Broken Motorsports Fiesta Group 2 to R2 build...

[Broken Motorsports]

I wanted to start a thread for the build of my Group 2 Rally Fiesta.

So just a quick update on all that has been going on over the past few weeks since i picked it up...

I picked up the car from the dealer April 1st.
[insert pickup pic here] ;)

Tuesday i dropped the car off at Borla to get a custom rally exhaust made for it. We are working along with TON to develop a more race ready option for rally, road course, etc.
Cage and a few other small bits arrive fromhttp://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/m-sportlogo.png to Team O'Neil (TON) April 28th.

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/BRAIDlogo.gif gravel wheels arrive in about 2.5 weeks from this post and are on a boat somewhere in the Atlantic. We are an official BRAID dealer, so if you have any interest in them, please contact us.
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/winracetacropolisb.jpg

Cage is slated to be installed on May 5th and 6th as of right now. Of course me going to Olympus Rally to play crew chief for Travis Hanson, current RA overall points and SP leader, doesn't help with timing to get the car stripped down and ready for the cage install. I have cancelled going to Oregon Trail at this point. So i will have a very hectic week next week once i get the car back from Borla to strip the car and get it ready for stitch welding. Stitch weld the entire body before bringing it to TON to get the cage done.

First event is STPR in Wellsboro,PA. Rally America (http://www.rally-america.com) or STPR.org: Redirect to current year (http://www.stpr.org) for more info. June 3-4. We are also planning on doing NEFR New England Forest Rally (http://www.newenglandforestrally.com) July 15-16.
Possibly Rally WV. Definitely Black River Stages and LSPR...

I will be updating this thread with pics and info along with any events that we will be doing/attending.

STAY TUNED!!!! for some fun exciting rally stuff! Pics, Vids, Interviews, etc...
You can keep updated on things through my www.twitter.com/williampetrow or my FB www.facebook.com/people/William-Petrow/689398863

Thanks and enjoy!
William Petrow
Owner/Driver
Broken Motorsports, LLC
Rally America #15

[Broken Motorsports]

I didnt manage to snap a before pic of the car with my iPhone, but here are some pics of the car in various stages of coming apart in 2 days...

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo2.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo1.jpg

You can follow this on my Facebook. Have been trying to keep up with it on the biz FB too, but...
search William Petrow and add me. Also search Broken Motorsports.

You can follow updates on Twitter: William Petrow (WilliamPetrow) on Twitter (http://www.twitter.com/williampetrow)
Dont worry i only update with rally info as well as the build. None of this "i just woke up" stuff. ;)

[Broken Motorsports]

More Pics of the build...

Stitch welding and panel removal...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/Front.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/floor.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/frontrail.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/firewall.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/Frontrightqtr.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/Frontstruttower.jpg

[Broken Motorsports]

UPDATE: Cage and bits are somewhere stuck in customs and have yet to arrive. We are working on our last week before the deadline for the cage to be installed at this point.

If the cage is not installed by next weekend we will likely not make it to STPR... :(

BRAID's show up sometime next week!

We will continue through the weekend to get the rest of the shell prepped and ready for the cage install. There is quite a bit that we still need to do as far as stitch welding and panel removal and modifications that need to be done for the R2 kit when we are ready for that in the future.

I will post more pics and info as we move along with things. IT is going to be a hectic few weeks till STPR! hopefully all goes well and we get the cage here. After that its smooth sailing!

[kturner]

this is quite awesome... hopefully customs speeds up a bit and you can get the cage together in time.

doesn't look like there is too much body goop on these things?

[Broken Motorsports]

There is actually not too much goop, but the sound deadening wasnt easy to remove like it is in Subaru cars and there are LOTS of panels that M-Sport allows you to take out of the car. So tons of spot weld cutting, chiseling and prying to get those all out.

Sheet metal on the floor is so thin you have to be careful not to rip holes in the floor when getting things of the spot welds...

[Drew84]

Wow, awesome. Good luck with the build. I can't wait to see this car in action.

[Not All There]

good luck, hope everything arrives on time

[rollo]

I was sure I'd seen a before pic on Twitter..

Yep..

http://lockerz.com/s/89496440

Looking forward to seeing the build progress. Yeah Fiesta! :D

[Broken Motorsports]

thanks for finding that rollo!

Some pics...

Stitch welding the floor

http://img.photobucket.com/albums/v600/RS22b/stitchwelding.jpg

On the trailer to the cage install....
http://img.photobucket.com/albums/v600/RS22b/trailerto.jpg

[Broken Motorsports]

The car is now getting the cage done. Unfortunately, there is only 1 guy in all of North America that is allowed to be welding these cages in at this time. So he has the car and it should get done by the weekend coming.

Then we only have 5 days to get it all put back together and ready to race next weekend at STPR in Wellsboro, PA!!!!

[MConte05]

Is that guy duplessis? I remember seeing a pic on FB of him welding a Fiesta cage at TON.

[Broken Motorsports]

No chris is not the guy. The guy that is did most of the cages at VTcar for the last while and also did Ken's Fiesta he ran here last year.

So top notch guy for sure! cant wait to see the car all caged and on the trailer on its way back to the shop so we can get it ready...

[Broken Motorsports]

BRAIDS SHOWED UP!!!!

