zetecinside.comThe home of Project Fiesta XR2000 16V, established since April 1998
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My XR2
Chassis

Ford Fiesta XR2 Mk1 (First registered as A269FEJ May 1983)

Body Shell

Steel, with MC Rallying GRP rear door • Airedale 4mm acrylic windows • MC Rallying fibre glass wheel arch extensions and front spoiler • Seam welded and strengthened throughout • All sound deadening and underseal removed • New sills and front wings • Painted in two-pack Ford Sunburst Red (Resprayed: August 2000) • Removable steel sunroof from Fiesta Supersport • Electrically heated Fiesta Mk2 tinted Laminated windscreen • Underside of car painted with Dinitrol 4941 wax rust protection

Engine

Ford Zetec-E (series 2) 16V DOHC 4-cylinder in-line 1998cc, iron block with alloy head and sump, featuring oil-cooled pistons and hydraulic tappets • Piper Cams BP270 camshafts • Piper Cams vernier alloy pulleys • ARP con-rod bolts • Mondeo oil pump • Fiesta Mk3 1800cc water pump • Escort Mk3 1800 Zetec sump and oil pickup pipe • Lightened and balanced Escort Zetec flywheel with new heavy duty flywheel-crank bolts • Brise 'Powermaster (Denso) Race' single wire 93mm 49A alternator, with Halfords HB887e Poly-Vee alternator drive belt • Vibra-Technics engine mounts • KKM Aluminium underdrive crankshaft pulley (25% smaller diameter than standard) • Varley Red Top 15 battery (5.5Kg)

Exhaust

Ashley Performance Exhausts 2.25" 4-2-1 manifold • Walker Dynomax (WLK-17216) back box • 2.25" stainless steel tail pipe • Manifold wrapped in Thermotec Cool-It wrap • 106dbA at 4500rpm

Gearbox

Competition 5 speed Quaife straight cut close ratio, heavy duty gear box, based on Fiesta RS1800 type-BC casing. • Modified, ball raced, Fiesta Mk3 remote gear change mechanism • B&M (part number #45096) quick shifter, purchased from www.summitracing.com • The gearbox features a 3.857:1 final drive, with 0.96:1 fifth gear overdrive for those circuits where fifth gear is required. She pulls 48MPH in 1st, 111MPH in 4th, and 130MPH in 5th gear.

Differential

Quaife patented Automatic Torque Biasing limited slip differential

Drive Shafts

Reco-Prop Group A specification (custom length) shafts • New Trilobe inner and XR2/XR3 outer CV joints

Clutch

AP Racing 220mm heavy-duty clutch and drive plate

Carburation

Jenvey TBP45i throttle bodies, with Jenvey TBR32 fuel rail (New 2008) • Pipercross 600 left hand 75mm airbox (New 2008) with cold air feed using Revotec 7" round air duct and supplied Pipercross 75mm hose • Jenvey 45mm air horns • Weber IW031 'Green' competition injectors

Engine Management System

DTA E48-EXP ECU • Featuring working Launch Control, and data-logger • Bosch 'LSM11' Lambda Sensor • Scratch built wiring loom

Dashboard

Stack ST-200 Clubman tachometer, with tell-tale switch • 7 x 14.5mm Ultrabright warning LED's: • 3 x RED = Low oil pressure • 2 x YELLOW = Alternator charge light • 2 X BLUE = ECU Gear shift light • Stack (New 2008) 52mm stepper motor driven digital instruments for Water Temp, Oil Pressure and Battery Voltage, housed in a Revotech carbon fibre instrument pod

Engine Lubrication

76 Racing 5W30 synthetic oil (4 litres) with remote mounted Capri 2.8i (HOF202) oil filter • Earls -8 stainless steel overbraided oil pipes (Perform-O-Flex) and JIC anodised aluminium fittings throughout. Hose lengths are 61cm and 65cm. -8 to 1/2 BSP adaptors connect the hoses to the oil take off plate and remote reservoir housing.

