jacko's rally project

[jacko]

Decided itd be a good idea to keep a record on maintenance, mods, services etc for my own reference and for other people to have a look so here goes;

Its gonna take me a while to get it all on paper!!!

Bought the car in nov 06 as an frp replica on an R plate. All frp parts minus interior and wheels and oddly all factory fitted! She is def an odd one and the ‘specialists’ aren’t sure what she is!

New block fitted winter 06 due to nikasil wear, cambelt
Engine cover sprayed, lightweight battery fitted, denso plugs, leads, coil pack, k&n panel, milltek exhaust and cat, piper manifold, compomotive mo6 18s et 15! S1600 carbon splitter, general tlc for a few months
New rear bumper summer 07 (silly tart in a clio bumped me at 5mph & put a crack in it! Kept it; want to fix it asap)

Alcons...oh dear! See my separate guide! Have 2 sets, stripped, blasted, powder coated, hispec pistons (£10! And shortened to run 18mm pads!), own pad rails made, own stainless bridge pipes made, all stainless bolts (titanium next!), pad rails remade for £7 each, full stainless brake lines & stainless goodridge fittings, currently running ferrodo 18mm pads
Hispec 2 piece discs

Autumn 07 squeek identified as powersteering pipe rubbing a hole in itself! Not available from ford! Cheers! Brazed over the hole! Sorted, steering rack rebuilt, subframe off etc
ijeet in 4x4 reversed his tow bar through front bumper! £1832 for new front bumper through insurance!

Summer 08 designed cold air feed
Autum 08 rebuilt frp gearbox with quaife diff, tighter driveshaft seals, focus 1.8 220mm clutch, vibratechnics torque link, vibratechnics engine mount
small bump to passenger rear arch, pulled out & resprayed

Spring 09 airbox inserts made, maf flowed
Passenger driveshaft snapped, ford £174 and 5 day wait, shaftec £64 and 3 days!
denso plugs, rear discs & pads
summer 09 polybushed rear, ford sparco steering wheel, ford motorsport boss, all custom made to run switches through a snap off system, ie no loose wires
Autumn 09 frp interior
Winter 09 mondeo 2.0 throttle body flowed, puma linkage added, fitted. small bump to front bumper, repaired

Spring 10 she had a makeover! Red / blue rally colours, white stickers etc. Sprayed all myself (!!) and isn’t too bad at all  stickers available through me.
Carbon bonnet, custom made (by me!) alloy hinges & prop, bumper has mesh removed s1600 style reg plate moved, inner frame modded, vertical vents to come later, plywood (yep!) behind splitter removed, replaced with foam insulation sheet and a 2nd layer of carbon so is now a sandwich composite.
F2 spoiler fitted, custom ali & carbon strengtheners in boot ready for carbon bootlid...want a 3rd brake light in the f2!
Passenger front bearing
Snapped drivers cv joint stub axle replaced bearing too
Lower arms polybushed & new ball joints, new track rod drivers side
drivers front bango leak, new washer
Passenger drive shaft seal replaced
Running led side lights, fogs, rear / tail (pants!), reverse lights. Want to do dipped / main too and indicators and fix earthing issues of tail lights
Everything has stainless bolts, some are custom made by me

summer 10
cat rewelded (3rd time!)
transmission tunnel now coated in sticky backed tin foil!
rear brakes now 280mm ;-)
oil, filter, clean k&n, thermostat, housing, hcv, alternator, aux belt. sparks and tracking next
rear wheel bearings, clutch foot rest

my frp

• jacko
• Oct 26, 2010

future; v6 4x4 supercharged, alloy everything! need some space to do it thats the problem...


POLLY; aka Charlotte's KA
silver ka, now has puma 9 spokes on lower profile tyres
autumn 10; alloys, tyres, gearbox mount, hcv, service, bit of cosmetic rust repair

to do
i refuse to service drum brakes so when they go shes getting frp rear discs!
puma 260mm front discs or st 280mm discs
lower it just a touch
spoiler

 

[Scotty1.7]

Holy shiza Jacko- thats some work ya put in matye- it does look the business though

 

[martinthrapston]

nice write up paul :-D

 

[yippeekiay]

What's with you and bumper's??...lol

 

[TyeBoi]

bout time you got a project up. now PHOTOS with ice cream involved!

 

[luke]

you sprayed the whole thing with rattle cans?!?!

 

[Anonymous]

aye.. hes done a good job with it aswell

Nice mate...

 

[jacko]

wahoooo! now have 280mm rear discs!!!!!

use st170 caliper carriers, discs and angle grind the lip off the splash guard so doesnt rub against bigger discs

 

[FlashBastd]

Bodger, should have got ST170 shields like I did!

PS, I think they are 270mm aren't they?

 

[mix2000]

Kudos on the paintwork.
(Thought to self, 'Porsche candy apple red would look class on the front of that machine though.')

 

[jacko]

yep, but had to be a ford colour.....

st170 are 280mm rear discs

dont like the lip on the splashguards so this worked out quite nicely...i have a splashguard and no lip....

 

[FlashBastd]

So they are, my apologies!

The ST170 splashguards don't have a lip though, they are flat at the very edge, and the same size as the disc, rather than being lipped and larger like the 255mm guards.

 

[jacko]

ooooo! might have to get some...

 

[jacko]

new for this month; oil & filter, clean k&n, thermostat, housing, hcv, alternator & aux belt.
to do; sparks, tracking (can do this myself at home!) and a left foot rest
spare alcons should be going off for powder coating and want to finish buttons on steering wheel

POLLY; aka Charlotte's KA
silver ka, now has puma 9 spokes on lower profile tyres
autumn 10; alloys, tyres, gearbox mount, hcv, service, bit of cosmetic rust repair

to do
i refuse to service drum brakes so when they go shes getting frp rear discs!
puma 260mm front discs or st 280mm discs
lower it just a touch
spoiler

 

[clarkie]

dude if you want some 260mm front disks which are drilled and grooved, and the calipers and carriers to go with let me know i got my ones sitting in a box in the living room, still have brake hoses on them too just need new pads. you can have them for £30 just want them gone asap but postage is a ball ache so id rather you collect if you want them

 

[jacko]

cheers, il measure the ones on my puma at school, if there 240 il have yours but its a later model so think theyl be 260...

 

[clarkie]

ok dude no worries. take them for spares lol

 

[BlackKnight1982]

I saw this puma in motorway service station in mid august! very nice motor!!!

 

[jacko]

cheers

 

[jacko]

new for this week;

rear wheel bearings and refubed hubs & carriers (cheers for help martin)
sparks (no2 is a lot whiter than others...running lean?)
clutch pedal foot rest....sparco...taken 2.5 years to fit!!! taken a lot of shaping, had to make my own bracket, used a scrap puma as a template, polished surface has been ground off to make it 'machined' and logo painted imperial blue pedals next!