firehawk Indy 500 205/50R16

Custom Parts & Designs
Traction Control Auto-Off Module

https://www.fiestastforum.com/threads/plug-and-play-traction-control-off-module.18531/

View: https://www.youtube.com/watch?v=ZKWcrsMD24I&feature=emb_title

Front & Rear 1/4" Spacer Lift (Stainless Steel, 5/8" Overall Lift F/R)


CoolerWorx Custom Linkage



https://www.fiestastforum.com/threa...ips-tricks-linkage-redesign-discussion.22928/

Drift Button Handbrake Modification

View: https://www.youtube.com/watch?v=Qzl50rKCBYI

 

[JDG]

Day 1 Photo (Post Detail)



Present Day

 

[JDG]

Rallycross Photos

 

[JDG]

Autocross Photos

 

[JDG]

Current Virtual Dyno

 

[JDG]

Other Photos

 

[JDG]

Front & Rear 1/4" Spacer Lift (Stainless Steel, 5/8" Overall Lift F/R)

 

[JDG]

Reserved

 

[JDG]

Reserved

 

[M-Sport fan]

When my FiST grows up, it wants to be just like yours.

 

[Philld_with_donuts]

Awesome build!! Love the before and after to see the journey it’s been down!
Can’t wait to see a few more photos in the rallycross section! Looks great!

 

[Woods247]

Man I wish my body could handle RallyX. That looks like a blast.

 

[akiraproject24]

Your list screams thorough, well done. May I ask did you grab the Ford factory Recaros direct from Ford or on the secondary market?

 

[JDG]

Your list screams thorough, well done. May I ask did you grab the Ford factory Recaros direct from Ford or on the secondary market?

Secondary market. With 30k miles.


Sent from my iPhone using Tapatalk

 

[M-Sport fan]

Front & Rear 1/4" Spacer Lift (Stainless Steel, 5/8" Overall Lift F/R)

View attachment 30526 View attachment 30527 View attachment 30528 View attachment 30529 View attachment 30530 View attachment 30531 View attachment 30532 View attachment 30533

Did they yield a 5/8" lift over just using the B6es and factory springs, or over the full factory suspension setup?

BTW; The white Pro Rallies DO look good on the white car when they are clean, sort of like a WRC test car, or even a recce car.

 

[M-Sport fan]

Autocross Photos

View attachment 30376 View attachment 30377

Is this the Warminster site?

 

[JDG]

Did they yield a 5/8" lift over just using the B6es and factory springs, or over the full factory suspension setup?

BTW; The white Pro Rallies DO look good on the white car when they are clean, sort of like a WRC test car, or even a recce car.

5/8" compared to a completely stock vehicle. But I can really do any lift between 0-3/4" with different height spacers.

Is this the Warminster site?

Yes. Warminster, PA old runway. Now called Warminster Community Park.

 

[JDG]

So after having some issues with the ignition coil wires that were caused by the posi-taps that come with the aux fuel kit (the posi-taps fatigued the wire over time causing two wires to break completely), I decided to buy ignition coil and MAP sensor pigtails and solder everything. I also added an additional wire to tap into the auxiliary fuel. I wired these extra wires with delphi weatherpack connectors for a clean install. I can also remove the auxiliary fuel very easily now without causing wire damage.

I also upgraded to a stiffer wastegate actuator, so back to 20psig of boost while we dial this new wga back in.

 

[shouldbeasy]

So after having some issues with the ignition coil wires that were caused by the posi-taps that come with the aux fuel kit (the posi-taps fatigued the wire over time causing two wires to break completely), I decided to buy ignition coil and MAP sensor pigtails and solder everything. I also added an additional wire to tap into the auxiliary fuel. I wired these extra wires with delphi weatherpack connectors for a clean install. I can also remove the auxiliary fuel very easily now without causing wire damage.

I also upgraded to a stiffer wastegate actuator, so back to 20psig of boost while we dial this new wga back in.

Well done! I just finished my Aux Fuel wiring - didn't even bother with the posi-taps - just cut wires and soldered - I'm not gonna hunt down electrical gremlins if I don't have to!!

Word to the wise, if you dive in to wiring, get a label maker and clear heat shrink. Doing 'professional' labels on everything has improved my electrical confidence dramatically. Very nice being able to remove and reconnect items by the labels!

Where did you tuck the SplitSecond box? I said fuck it and went through the firewall and under the dash to the glove box (having to extend all the wires of course).

 

[JDG]

Well done! I just finished my Aux Fuel wiring - didn't even bother with the posi-taps - just cut wires and soldered - I'm not gonna hunt down electrical gremlins if I don't have to!!

Word to the wise, if you dive in to wiring, get a label maker and clear heat shrink. Doing 'professional' labels on everything has improved my electrical confidence dramatically. Very nice being able to remove and reconnect items by the labels!

Where did you tuck the SplitSecond box? I said fuck it and went through the firewall and under the dash to the glove box (having to extend all the wires of course).

It currently sits on top of the engine bay fuse box but I will be moving it soon to be mounted vertically on my mele battery box (still staying in the engine bay). This is to make space for an additional relay panel I am building for all the auxiliary lighting.

I am no stranger to wire labeling but decided not to in this case because everything is pretty obvious and the split second controller doesn't care which wire is which as far as ignition coil #1,2,3,4 and injector #1,2,3,4.