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Old January 12th, 2017, 10:07 AM   #251
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Got most of my couplers in, and wrapped the intended pipes up. Once the trans in back in the car, I'll mock them up and order some clamps.

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Old January 20th, 2017, 05:22 AM   #252
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Not much to report on the PGT, still waiting for my trans to be done. However after dealing with several other issues with my Fiesta ST, I decided to call it quits.

Probe has a new stable mate

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Old January 21st, 2017, 08:21 PM   #253
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What issues did you have with the Fiesta ?
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Old January 22nd, 2017, 06:02 PM   #254
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And you even went Subaru rather than FRS/86

I was at a toss up when buying a new daily, between one of these and a 2011 Hatch.. ended up with the hatch to haul more stuff easily
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Old January 23rd, 2017, 04:58 AM   #255
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What issues did you have with the Fiesta ?
It was rusting, all doors/hood/hatch had rust forming on the inside seams, ford only approved to fix two doors, the hood and the hatch. All they did was ground the rust off and repainted the insides. The rust would come back, and they didn't get it all.

I also brought it in for a whining trans, which i suspected input shaft bearings (early build issue) Dealer denied it was an issue, said it was the wheel bearings, they botched the wheel bearing install 3 times, ended up replacing the knuckle and the cv, car never shifted smoothly after that, have no idea what fluid they put back in. Trans still whined, loud enough you could hear it over the radio at speed.

The bearing they did was also still groaning.

To top it all off, it began leaking oil and the clutch was engaging funny/making noise, which were also symptoms that early cars with a failed clutch hub had.


All this by 38.5K miles, in a car I religiously maintained/cleaned/care for. I was disappointed to say the least.

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And you even went Subaru rather than FRS/86

I was at a toss up when buying a new daily, between one of these and a 2011 Hatch.. ended up with the hatch to haul more stuff easily
I honestly liked the Gen 1 toyota better, but I needed a new one and the refresh on the Toyota is butt ugly. I will say I freaking love this car. I really enjoyed the driving dynamics of the fiesta, but this car feels fantastic, even with the lack of torque. The space thing will take a big of getting use to but the fiesta didn't have all that much room either, so I will be able to make do.

Will need to borrow my roommates truck to go get the trans though, no way in hell it will fit in the subaru haha.
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Old January 24th, 2017, 11:38 PM   #256
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My wife's 2014 fiesta has no rust in 70k miles. But the green envy paint sure has chipped bad.
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Old January 30th, 2017, 09:03 PM   #257
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Thumbs up

Amazing winter progress. I have the HKS intercooler pipes as well, with original couplers that are still intact. Any idea if the turbosmart bypass valve bolts to the stock location? Thoughts on the rebuilt power steering rack?
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Old January 31st, 2017, 08:29 AM   #258
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Quote:
Originally Posted by 89probegt View Post
Amazing winter progress. I have the HKS intercooler pipes as well, with original couplers that are still intact. Any idea if the turbosmart bypass valve bolts to the stock location? Thoughts on the rebuilt power steering rack?
Thank you!

I think if you had a 1.875" T pipe with a 1" outlet for the bov, you could place it right in. Since the factory bpv is molded into the connector for the upper charge pipes, you would need to replace the whole assembly to add a new BPV and reuse the rubber intercooler hoses.

No thoughts yet on the rack since the car is still all apart. The detroit axle reman does not come with new rack bushings. IT does make some noises rotating side to side but it is dry at the moment so I will withhold comment until I drive on it.

Trans shop is really dragging their feet, I'll give them a slight benefit of the doubt given that I dropped it off right before christmas/the holidays. But if its not going to be done before mid february I'm gonna have to bring it elsewhere. First autocross event is beginning of April and I need to bed in the clutch and break in the trans prior.
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Old February 21st, 2017, 08:24 AM   #259
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Not much to report, the trans shop finally has the box apart and now they have all the proper seals/bearings/bolts to reassemble, which took some legwork on my end. Hoping to have it done by the end of the week.

