DannyB
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Registered: 6th Feb 08
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Hello strangers, seeing as there's talk of reviving this place I thought I'd share my latest project. Back in December of last year I bought a 2005 MK6 Fiesta ST rolling shell for the grand sum of £400, a bargain seeing as these are going for £2000+ for a good condition example on the road. It was bought from a friend who races MK6's up here and it was a spare shell for him, so I already knew it was going to be structually solid. The plan in mind was either K20 or a 1.6 Ecoboost from a MK7 Fiesta ST180. A few people I know have K20 Mk6's and they are awesome, but I decided on an Ecoboost to keep it all Ford and the fact that they are a very good tunable engine when done properly, luckily one of the lads from the track group I'm involved in specialises in building and tuning these cars.
So, the shell arrived to me in January this year and upon inspection it was better than I expected underneath. It needed the usual repair to the O/S/R inner sill (roughly the size of a £2 coin) this was welded and then I fully cleaned and undersealed the car. At this point I had already bought a powdercoated front subframe and the rear axle was also sent off for powdercoating. Might aswell do it right the first time!
I decided to just go all out and 90% of the parts are now brand new underneath;
Front lower arms
Track rod ends
Tie rods
Anti Roll bar links
Wheel bearings and hubs
Rear wheel bearings/hubs
Handbrake cables
Upon rebuild every bush on the car was replaced with Powerflex black series bushes also. For now I've decided to stick with the standard brakes until a set of bolt on Hi-spec or similar come up for sale so I've used Brembo front discs with mintex m1144 front pads, rears are all brembo. Whilst I was in there the calipers were cleaned and painted black. HEL braided lines were fitted and I'll be using typ200 fluid. I also fitted solid rack bushes up front.
Suspension wise I went with a set of GAZ GHA's, adjustable front top mounts, the rear are now a true coilover with solid top mounts. Spring rate was custom set to suit what I'll be using the car for. The rear recieved proper 12mm axle spacers on rebuild. I had a set of Zetec S front hubs powdercoated and they were fitted upon rebuild, the Zetec S hubs allow the arms to sit at a better level once lowered, improving the overall handing and feel. The front anti roll bar was powdercoated silver to match the new rear Whiteline ARB that was fitted.
Wheel wise I've gone for 15'' Speedline Corse 2118 and Nankang NS2R's for a track wheel. I'll buy different wheels for road use
The interior is pretty nice I think. The MK7 dash has been fitted and everything works, lights, radio and satnav etc (more on that later) 2 Sparco seats with LUKE harnasses and a 330mm Sparco wheel. A cage will be added over winter.
So, with the Ecoboost decided on it was time to source everything needed for the conversion. There is alot needed lol I managed to source a complete engine, gearbox, all looms, driveshafts, mounts, ecu, BCM, all modules, clocks, complete dash, all key pick ups, steering column, ABS pump, throttle pedal, fuel pump...It's basiclaly now a MK7 in a different dress as pretty much everything out of the MK7 is needed. The standard gearbox was sold on and I bought another with a Quaiffe diff.
Power wise, this year the car will be roughly 250bhp. Set up correctly with a diff it will be alot of fun. Basic breathing mods like an Airtec induction kit, big hidden front mount IC, 3'' decat and full 3'' exhaust have been bought. These conversions can run hot so an Airtec radiator will also be going in and I've put MK2 Focus RS vents in the bonnet to help. Along with a map by Connor it should go very well. The front bumper has had holes cut for airflow.
I've added a TRC style front splitter and rear diffuser to make it look abit meaner
That's pretty much it I think, I'll edit with anything I've missed 
edit: I forgot to mention that I bought all genuine service bits for it before the engine goes in, timing belt kit/water pump, oil filter, spark plugs and a Fiesta ST200 clutch as they are a nice upgrade to a standard ST180 clutch and handle extra power very well, people prefer them over aftermarket. There's still a good bit to go yet, still needs bits pieced to the back of the MK7 dash etc but we're getting there.
[Edited on 07-12-2023 by DannyB]
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DannyB
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Registered: 6th Feb 08
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My bonnet suffers from the usual bonnet crease and finding a good bonnet that's not creased is hard! I bought a wee bonnet lip to hide the worst of it, always thought these looked quite good!
