Ok, so time for a fairly large sized update!

 

So after I worked on the car on the 18th all geared up ready to get it at least through the MOT the next day. So I got to work. Replaced all the original vacuum lines with the green hose I'd bought...

 

 

 

Next up I prepped the under exhaust brace, the battery clamp, the bonnet release mechanism and the two brake hose retainer clips for some paint...

 

 

Fresh coat...

 

 

 

Next up I needed to do some repairs to the wiring loom, as some connections had broken off when I took them apart. I'd bought a second hand connection for the reverse light switch from the scrapyard, but I needed the ignition on so that I could make sure that the wires were the correct way. So I popped the battery on. Ignition lights came on in the car... next thing smoke started coming from the passenger side wheel arch. The damn plastic sheath on my new brake hose was literally melting. I was quick to react and doused it in water and disconnected the battery. Pretty much a write off for the line and no MOT the next day...

 

 

Upon closer inspection, I'd accidentally wired the polarity wrong on the starter motor. Both cables were thick and black, and both fitted on either connection. Plus the wiring routing didn't give the game away, as it routed fine. Pretty poor design - especially considering one of them wasn't red to indicate live! So ladies and gents - be careful with this if you have your engine out!!

 

Licking my wounds, I decided to call it a night before I lost my rag even more. I went home and ordered a new brake hose!

Edited 4 November, 20178 yr by alex_e3

Ok, so MOT cancelled and onward bound!

 

First job the next day was to make all the repairs to my wiring loom. A fair bit of soldering and insulating later, it's difficult to tell which has been repaired...

 

 

 

Next up I wanted to replace the PAS fluid and put some fresh stuff in. So out came the vacuum pump to get the old stuff out...

 

 

New fluid then in and system bled.

 

 

Fitted my ECU and strut brace in place...

 

 

 

Secured the other ballast the same way as I'd previously done the other...

 

 

 

I then cleaned up all the components of the battery tray and carefully routed the wiring on the battery back together...

 

 

 

I decided to route my oil cooler hoses carefully. The main aim was to ensure that they were clearly away from anything that would cause them to perish (as Joe unfortunately found out at Combe!). So I used a few cable ties and routed them so as to avoid any kinks...

 

 

 

 

 

Next day, I set about making some custom brackets for the oil catch can and for the oil cooler itself. I used aircraft grade aluminium to do this. It took an absolute age to get this done!! Lots of filing and drilling required.

 

Catch can bracket...

 

 

Oil cooler brackets (attach to the FMIC fitting bolts)...

 

 

 

 

 

I ensured my cooler 90 degree connections were fitted with PTFE tape to prevent leaks, then I went to fit my pipework. Unfortunately it turned out that one of my pipes was miles too short. Hence I had to change that one and use the original pipe that Darkside supplied. I re-routed the new pipe and cable tied everything again, then cut the ends to size and final fitted onto the cooler...

 

Edited 4 November, 20178 yr by alex_e3

Next day, I fitted the exhaust...

 

 

 

 

 

If I'm honest I'm still not happy with the exhaust. The fitting leaves a lot to be desired too IMO. Hence I'm going to approach a local company called Alunox tomorrow and see what they can do about the back section.

 

 

I then put the original filter and pipework back on after cleaning it up. I do have custom pipework to put on along with a red and black S2000 filter. However, I'm STILL waiting on a 15 degree pipe from ASH hoses 3 months after ordering       So will fit this later on. 

 

 

Next up came the dreaded moment.... starting her up! I filled her up with fluids first and had a quick check for any obvious leaks. Primed the fuel pump several times and also had to get a jump off another diesel (ironically a red Mk1 Fabia vRS!!). It turned and turned and wouldn't fire. So left it for a bit and then tried again. Next thing I just heard a tiny tiny cough from the engine. So fuel had finally got through! Next thing she burst into life

 

Only started it up briefly just to make sure it ran. Checked for leaks after and everything seemed ok. So I then got on with the rest...

 

 

I then coated all the brackets with primer...

 

 

I decided to use the original Mocal oil cooler bracket to strengthen up my brackets, as they weren't as solid as I'd have liked.

 

After a rub down with wet and dry, all painted up in satin black...

 

Edited 4 November, 20178 yr by alex_e3

Next day I went back to the car and started to fit my brackets. I'd bought some new bolts, washers and nyloc nuts to do this.

 

Catch can final fitting...

 

 

 

 

Oil cooler final fitting...

 

 

 

I'm really happy with how this has gone on. The brackets have a little bit of give to allow for movement, but are fairly solid. I've cable tied the pipes up onto the boost pipework to keep things neat and organised.

 

 

Next up I fitted my custom top boost pipe. I'd already bought the adaptor for the ASV and re-used my original seal. I cut down the 90 degree reducer. Final result...

 

 

 

Lights all back in and functioning...

 

 

 

I then spent AGES cleaning up the arch liners. I'd sourced new fronts from the scrapyard. Alloys then back on. There's a fair bit of clearance to the Brembo's with my TT Comps too   Then finally... back on the ground for the first time in over 3 1/2 months...

 

Edited 4 November, 20178 yr by alex_e3

Liking the oil cooler mounting

 

Mine is still tucked away in the side mount position.

So today came THE day.... MOT time!

 

I went down this morning and finished fitting things like the slam panel, bonnet catch, front bumper etc...

 

I also had yet ANOTHER check to ensure that there were no fluid leaks. All good to go!

 

She passed with flying colours anyway

 

 

Later on this evening I went and got the geometry set on the car again after renewing all the steering components. So it goes where I point it once again ha ha!