In the meantime, I cleaned and painted my knuckles to tidy them up and prepped/painted another valve cover to ready myself to install yet another vcg and reduct the pcv back to the factory orientation (per rules)





The good news is, I had a look at my spare f2t out of the white 90PGT and the head looks freshly rebuilt. This seems like a good candidate for a reseal over the summer to replace the tired engine in the car.

Also after some careful thought, I'm planning to add a Treadstone TRV125 IC to the intake setup to maximize cooling effectiveness (3.5" thick core) It seems like it will fit the factory location quite well.
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Last edited by plx92; February 21st, 2017 at 08:27 AM.
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Old February 23rd, 2017, 10:39 AM   #260
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Transmission has finally returned home, fresh oem mazda seals/bearings and the new torsen mounted inside.



Fortunately I caught this prior to factory diff implosion, I have 1 spare gearbox, but they are getting harder to find.




Need to source a few crush washers for assorted sensors, and pick up some Redline D4 and I should be in business.

Hoping to get the gearbox and most associated components back in the car this weekend so I can get the car back on all fours. Also picked up a new set of wheels that should fit a bit better and utilize a set of leftover re's from my fiesta. I will add updates as I go.
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Old February 27th, 2017, 08:06 AM   #261
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Got the transmission and most of the running gear back in the car this weekend. New poly mounts took some swearing and prying to line up but all is socked up tight. Trans seems to cycle through gears smoothly.



Quick reference of the difference between aftermarket c clips and factory Mazda clips, used the mazda clip to ensure no install/removal issues:



Already had bronzoil shifter bushings, which I tighten up using a few washers for zero slop, but I also picked up this new poly bushing to replace the shift stabilizer which was dry and disintegrating.



Quickly mocked up the airbag and ic pipes. Need to work on wire management to clean things up but it should tidy up well. Have a few 2" 90 bends and the last remaining silicone couplers on order to fit the new Treadstone cooler which should be here this week.




New wheels are also here, they also seem to fit well and are by far my favorite wheels i've had for the car. These are Konigs new offering the hypergram, flow-formed using enkei's process and only 16lbs!




Hit a bit of a snafu as well, while everything was apart, I decided the replace all the 28yr old fuel hoses to avoid any surprise issues in the future. Got all the stubborn hoses off except the one that attaches to the FPR hardline. I carefully attempted to slice it with a razor, but not quite carefully enough, knicking the hardline with the blade




I pulled the upper plenum off (only way to remove/replace the hardline) so i', taking the time to have the injectors cleaned/flowed and clean out my IAC and TB all of which are quite grungy.


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Old March 2nd, 2017, 09:06 PM   #262
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Awesome update again. Wish I had the time to do half of what you have posted here!!

Quick question regarding the Energy Suspension bushing you installed (4.1106g). Which bushing specifically did you replace? I took a pic of my Ford Shop Manual (hoping it shows below) - could you indicate which bushing in the pic it is? Is it #20, #12 or another?

http://s56.photobucket.com/user/05fo...tml?sort=3&o=0
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stock turbo, HKS I/C Pipes, SBC TZ clutch, KVR cadmium/slotted rotors & pads, SMC SS brake lines, K&N filter, intake silencer-delete, A/C-delete, FSTB, Probesport RSTB, Probesport STS, custom mandrel stainless exhaust with Magnaflow muffler and highflow cat, Tokico "blues", Eibach Pro Kit, Yokahama Avid H4's on 17" Enkei TBS-11's, Raxles axles, Energy Suspension endlinks, ARP cyl head stud and exhaust manifold stud conversions

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Old March 3rd, 2017, 04:47 AM   #263
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Originally Posted by 89probegt View Post
Awesome update again. Wish I had the time to do half of what you have posted here!!

Quick question regarding the Energy Suspension bushing you installed (4.1106g). Which bushing specifically did you replace? I took a pic of my Ford Shop Manual (hoping it shows below) - could you indicate which bushing in the pic it is? Is it #20, #12 or another?

http://s56.photobucket.com/user/05fo...tml?sort=3&o=0
Thank you!

