Specification
Last Updated on June 09 2010


Chassis

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

Body Shell

Steel bodyshell • MC Rallying GRP tailgate • Performance-Trim Carbon honeycomb bonnet • Demon-Tweeks bonnet and tailgate pins • Airedale 4mm acrylic side and rear windows • MC Rallying fibre glass wheel arch extensions and front spoiler • Seam welded and strengthened throughout • All sound deadening and underseal removed • Replaced sills and front wings • Painted in two-pack Ford Sunburst Red (Resprayed: August 2000) • Removable steel sunroof (Fiesta Supersport) • Fiesta Mk2 tinted laminated windscreen • Underside of car painted with Dinitrol 4941 wax rust protection

Engine

Ford Duratec 2.0 16V DHE420 4-cylinder in-line 1998cc, alloy block with alloy head and sump, featuring oil-cooled pistons • 8000rpm red line • Brise 'Powermaster (Denso) Race' single wire 93mm 49A alternator, with Halfords Poly-Vee alternator drive belt • Zetecinside cutom-made alternator mounting brackets • M-Sport Group N gearbox mount • M-Sport Group N engine mount • Ford Fiesta MK6 2.0 ST150 Platinum Spark Plugs (SP6644A) • Cosworth Duratec cam cover (with COP fasteners) Part Number KK3545 • Tensioner for waterpump/alternator and airconditioning pump belt on 2004 Focus / CMax 1.8 Duratec HE Engine (Part number 3M5Q-6A228-AD, FINIS number 1315781) • EGR blanked off

Exhaust

Tony Law Exhausts full race system, with 4-2-1 manifold featuring equal length primaries. • Single rear silencer • 2.5" tubing • Lambda sensor boss • Corrosion resistant coating • Underfloor heat protection using Cool-It Acoustical And Heat Control Mat

Gearbox

Standard Ford IB5+ gearbox with cable gear selection and hydraulic clutch • Waiting to be rebuilt with SCCR gearkit and ATB LSD • Changing to Quaife IB5 Sequential (in 2010) • 4.3:1 final drive, with 0.96:1 fifth gear • Fiesta Mk6 gear linkage and cables (Finis 1489301) • Nylon Quaife-style gearknob (tapped to M12x1.25 thread) • Geartronics Sequential gear indicator display (LED)

Differential

Quaife patented Automatic Torque Biasing limited slip differential

Drive Shafts

Reco-Prop GpA passenger side axle-bar with Fiesta Mk2 Trilobe joint • Commercial Propshaft Services GpA drivers side axle-bar with Fiesta ST Mk6 (23 spline) Trilobe joint • Fiesta ST intermediate driveshaft • XR2/XR3 (22 spline) outer CV joints

Clutch

AP Racing 220mm heavy-duty clutch and drive plate • Fiesta ST slave cylinder • M-Sport BR16020004A -4 Clutch Master Cylinder Adaptor (7/16 UNC thread) • Rally Design -4 s/s flexible hose with 3/8 UNC s/s banjo for master cylinder connection

Carburation

Titan-Motorsport direct-to-head roller barrel throttle bodies • Titan-Motorsport fuel rail • Titan-Motorsport 100mm air horns • Active Electronics RP5110 throttle position sensor (110° swept angle) • ITG foam air-filter

Electrics

Varley Red Top 15 race battery (Weight 5.5Kg) • www.customcarbon.co.uk carbon battery box • Zetecinside custom-made light-weight wiring loom using ITT Cannon Neptune connectors • Gold plated contacts throughout • Vehicle Wiring Products thinwall cabling • Wrapped in Nomex heat resistant sleeving • Zetecinside custom-made light-weight electrical control box, featuring fuse box, power relays, and control switches • Battery isolator switch with alternator pull-down resistors • LMA stainless steel 3 metre battery isolator pull cable

Engine Management System

DTA S80 Pro ECU • Featuring Full throttle gear changes • Launch & Traction Control • 16MB capacity data-logger • CANBUS output data stream • Innovate LC-1 wide band lambda sensor / controller