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo-1.jpg

[Guamanian_powered]

I have always been curious as to how you convert a ford fiesta to awd. Is ther a production version, or is there a kit for that type of project? For some reason, i am unable to google sufficiently enough to find an answer

[Nubby]

I have always been curious as to how you convert a ford fiesta to awd. Is ther a production version, or is there a kit for that type of project? For some reason, i am unable to google sufficiently enough to find an answer

Well, if you're talking about the S2000 Fiesta, here's the business bit that makes that car AWD:

http://www.xtrac.com/pdfs/532%20SUPER%202000%20RALLY%20GEARBOX.pdf

There's a spec rear diff as well. All diffs are mechanical. And yes, the AWD system probably costs as much as 3 or 4 fully loaded Ford Fiestas.

I'm not sure what Block's car uses, probably the same system as the Euro RallyCross Fiestas and I think that's a bespoke system built by the shop that builds those cars, but I could be wrong.

[Nubby]

Is this an R2 "big kit" or "little kit" build? Either way, super cool.

[Guamanian_powered]

Well, if you're talking about the S2000 Fiesta, here's the business bit that makes that car AWD:

http://www.xtrac.com/pdfs/532%20SUPER%202000%20RALLY%20GEARBOX.pdf

There's a spec rear diff as well. All diffs are mechanical. And yes, the AWD system probably costs as much as 3 or 4 fully loaded Ford Fiestas.

I'm not sure what Block's car uses, probably the same system as the Euro RallyCross Fiestas and I think that's a bespoke system built by the shop that builds those cars, but I could be wrong.

I see. Thanks for the info

[Broken Motorsports]

Is this an R2 "big kit" or "little kit" build? Either way, super cool.

This is actually just a cage. I had brand new RaceTech seats and belts from last year i only used for 2 rallies so im moving those over to use.

It is possible i will get an exhaust and an intake for the car prior to NEFR, but we will see. Still lots of stuff to get for the car and only so much funds to do it with.

[Broken Motorsports]

OK so just some quick updates.

Cage is done! just need to figure out when im going to get it. Possibly this weeknd but not sure what day with Formula D @ Wall and HyperFest at Summit Point on Saturday.

I got a new tent for the car. It is so nice having something like this! My old 10x20 is... well, old. It needs lots of TLC and doesnt have all the nicities that this one has.
Note all the parts under the tent. All for the Fiesta.
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/FRtent.jpg

Gas tank in the US is larger than the Euro tank and thus the M-Sport tank guard doesnt fit. So we are building our own kevlar tank guard, floor skids and sill guards.
Here is the tank all waxed up:
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/gastankwax.jpg

Here is the fiberglass mold we are using:
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/gastankmold.jpg

More pics will come as we do this tank mold and get the first guard finished up.

[geekmonster]

very cool build thread.

[Broken Motorsports]

Why interior jungle gym???
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/cage.jpg
Because Racecar!!!

[Pretendingtowork]

ha lol!!!

[Broken Motorsports]

Some pics of the progress. This is the time consuming part of the build, aluminum tape all the holes in the body to keep as much dust out of the cabin as possible. This will be a crucial part of the build as once dust gets inside can cause problems seeing, breathing and dehydration.

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/alumtapepapers.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/interioralumtape.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/FenderwellAlumtape.jpg

WE are getting closer to painting the body, but have to make sure we get all of this sorted and ready before we move on to masking the shell later tonight....Hopefully paint tomorrow.

[carl]

lol at all the tape backing on the floor! I love aluminum tape! my crew hates to remove it though

[Broken Motorsports]

haha yea. thats not even half of the car done with alum tape yet.

I started working on that again today to try and finish it up but had to hand off the special scissors to the composites guy so he can cut some fiberglass stuff. So i decided to seam seal the points in the firewall where the cage goes through.

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0106.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0111.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0107.jpg

And a little birdie told me to seam seal the holes in the floor that i welded up too...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0112.jpg

[Broken Motorsports]

finally done with the alum tape party!
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0114.jpg

and the paperbacks...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0116.jpg

[carl]

you should put speed holes in all that aluminum tape, it looks heavy lol

[Broken Motorsports]

haha. yeah. prob not.

[Broken Motorsports]

SO will post some updates from today...

Car is all taped and in spot for paint...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0117.jpg

Jeremy shoots first...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0119.jpg

Engine Bay done...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0123.jpg

Im already covered in paint...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0121.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0128.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0132.jpg

Jeremy finishes his side...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0129.jpg

Coat #1 done...
http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0134.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0135.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/IMG_0136.jpg

[Drew84]

You've got a lot of work to get done...good luck. I hope you make it to NEFR.

[Broken Motorsports]

Tuesday we got the last coat of paint on it and were able to get a coat around the back hatch area and rear wheel wells.

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo6.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo1-1.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo2-1.jpg

After that dried, it was time to take off all the masking tape and see what it looks like. Some said "Fiesta in a Tuxedo", some "Panda Fiesta", others said "Killer Whale". What do you think?

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo5.jpg

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo4.jpg

Last night i played with getting the heater core/blower combo to fit as well as the dash even though the dash needs a bit more trimming to fit just right.

http://img.photobucket.com/albums/v600/RS22b/Fiesta%20Rally%20Build/photo3.jpg

Tonight the plan is to get the dash 100% fitted and then work on getting the brake lines and fuel rails in and start putting it back together.

[gizzmo]

I like Killer Whale. Looks good Billy! You guys should've finished the smores man, I ended up with two melted hershey bars and a mass of oversized pink and white marshmallow when I got back to Indy :lol:

[geekmonster]

looks suh-weet!!

[rollo]

Orca Fiesta :)

[Drew84]

I saw it it running! I didn't have a chance to say hi Billy.