Bushing that I replaced was part #12
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Old March 6th, 2017, 05:38 AM   #264
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New intercooler came in, nice piece. Comparison to the original tube and fin intercooler, the new bar and plate style should cool more efficiently:





However the way it fits in the car....places it directly behind the bumper support lol And unfortunately street prepared class rules prohibit modification of the body and structural members. Now I assume it will get some shred of airflow as it, but I have an idea that may promote proper airflow through the core and retain the body as is.

Placement of the new intercooler routing the piping through the original mounting locations. I mocked it up positioning the cooler offset to the right but it still never really put the core in direct airflow:









Both sides of the bumper support have a decent sized opening, I had an idea that I could utilize these to direct airflow into the core.
Quick mock up with some cardboard, ducts will be made out of sheetmetal:







In additional to mocking up the cooler, I replaced all my 28yr old rubber fuel hoses with new lines and clamps. Got my injectors back, 2 of them were seriously suffering according the the flow analysis. They were able to be cleaned though and returned to the proper functionality, good as new. I replaced the o-rings and seals and reinstalled the rail as well.

Next step will be to clean my intake and tb/iac and get that all remounted. Any thoughts on gasket shellac or grey rtv on the plenum to lower intake gasket to promote seal, or should I just use the paper gasket?
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Old March 13th, 2017, 10:34 AM   #265
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Signed up for the first autocross of the year on April 15th so I'm officially working towards a deadline, more so since I want to get some street miles on it before hand to break in the clutch and shake the car out.

Over the past week I've been chipping away at little things. I reassembled my intake/tb after a thorough cleaning new seals all around. TB and IAC were quite grungy, before:



After:


Also wanted to replace the coolant hoses that were behind the intake that run to the IAC/TB and Lower plenum, not a fun job given their location and the lower intake being in place still. The factory molded hoses are also all but obsolescent (even still, who wants to buy "new" 30 yr old hoses) Took some finesse to route the new hoses without kinks and rubbing risks, but I believe they are all situated nicely now. The old hoses were a time bomb:



After the intake was back on I was able to better mock up the piping locations and I'm now ready to build some permanent brackets for the IC and begins tightening couplers down for the last time. Hoping if I can work through some of the little things this week I should be able to be back up and running in a week or so time permitting. Much excite.

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Old March 19th, 2017, 03:45 AM   #266
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Love scrolling through this tread, keep up the good work!
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Old March 20th, 2017, 10:08 AM   #267
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Love scrolling through this tread, keep up the good work!
Thank you!

Made some good progress this weekend, I sold my Forza seats a few months ago, and picked up a set of reclinable sparco seats. The bolstering is actually a bit more supportive and MUCH easier to get in an out of. Safe to say interior is right where I want it and should be the final iteration.

Replaced all the slider fasteners with grade 8 hardware during install.



Made big strides in knocking out items on the to-do list, made up a bunch of brackets to hang the new intercooler in place:







Made up a bracket to solve where to position my battery distribution block:





Most of the intercooler piping is all tight and positioned correctly, I checked overall wiring and hoses and made sure they were properly insulted/fixed.

Time had finally came to fill the trans up, before doing so I replaced the o-ring seal on the speedo gear to prevent any leaks.



Weapon of choice for the gearbox (more convenience, was planning to run redline d4 but sourced this locally):



Final bit that I got done was to plumb the airbox with a high pressure cold air feed, 2.5" home depot flexible tubing though the fender well, right into the box. I removed the factory "resonator" tube and zip tied the piping right in.









Tuesday evening I should be able to go by a friends shop and make up the ducting for the intercooler. Once those are installed I can install the bumper and exhaust and fire her up!
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Old March 23rd, 2017, 05:08 PM   #268
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Never was a fan of the 1g looks but wow....the time you have into it. I don't think you can really call it a project...life style seems to fit better.
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