#ZedShed 1983 Fiesta 1.3S (Full Resto)

[Lee]

New year means new projects and a slight new direction. Now we’re nearing 100 Zed builds we wanted to do something a little different, we often get asked to do other cars so we thought we’d give it a try. A good friend I work with has this gem of a 1983 Fiesta which he started to rebuild 9/10 years ago, think he needs a little nudge to get her to the finish.

This was her pre rebuild 10 years ago.

The inspiration for the look & stance

Fast forward to today……. Collection day.

5mins later she’s made it to the unit.

First impressions are very good. The shell is in cracking condition considering it’s 40 years old. Two small areas up front in the footwells will need cutting out and repairing correctly. I’ll let the photos do the talking.

Overall image

Rear near side front n back

Rear offside front n back

Front near side in and out.

Front offside in and out

At this stage all the interior is out along with the engine. Engine has had the head rebuilt to accept modern day fuels. Gearbox is in the car but she will be coming out so we can get the whole underside back to bare metal and the running gear off for powder coating.

Gearbox still in.

Areas for cutting and welding.
Drivers side

Passenger side

This is going to be a mega exciting build we start tomorrow

 

[pgunter]

Looking forward to this different resto

 

[backseateducation]

Fantastic. Got to love an old ford, I've had a few over the the years. Looking forward to seeing this done

 

[andyglym]

That's great mate, proper old skool

 

[TaffDaddy]

Looking forward to this one @Lee . Brings back memories of my first car although mine was the Quartz version which was faster than the standard as it has stickers

 

[MuttyMax]

I had red XR2 which I called “the buzz bomb”…. … fondly remembered … I still have the rectangular racing 155 hella lights with the original white covers in my shed .. which looked really cool (at least I though so) ..… even remember the reg no. A752DPA…. Ahhhhh ….🫠

 

[PHILIP BAXTER]

What a great project.

 

[Lee]

Today we made a start getting the shell back to bare metal. First up we started at the rear this then at least keeps the car balanced on the ramp, no engine up front means she’s very light already.

First job was wheels off and rear drum hubs off. Got to love the simplicity of 70’s car design. Castle nuts, split pins and tapered bearings.

Drum off with integral tapered bearing.

Shoes removed along with brake cylinder.

Interesting how the roll bar joins to the shock, we did notice how all the rubber items were cracking so these will be fun hunting down.

Interesting Gaz Gold shock design, it sits on a pin off the subframe arm.

With the last of the brake components disconnected we only had one bolt each side left to drop the subframe

When the subframe was down we did notice what looks like an un-natural bend in what I can only guess is some kind of torsion bar for stiffen the rear subframe. See picture.

With the subframe out we get good access to all the areas now and can see some previous repairs.

Good overall shot

Near side

Offside

Subframe with all its bits ready for strip down

Next up we’ll get the fuel tank off and start removing the old under seal

Exciting

 

[t-tony]

Looks like someone has had a trolley jack under that Panhard rod to me. Probably in a tyre house somewhere.

Tony.

 

[Lee]

Saturday we did lots of stuff. The front end is now apart ready for cleaning and metal work to go away for powder coating. Engine bay and underside needs a good clean.

Selection of photos showing the front end assembly. Brake discs spin freely relative to the hub so I’m guessing these are an upgrade over the original 1.3 maybe from something like the XR2

Nice simple joints and hardly any corrosion.

Coming apart nicely

Next up was the two part central subframe so we could remove the gearbox.

Came out no issues at all

Leaving a relatively empty engine bay.

Both front arches now empty

All the metalwork is now ready to head off to powder coat. Front end components are in one box and the rear in another. Not that there’s a huge amount of bits.

Next up we removed the fuel tank. Knowing this car has been off the road over a decade we need to inspect the inside. The engine runs on a carb so dirt n debris is a big no no.

Diddy tank removed, can see where the car was under sealed around it.

Was hard to get the right angle to get a photo inside. Look at the state of the fuel

I’m no expert but this don’t look great, some advise on a direction for this would be handy. I wonder if these can still be bought new.