 

Brakes are barely bedded in, but oh my god they're already awesome!!   I'm also currently running back on a standard boost map until my clutch is bedded in. Car is also absolutely rancid inside and out. So I will be giving it a huge valet inside and out over the coming week weather dependent.

 

 

I still have things to do to the car. The timing needs fine tuning, as currently still sat at -2 degrees. Plus little bits and bobs. I'll be slowly working on the gauge pod for the centre of the dash so that I can get them working - all wiring and senders are done, so they should just plug in and work. The gear linkage is still not perfect, despite me completing the reset procedure twice - very odd. Car is going in for the air con to be serviced and re-filled tomorrow or Sunday.

 

Also I have this little gem to fit...

 

 

MASSIVELY chuffed with this steering wheel! It's so nice   I got it done so that it matches the stitching on my A1 seats. My gear knob and handbrake cover will be on the way there soon too

Edited 4 November, 20178 yr by alex_e3

Liking the oil cooler mounting

 

Mine is still tucked away in the side mount position.

 

 

Cheers Jase! I'm really pleased with how it's gone on! Plus it actually looks even meaner through the widemouth now

 

Bonus is that if (when oil temp gauge is plugged in) the oil temps are too low day-to-day, then I can simply put a numberplate in the middle and then remove it for trackdays etc...

Great updates

Fekin awesome

Great read from start too finish - give me plenty of inspiration! Have to admire your dedication and knowledge!

Wrexhams only up the road as well! Might see it out and about

Cheer mate   Anyone can do what I've done, it's just having the bottle to take it apart ha ha!

Air conditioning tested for leaks, lubricated and re-filled today...

 

 

 

Air con is the coldest it's ever been since I've had the car now! Pleased

Edited 4 November, 20178 yr by alex_e3

Does the bumper not catch the oil cooler pipe?

I know the top outlet runs along the bumper basically (that's why you have to cut the lug off for the fmic) but then having those extra pipes must get in the way?

PM me if you need any size pipe made at any angle, any size legs, any bore, beaded or not etc...

Does the bumper not catch the oil cooler pipe?

I know the top outlet runs along the bumper basically (that's why you have to cut the lug off for the fmic) but then having those extra pipes must get in the way?

PM me if you need any size pipe made at any angle, any size legs, any bore, beaded or not etc...

 

Cheers for that mate - I'll be in touch if I do

 

Nope no catching at all. I mocked it all up before I made the brackets. There's a bit of clearance above the pipes too!

It's like a toddlers colouring competition that under bonnet area now!!!

Are you running without a crash bar?

Also what size is your sticker plate. I'm tempted to run one there.

Great to see it running.

Are you running without a crash bar?

Also what size is your sticker plate. I'm tempted to run one there.

Great to see it running.

 

For now mate yeah. I want to get a single pass cooler mounted near the front of the bumper in prep for the BKD head conversion soon. So will make a custom one then to mount it off.

 

Sticky plate was standard size. I've chopped the edges down slightly so that it isn't huge. Lettering and spacing is all legit. I think there's info earlier on in the thread on it...

 

Cheers pal

 

 

 

Had a few teething problems. Also got a few more bits done. Will post them up soon

What bhp will you be looking to achieve Alex?

Sent from my iPhone using Tapatalk

What bhp will you be looking to achieve Alex?

Sent from my iPhone using Tapatalk

 

I've not done anything in this rebuild to change the power since the 2260 was fitted. I'm just at a lower boost for another 500 miles and then I'm good to wind it back up to 2.5 bar again  Power wise I've had 2 RR's done - 1 at 256bhp and the other at 269bhp. The first one was under-fuelling on the rollers too...

Great Write up

I feel I may be buying a oil cooler after snetterton tomorrow lol.

Just been looking through the thread and there's some great pictures of how to fit everything plus lots of other guides to fitting parts, so thanks for taking the time to go into such detail Alex.

Cheers Steve! I think it's good to do a full write-up so people can see in more detail what they've gotta do if they're considering something similar. I'm also yet to see the temperature benefits of the oil cooler, as I have to custom fit my new pod before plugging my gauges in. Wiring is all tucked behind the glovebox ready to go!

 

 

Over 600 miles done now. Few teething problems en-route (which I will update with soon). Upped the boost at just over 500 miles back to 2.5 bar. I'm just not gonna boot it at low revs until about 900 or so miles. Opened it up a fair few times now after 3k revs. All running well. Checked my coolant and oil levels this morning with the car cold - levels are spot on and absolutely zero pressure build up in the expansion tank

 

All looking well for a track day that I have booked in less than 3 weeks

Are you considering a safer low boost map for trackdays?  I know I am thinking about it.  But then I also sometimes just can't help myself and would want max power

Are you considering a safer low boost map for trackdays?  I know I am thinking about it.  But then I also sometimes just can't help myself and would want max power

 

 

Funny you should mention this! Yes I reckon I'll knock it down to 2.2 or 2.3 bar just to be on the safe side.

 

However, one of the next mods on the car is to do some ECU fettling so that I can run live switchable dual maps

So the Fabia has just become a Superleggera this evening

 

 

 

Had to take the dash out to try and fit the extra gauges.

 

I'm going to be getting it all flocked now once I've custom fitted my gauge pod to the top. I've got a track day this coming Saturday at Oulton Park, so I'm going to temporarily fit the pod with ties so I can run the extra gauges. May get some foam to pad the metal parts for now...

Edited 4 November, 20178 yr by alex_e3