Dashboard

Stack ST-200 Clubman tachometer, 0-4-10.5Krpm, with tell-tale switch • 5 x 14.5mm Ultrabright warning LED's: • 2 x RED = Low oil pressure • 1 x YELLOW = Alternator charge light • 2 X BLUE = ECU Gear shift light • Stack 52mm stepper motor driven digital instruments for Water Temp, Oil Pressure and Battery Voltage, housed in a Hansell Composites custom-made carbon fibre dashboard. • Rotary 11 position switch for Traction Aggressiveness • Race Technology Dash3 Lite LCD Digital timing display

Engine Lubrication

76 Racing 10W60 synthetic oil (4 litres) • Mocal remote filter plate • Halfords HOF207 oil filter • Earls -10AN Swivel Seal connectors and -10 Pro-Lite 350 oil hose • Zetecinside custom-made CNC machined Duratec oil adapter takeoff plate (fits in place of the standard oil filter housing, and allows oil lines to run from the front of the engine block to the remote filter housing) • Oil filter take-off plate, with 15psi / 1bar Oil pressure switch 1/8npt, Stack oil pressure sender 1/8npt, and Ford Oil Temperature sender (M12x1.5) • Runs approx 90 psi when oil temperature is cold

Gearbox Lubrication

Silkolene 75W90 Synthetic gear oil (capacity 3.1 litres)

Cooling

Radtec custom-made alloy radiator (100% greater capacity than the Ford Fiesta RS1800 radiator) • Twin Spal 9" suction fans, computer controlled (VA07-AP12/C-58A) • 26cm (w) x 66cm (h) with 40mm core and 32mm pipes • SFS Performance hose kit (black silicon) with a custom-made top hose based on the TVR Cerbera with take-off for the VW header tank • DEI heat shroud (Withstands direct heat up to 250°C and reflects radiant heat over 1000°C)

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 (hydraulic clutch version) 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

Focus Mk1 solid rear disks, lightened and cross drilled • HiSpec Ultralite-2 calipers mounted upside down • Ferodo DS2500 pads (Mitsubishi EVO IV)

Front suspension

AVO alloy gas adjustable 2.25" coil-over shocks [adjustable spring platform] • 275lb springs (300lb when running the Zetec 2.0) • TAS(UK) spherical bearing top mounts, giving adjustable camber, caster • Kustom Engineering adjustable rose jointed TCA's, tie-bars and mounting brackets • -1.5° negative camber, +3.5° caster, and 0° toe-in

Rear suspension

SPAX gas adjustable rear shocks • 450lb springs • Kustom Engineering adjustable rose-jointed aluminium radius arms with alloy rod ends • Kustom Engineering adjustable rose-jointed aluminium panhard rod with alloy rod ends • RPV powder coated Fiesta Mk1 rear axle, modified to accept Focus Mk1/2 rear hubs, allowing adjustable camber and toe-in, currently running with -1.5° negative camber and +1mm toe-out on both rear wheels • RPV powder coated rear anti-roll bar giving from 4x to 8x the stiffness of the original Fiesta Mk1 XR2 anti-roll bar

Drivers Seat

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

Seat Belt

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

Fire Extinguisher

Electrically operated Lifeline 2.25L AFFF 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 Superleggera's, 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 Perform-O-Flex stainless overbraided -6 fuel hoses with alloy swivel seal fittings [inside car] • Earls Pro-Lite 350 nylon braided -6 hose and alloy swivel seal fittings in the engine bay • Titan fuel rail

Miscellaneous

JXD solid state video recorder • Sony 480 line bullet camera • Maplin Electronics Electret microphone *audio for the camera* • Race Technology DL1 GPS datalogger • Race Technology S80 CANBUS adapter

Power Output

In standard form, around 180 BHP • With the Cosworth Caterham CSR220 cams, should see around 220 BHP

Max Speed

130 MPH

Vehicle Weight

715 KG (1574 lbs) May 2006 with 63:37 split front/rear and 50:50 split left/right
670 KG (2009) with Duratec engine, alloy radiator, and Carbon honeycomb bonnet