I've also bought a flocking machine to flock loads of interior pieces myself, rather than pay a fortune. It's easy enough to do and with more practice I think they'll be up to standard to use in the car. Here's a test piece I did of some random trim I got out of the scrappies
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DannyB
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Registered: 6th Feb 08
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Another job ticked off the list. I had visions of the rear panel being quite bad behind the bumper and had planned on cleaning it up and undersealing it but there was no need, it's mint
The original rear towing eye was cut off and painted to prevent any rust and I fitted a proper TRS tow hook to the most solid place we could find
A hole was cut in the rear plastic next to the reflector so it would poke through nicely. I have the same hook to fit to the front too but I'm waiting until the intercooler etc is fitted to find the best placement for it.
[Edited on 03-11-2022 by DannyB]
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DannyB
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Registered: 6th Feb 08
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Another silly thing ticked off the list, fitting extended wheel studs. I wasn't happy with the amount of thread the wheel nut had, as you can see it doesn't look like alot
Fitted ones that are roughly 20mm longer
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DannyB
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Registered: 6th Feb 08
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So, the engine is now in and running. Although I'm waiting on more parts to arrive to take to Connor to finish up. Meanwhile he's been doing lots of other small bits.
It turns out this intercooler is too big, so it's staying on for mapping and then I'll buy another that will fit behind the bumper better as I dont want a cut bumper with exposed intercooler, not a fan of that look.
Weve opted for a side exit exhaust. It's 3''back with a decat
Connor got the engine fitment perfect, shafts are nice and level and the arms sits a lot better due to us using Zetec - S hubs over the ST ones which allows the arm to sit as you see.
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VegasPhil
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Registered: 16th Jan 05
Location: Fareham, Hants Drives: Octavia VRS
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Nice build. Can’t believe how old these are now. I remember my mates having them from new ha!
Corsa 2.0 16v Vegas - Sold
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SetH
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Registered: 15th Jul 01
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This is a very cool build.
did the Mk7 dash literally fit straight in? amazing.
I had an ST180 when they were new, Mountune map/airbox. Easily one of the best cars i've had, many times more fun then the M4 CP that followed it!
is there much weight difference between the Mk6 and Mk7/7.5?
This looks like it will be a proper weapon
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DannyB
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Registered: 6th Feb 08
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quote:
Originally posted by VegasPhil
Nice build. Can’t believe how old these are now. I remember my mates having them from new ha!
Yep! this one being a 55 is pre facelift, which I prefer anyway. Not a fan of the lights with the bulge!
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DannyB
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Registered: 6th Feb 08
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quote:
Originally posted by SetH
This is a very cool build.
did the Mk7 dash literally fit straight in? amazing.
I had an ST180 when they were new, Mountune map/airbox. Easily one of the best cars i've had, many times more fun then the M4 CP that followed it!
is there much weight difference between the Mk6 and Mk7/7.5?
This looks like it will be a proper weapon
Kind of...the main support bar needs to be from a MK7 then slight modification then the dash will mount straight to it. The conversion also used the MK7 steering column so all that mounts up nicely. You can keep a MK6 dash which many people do but i think it's nice with the new dash.
Yeah the MK7 ST180 are a brilliant car and easily tuned. Luckily for us up here we have Devine Autotech (the guy converting mine) who specialise in the MK7 platform, currently the world record holder for the quickest ST180 1/4 mile too, he has tuned many of the track cars to 340-380 bhp reliably and they go extremely well. Mine will be around 350bhp once it gets a hybrid next year.
I would imagine kerb weight between the 2 standard will favour the MK6, fair bit smaller, smaller engine no turbo, smaller gearbox etc. Mine will have 2 seats and a cage so should still be a wee bit lighter.
