Fiesta st AWD Build

Fiesta st AWD Build This is my world to build a 2.8, 5 cylinder AWD Fiesta ST180 running EMU Black. Enjoy the content �

Join me in the highs and lows of what it takes to self build this ambitious project with a 10k budget.

UPDATE!All fun and games here 😃. The car is now on the spit which is so much easier 🙂 And therefore I have managed to se...
12/03/2025

UPDATE!

All fun and games here 😃. The car is now on the spit which is so much easier 🙂 And therefore I have managed to seal the chassis to floor with plates and hopefully next week the rear frame will be fitted. bare in mind once the back is complete it will be stripped again so I can blast the underneath, seal and paint it.

slow progress but it is coming together. Once the car is finished underneath it will be going off on trailer to have the management installed so the car is all running. then after that I will install the arches, wrap the car and then pull the engine for its rebuild 💪

Morning every body. Just a quick update as I've had mountains of messages about this build and weather it's still going ...
09/01/2025

Morning every body. Just a quick update as I've had mountains of messages about this build and weather it's still going on.

The short answer to that is YES! 🤣 so I've had a very busy few months running my new business and that with the weather its been a nightmare to get on with the project.

but last week I had the wheels refurbished and have also recieved my coilovers for the build. I am hoping to get back on to the fabrication in the next 2-3 weeks so I can finally get it on its wheels and moved to my unit for the wide arches and wrap that I am doing on it.

so as per usual please bare with me 🙂

Had a small 2 step forward 1 step back moment today 🙈so I got one side of the top finished and then decided to fit the s...
23/08/2024

Had a small 2 step forward 1 step back moment today 🙈

so I got one side of the top finished and then decided to fit the shock to see if it's all good. unfortunately it did not fit as the original focus spring is massive 🤣 so I then had to cut extra sections out to clear the structure behind the wing. at least the other side will definitely fit now I know what's needed 🤣

it does take time and will take me longer. but its got to be right and it's got to be strong. And this is a learning curve which I'm enjoying 💪 so next time i post an update the tops should be all complete and tidy ready for paint prep and then the subframe should be on to get the engine in 👌

Another small update:I've managed to template the strut tops and fabricate the sides to make way for the mounts. The fab...
15/08/2024

Another small update:

I've managed to template the strut tops and fabricate the sides to make way for the mounts. The fabrication looks very messy as the welder I was using as a spare is very temperamental and I had some issues with it which sucks. But it just means more work tidying it up later.
all top mount holes are now drilled ready, the 2 tops have been bolted together to sandwich the original fiesta tops to the new fabricated ones so I can weld them together. This will make it super strong so I get no flex or bump damage to the tops. so far from finished but like I say....progress.

Then the rain came and f@ my day up 😁

So next I will be finishing the subframe and mounting that so I can make sure all the suspension and rack goes on without problems. THEN I can fabricate the mounts so the engine has its final resting place 👌

08/08/2024

Welders packed up. so that's put a holt on things til I can source another 🙈

FINALLY!! a little update for you lot.Today I stripped the rest of the engine bay down ready for fabrication. Then I had...
06/08/2024

FINALLY!! a little update for you lot.

Today I stripped the rest of the engine bay down ready for fabrication. Then I had to make a start on stripping bits off the engine to make the fitting process easier for me.

This also gave me some thinking time on what the best route is for fitting the focus running gear. So I've decided to use the fiesta subframe to cut down the need for fabricating the chassis to fit the focus one. Although I will have to do some fabrication to the fiesta subframe to fit the focus lower arms. I will be using the fiesta steering rack once I work out how to extend the rod ends to suit what looks like 3 inches more of length. the anti-roll bar fitted straight to the fiesta subframe which was very handy I must say.

Once the engine was stripped down I removed the gearbox ready for the volvo one to fit. But I also had to swap out the selectors as the volvo one works on the opposite side to the focus. Thankfully it was a straight swap. I then had to drill and tap a blind hole for the gear cable mount from the focus to fit correctly to the volvo box.

The box then slipped into place like a glove 🙃 I managed to mount the transfer box into place which also fit perfectly which is no surprise seeing as its a volvo engine 🤣 BUT.....one thing that does suck is the down pipe from the turbo will not fit due to the transfer box making an appearance now, but that's not a major concern yet.

So that's it for today. but what a massive amount of progress. tomorrow I shall be modifying the fiesta subframe to fit the lower focus arms ready for the suspension to fit into place so I can offer it up to the car.

The rear diff will be changed now due to ratio differences and I will be using an XC60 rear diff to pair with the front end. I hope you enjoy the pics 👍

05/08/2024

I will be doing a small update tomorrow guys/girls. had a busy few weeks so work on the car has been non existent. 👌

Shout out to my newest followers! Excited to have you onboard! Callum Douse, Phillip Roberts
16/07/2024

Shout out to my newest followers! Excited to have you onboard! Callum Douse, Phillip Roberts

Bit more done today, but run out of welding wire which was great tbh because I had a thumping headache. surgery Monday s...
11/07/2024

Bit more done today, but run out of welding wire which was great tbh because I had a thumping headache. surgery Monday so this is stopping for 2 weeks whilst I recover.

But I got the chassis legs welded and sealed. then popped the floor on and tacked it in. got the new battery location set and channel gap to run the brake lines through once completed. slow but steady.

Some Progress!Managed to get a full day in finally. The floor got cut out today and the new floor bent to shape. After ...
10/07/2024

Some Progress!

Managed to get a full day in finally. The floor got cut out today and the new floor bent to shape. After a little tidy up and alot of shuffling I got the bu**er in to the car and I was very determined to keep it in one piece. so all that is required to do now, is trim up the edges ready to press the edges to weld in to place.

Then I need to cut plates that go from the chassis legs to the floor to box it all in.

I also got some measurements done for the new rear end. The shock mounts need to widen 1.25 inches and the trailing arms are 6 inches longer. The spring cups and rear frame arms are actually the same width as my chassis legs and so that makes fabrication there so much easier.

Once the rear is all set and in place I can start the front. until I get the front on I am not sure if the tunnel will need to be bigger. But that's a problem for a later date.

Just a few bits done today. The weather has put a holt on what should of been a very productive day.so I stripped the wi...
05/07/2024

Just a few bits done today. The weather has put a holt on what should of been a very productive day.

so I stripped the wiring out the back, made a template for the new floor and then cut it ready to fit.

the floor is being sent up to be bent at the front and then offered up to cut the section out for the battery place behind the passenger seat. so that's all until Monday 😕

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