Gearbox Lubrication

Silkolene 75W90 Synthetic gear oil (capacity 3.1 litres)

Cooling

Fiesta Mk3 RS1800i 16V Fiesta radiator • VW Golf Mk3 header tank • Kenlowe 9" suction fan, computer controlled • Raceparts silicon blue water hoses ( 45mm x 32mm x 150mm long )

Steering

Momo Race 80 suede steering wheel with Momo boss • Fiesta Mk2 XR2 steering rack • Fiesta Mk2 steering column

Front Brakes

Halfords DOT 5.1 Synthetic brake fluid • HiSpec Racing 114-4 four pot alloy race calipers with 285mm lightweight disks • Ferodo DS2500 pads • Rally Design Mk2 Escort adjustable brake bias pedal box featuring • 0.625" (front cylinder) and 0.7" (rear cylinder) • 7/16" cupro-nickel brake pipes and M10x1mm fittings throughout • Master cylinders fed by two fluid reservoirs, using -4 flexible Rallydesign RD1424 24" reservoir hoses with 7/16" fittings • Willwood brake pressure regulator restricting the hydraulic pressure to the rear calipers

Rear Brakes

Fiesta Mk3 solid disks (BD1062) with Granada Scorpio/Sierra 4x4/Cosworth rear calipers • Ferodo DS2500 pads

Front suspension

AVO alloy gas adjustable 2.25" coil-over shocks [adjustable spring platform] • 300lb springs • TAS(UK) spherical bearing top mounts, giving adjustable camber, castor • Custom made adjustable rose jointed TCA's, tie-bars and mounting brackets. • Setup in May 2008, by Northampton Motorsport, to give -1.5° camber, 3.5° caster, and 0° toe-in.

Rear suspension

SPAX gas adjustable rear shocks • 450lb springs • Trans Auto Sport adjustable rose-jointed radius arms • Trans Auto Sport adjustable rose-jointed panhard rod • Custom made powder coated Fiesta Mk1 rear axle allowing adjustable camber and toe-in, currently running with 1.5° -ve camber and 1mm toe-out on both rear wheels • Custom made powder coated rear anti-roll bar giving from 4x to 8x the stiffness of the orignal Fiesta Mk1 XR2 anti-roll bar

Seat

Motordrive Pro2 Tall Highside composite seat with Motordrive 5mm alloy brackets

Seat Belt

Sabelt Pro 6-point with QR, and 3" wide belts

Fire Extinguisher

Lifeline 2.25L AFFF (Electric) with polished alloy cannister (expires 2010)

Roll Cage

Safety Devices full cage with fixed rear diagonal brace (38mm CDS [cold drawn steel] tubing) • 38mm CDS Welded X door bars • 38mm CDS removable lateral brace running across the car, behind drivers seat

Wheels

15" x 7" OZ Superleggeras, ET37, silver

Tyres

Michelin N00 compound 19/57R15 slicks

Fuel tank

ATL D108S D-Cell (30 litre) with integrated collector and foam filled

Fuel system

Weber competition fuel injection pump : WFP503 • Weber fuel filter : WFF042 • Weber 3 bar fuel pressure regulator • Earls stainless overbraided fuel hoses with alloy fittings throughout

Miscellaneous

JXD solid state video recorder • Sony 480 line bullet camera • Maplin Electronics Electret microphone • Race Technology DL1 GPS datalogger

Power Output

Stage 1: 178 HP at 6243 RPM (7200 RPM max)
              153 ft/lb of torque at 5250 RPM
Stage 2: 195 HP (Gas flowed head, steel crank and rods)
Stage 3: 230+ HP (raised C:R, race cams)

Max Speed

130 MPH (0-60 6.52 seconds, 0-100 17 seconds, quarter mile 14.72 seconds & 95 mph September 2003)

Vehicle Weight

715 KG (1574 lbs) May 2006 with 63:37 split front/rear and 50:50 split left/right


Where next ?
Top of page • Stop press • Story so far • Home page
Jenvey Dynamics: Fuel Injection specialists. Check out their web site for more details Earls Performance Products. All things hydraulic. Check out their web site for more details RT Quaife Engineering Limited. Specialists in the design and manufacture of gearboxes and differentials. DTA fast. Engine Management Specialists Yokohama Motorsport tyres Piper Cams Webcon(UK) Fuel Systems Motordrive Competition Seats Race-Technology.com: Manufacturers of the DL90 GPS data logger