Switchback's Fiesta Fun Car Build

[EscortSportage]

Ah, my bad. Coolant piping you’re good, it’s the cold side charge pipe from intercooler to throttle body that won’t fit with a bigger radiator.

Ill have to trim the plastic around the cooling fan, I was looking at this yesterday since you mentioned it. Seems like the fan assembly will be the issue.

 

[Switchback]

It’s been a minute since I last posted here, but work continues! I recently installed the Pierce Motorsports tow hook kit, but made a bit of a change to the design.

As you who have installed this kit know, you have to *somehow* get a pair of bolts and washers inside the crash bar to hold the bracket in place. Instead of doing that (and hating life) I used a rivnut tool we have been using on the Lemons project. It worked perfectly and from my research is as strong (if not stronger) than the original washer and nut setup Pierce includes with the kit.

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While I was in there, I also replaced the center bumper support as it was broken. The bumper no longer sags as much! The original piece is held in there with hot glue so after the tedious process of peeling it off I got some new hot glue (the industrial heavy duty stuff) and glued on the new bracket.

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EDIT: apparently mobile safari doesn't like to embed images properly. I'll fix it tonight when I'm home from work.

 

[Switchback]

My bad luck just keeps on coming. While swapping out the turbo for a slightly used one and installing new exhaust manifold studs, I found that one of the previous owners snapped one of the exhaust manifold studs (far passenger side). This is very possibly why I was having low boost, if the exhaust manifold was leaking/warped.



I'm seriously starting to wonder if I should just rid myself of this Fiesta and go get something else.

 

[Fusion Works]

Plug the port and weld a nut to the end of that stud, then back it out and move on with the car. It will be a bit of a pain, but beats pulling the engine.

 

[Switchback]

Plug the port and weld a nut to the end of that stud, then back it out and move on with the car. It will be a bit of a pain, but beats pulling the engine.

Honestly my comment is more about everything that's continued to happen to the fiesta since I bought it. Exhaust, Timing, Brakes, Tires, Transmission (4 grand for 2x slave cylinder replacements), and now the exhaust manifold stud that's likely the cause of my boost leak. Just saying I've had really bad luck with this fiesta.

 

[Switchback]

Well after a weekend of swearing, yelling at the sun (and sweating) a friend and I were able to pull the stud out. Welding was a bust, harbor freight reverse drill bit worked and I've replaced the studs with ARP studs from whoosh. I really want to encase this bit of stud in resin as a victory trophy.




The Fiesta has been reassembled with a used turbo, time to see if I'm making any more power and if the car is stable and healthy again. I will say the test drive I did while the Scroth belts were installed made me feel very racecar.