Next step is to acquire some cleaning products and steam clean the underside. Then get our fab guy next door to come make some tidier repairs.

Was dark when we finished. Project Fiesta moving on nicely.

 

[Jack Ratt]

In the grand scheme of things and compared with modern cars there aren't many individual parts on these old Fords and aren't they tiny? The bodywork looks very solid so doesn't look like it's had a hard life.

 

[Zephyr]

Is there a cross reference with modern after market parts such as bushings, rubbers etc for such an old car or you just try anything that fits and use it?
(asking as currently trying to figure out how to proceed with a similar project)
Thanks.

 

[Althulas]

Ed’s China had a entertaining approach to dealing with a rusty fuel tank.

View: https://youtube.com/watch?v=Iu2TD3OUI3Q&si=EnSIkaIECMiOmarE

View: https://youtube.com/watch?v=XHi9iQNNII0&si=EnSIkaIECMiOmarE


I know you can buy coatings/sealers for the inside of a fuel tank but after the time, effort and price I think I would opt for a pattern part unless originality is key.

MKI

https://www.carbodypanels4u.co.uk/ford/fiesta/ford-fiesta-3-door-hatchback-1977-1983-mk1/fuel-tank-petrol

MKII

https://www.carbodypanels4u.co.uk/ford/fiesta/ford-fiesta-3-door-hatchback-1983-1989-mk2/fuel-tank-petrol-non-injection-40-litres-top-sender-1986-1989

Looking forward to the rest of the story

 

[t-tony]

I would never be confident on coating the inside of a tank and certainly wouldn't use E10 fuel in one.

Tony

 

[Lee]

Been slow progress between catching all the lurgy going around. Least we can call it progress. All the metalwork was stripped and bushes removed for powder coating which all came back looking amazing.

All stripped

dropped off for Grit blasting, Zinc coating, powder coating

Collection day was earlier this week and it all looks amazing.

we’ve also taken delivery of the bushes and front to back nut n bolt kit. Really looking forward to putting this lot back together in the next week or two. Will get her rolling ready to fix the small holes.

 

[andyglym]

Been slow progress between catching all the lurgy going around. Least we can call it progress. All the metalwork was stripped and bushes removed for powder coating which all came back looking amazing.

All stripped
View attachment 250199
dropped off for Grit blasting, Zinc coating, powder coating
View attachment 250201

Collection day was earlier this week and it all looks amazing.
View attachment 250205View attachment 250203View attachment 250207View attachment 250213View attachment 250209View attachment 250211
we’ve also taken delivery of the bushes and front to back nut n bolt kit. Really looking forward to putting this lot back together in the next week or two. Will get her rolling ready to fix the small holes.
View attachment 250215

Looks spot on that mate

 

[Lee]

Now the 3 series is out the way. I’ve started rebuilding the rear end of the Fiesta

Cleaned back one area that needs cutting out. Underseal revealed this mess.

so satisfying assembling these arms.

 

[Lee]

After the dry run me n Chris (the owner) got cracking doing the fitting, lots of trial n error making sure things are oriented right and bolts being in logical places so future maintenance is easier.

Not a lot of assembly to show so here’s the assembly back on.

was a Ford theme in the unit, what has happened to us

Mk1 Fiesta next to a MK7.5 300bhp monster. Once we got asfar as we could today with the rear we started assembling the front, doing a dry run making sure we have the right bolts and bushes in the right places. The roll bar bushes really gave us some trouble due to the thickness of the powder coat they struggled to fit.

gearbox bracket and new engine mounts.

really helpful doing these dry runs, highlighted the next load of parts to order. The current aim being getting her rolling so the guys next door can do some welding.

 

[ktnez99]

How are you removing the under seal @Lee? And what welders next door?

 

[Lee]

How are you removing the under seal @Lee? And what welders next door?

Underseal has been removed off with a combination of friction and steam. Welder next door called Ian lol