The car is now built up and 90% finished, mapping should be done over the next week I would say
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DannyB
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Registered: 6th Feb 08
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So, all the niggly bits have been sorted now I.E wiring rear lights, ABS, gear stick assembley, throttle pedal, wipers etc. The car now starts off the button, drives and stops. A base map is on and the car should be mapped this week. A few purchases have been made, I've been buying up stuff for the track car door cards as I think I will be using manual winders as opposed to the electric windows, I've also bought a nice forged carbon gear knob from a chap on Instagram, I've had some carbon kevlar front arch liners made just to make it look nice lol, I've got a carbon kevlar rear filler pipe protector, again...will look nice more than anything and I've got a set of Hispec 4 pots with 300mm floating disc set up that I need to collect. Not long now
It actually looks at home in here
The side exit, I'm going to add some heat tape to the skirt and possibly some heat wrap to the end of the exhaust to stop any melting
The brake kit that will be going on the car
A video of it running (click image to watch on flickr)
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SetH
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Registered: 15th Jul 01
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This build makes my fanneh moist!
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DannyB
Premium Member
Registered: 6th Feb 08
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The car was mapped today, 247bhp and 280lbft torque. Really happy with that considering it is just breathing mods it has with one of Connors maps
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DannyB
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Registered: 6th Feb 08
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So I got the car back last week and I'm very happy with it, there's still some tidying up to do, fit the big brake kit on the front, and some other stuff I've been buying and had set aside.
One of the major things was the intercooler, I was sure I was going to have to either replace or modify it to fit. I'd measured the IC before buying and knew it would fit in the main recess but where it was mounted was higher up, so it was fouling all over the place. In the end we lowered the IC mounts, trimmed a lot of plastic behind the bumper and removed the lower grill and hey presto...the biggest IC i've ever seen behind a MK6 bumper :clap:
It fills the whole lower grille space now, looks decent I think
Very happy with how the exterior looks now
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SetH
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Registered: 15th Jul 01
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Like that a lot, I bet its a blast to drive.
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DannyB
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Registered: 6th Feb 08
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quote:
Originally posted by SetH
Like that a lot, I bet its a blast to drive.
Its quick mate that's for sure. Haven't had it out of 3rd gear yet though as the road at work is a bit bait. Plus it needs proper geo set up so will feel different again once done
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DannyB
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Registered: 6th Feb 08
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Some progress on the car since the last update, I'll make a full post with pics once I've sorted them but the biggest update would be the new hybrid turbo which Connor (Devine Autotech) specs himself, a hard boost pipe kit from Pumaspeed was also fitted, fresh plugs and a service and back for mapping yesterday. It made a healthy 335bhp at 1.7bar. The car is ridiculous to drive now, very quick but puts the power down very well. Oh, bought a new plate too
[Edited on 31-08-2023 by DannyB]
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DannyB
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Registered: 6th Feb 08
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I had more work on the car done recently, I went for a set of Connors custom Newman cams, Bosch +30% injectors and a new actuator and another map to suit and it made 362bhp 421nm. I'm pretty much maxxed out on this hybrid now, I'll probably leave the power alone, I'd need a bigger turbo etc to get near 400 but tbh I don't think it's worth it, it's quick enough lol. The car is wild now, 3rd gear just keeps on going. Mega fun.
I also fitted a Coolerworx shifter which has totally transformed the way the car changed gear, highly reccomended. I bought a Direnza torque mount which should stiffen the engine movement up a bit, that mount was the only standard one remaining on the car. We've changed the front windows to a manual set up now too, as I had no st180 door looms we had to hard wire the drivers side electric window, much easier to do away and have manual on both sides. It's off the road for winter now and will be doing a few more things so I'll keep updating for anyone lurking.
Click image for full size
[Edited on 07-12-2023 by DannyB]
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DannyB
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Registered: 6th Feb 08
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So, the car is featured in this months FastFord MK6 Fiesta special if anyones wanting a nosey
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DannyB
Premium Member
Registered: 6th Feb 08
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For those still reading from afar, the car is going well, stuck a bigger spoiler on, usual stuff like changing out pads and servicing etc just the usual really. I've just been using it tbh and it's been brilliant. I had it down to Silverstone at FordFair, loads of Knockhill track days etc. Bigger turbo going on it over winter with a few other small mods
Fastcars feature on it
https://www.fastcar.co.uk/cars/ecoboost-swapped-mk6-fiesta-st/
Some in car footage from Knockhill
https://www.youtube.com/@fiestaturbo
My Tiktok for more videos
https://www.tiktok.com/@mk6ecoboost
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