Project - Father & Son

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Puma D

Member
Joined
Mar 20, 2021
Messages
69
Morning All,

Firstly Happy Bank Holiday to you all ! So this is a Project that has been done by my son and I, First time we have built a track car and it is a ongoing project that will eventually develop into a good track for us both to drive. I have been in the Automotive sector for 30 years in one form or another and my son is an apprentice engineer - Both Car mad LOL anyway enough chit chat, time for the build progress (First post will be pic heavy as I was meaning to post as we went along but just been too busy)

Start of Project

Stock Ford Puma 1.7 125Ps, 1999, 75K from new with FSH - 2 Owner car.

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Took the car to a local Weigh Bridge with a full tank of fuel car weighed in at 1040kgs Dead

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Then started the strip of the interior, Everything bar the Dashboard was to come out....

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Few cosmetic touches as we went along - Painted the rear drums

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Removed the Original Air Box and replaced it with a Ram-Air Filter with two cold air feeds (One original from the inner wing, the other through the lower valance)

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Removed the original discs and calliper's

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After much research and options we decided to go for Focus ST170 Calipers with 300mm Vented Discs and Cosworth Pads

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The Caliper needs a little fettling on outer edge grinding down a touch as we wanted to retain a 15" Wheel, Opted for Speedline Mamora Alloys with a Peugeot offset (Wanted the wheels to fill the arches as stock wheels sit too much inwards) Wrapped the wheels in Michelin Pilot Sport 3's

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This was Stage 1 of our mod's (Original front seat were just kept in whilst we decided on what seats we wanted)

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Many thanks for your comments, The car is solid underneath, Previous 2 owners never sacrificed on maintenance and were from the same area, it was only ever serviced and maintained by Ford Main Dealer and 1 independent specialist. I wanted a good base car. Will do more updates shortly as the project has come along a bit more and managed to get in two track days so far.
 
Next step was to sort out the Seats, Due to both me and my son being tall (Over 6ft4) we wanted a seat suitable for track but also suitable for road use. we opted for the Sparco R100 which we managed to pick up a Brand New set of eBay that had never been installed (1 seat had a very slight mark). This was the easy part.

Fitting the seat was an absolute B*tch of a job for those of you who don't know the floor pan on a 1999 Ford Puma is not the same as a Mk4 Fiesta (earlier puma's have the same floor pan) Thus the OMP Subframes I purchased were not a direct fitment. The rear inner whole although lined up had an approx gap of 20-25mm so required some sort of packer (I later learnt that Sparco do an adapter - Grrrrrr) Irrespective of this the actual location of the subframe for driving position is just so poor. I sat down with a mate of mine (no pun intended lol) and we basically cut and rewelded the Subframe so now I have plenty of adjustment forward and backwards and the seat sits central to the pedals and steering wheel.

Prior to Drivers seat Adjustment - Also used 4 Point Sparco Harnesses

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Went for a OMP Flat Bottom Steering wheel, Horn works as it should by taking back ring of original wheel and Airbag delet resistors installed on Steering wheel and Seats - No warning lights on Dash.

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Also Installed 3 OMP Strut Braces - Front Upper, Front Lower and Rear Upper, Then removed the Spare wheel, and Under tray that hold sit in place. Then removed the rear bumper and put in 7 x 76mm holes to allow the air to flow through the car and out as the rear bumper acts as a massive air brake. (Had to trim the lower half of the inner bumper reinforcement too.

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Next on the agenda we carried out the following:
Goodridge Braided Lines
RBF 660 Brake Fluid
Shell Helix Engine Oil
Sytec Fuel Pressure Regulator
4 Branch Manifold
Full Exhaust System
PI Lowering Springs
Fire Extinguisher
Door Pulls

Made plates for the Switches just to make the door look a little more appealing and some race car style handles

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We are eventually going to install coilovers however for the interim we went for Pi Lowering springs (40mm All-round) Also Installed a 4 Branch 4 into 2 into 1 Manifold, Had this Heat wrapped before installing and then went for a Sportex Rear box and Hoffmann centre Section (Although fitment of centre section is not great so going to get a customer centre section made so it doesn't catch on body,

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Now that the car was starting to take shape and I had been invited to a Private Track Day at Castle Coombe in the end of July, I wanted to weigh the car and see how much weight i had managed to shed from the Puma . Same criteia Full tank of Fuel and it came in at 1000kgs on the nose.

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My son and I wanted to make the car look a little more "Racy" the problem was as with everything in life we were on a budget for this build which was rapidly depleting so I managed to track down a kit from a Decal Company and requested a few small tweaks and then between Father and Son and one of my Best Mates and his son the 4 of us gave it a go ourselves. The end result I'm sure you will agree looks Wicked ! IMHO. No bubbles, no creases but was a bitch to do lol.

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Finished Result........

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First track Day shake down at Castle Coombe ...... (My mates Escort Cosworth in the background)

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On the grid with my Mates Ford GT Heritage Edition

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Wooooow amazing!!!!!! Great job, ford rallyesport decals are perfect :grin: :grin: :grin:
How it sounds the sportex? I want to put in to my puma 1.7, it sounds too high, or is quite loud and rumble? :?:
 
Hi !

Many thanks for your comments, The Sportex sounds lovely - You get a little lift off crackle (But that could be because I also have a 4 branch manifold) it's not too loud either - When I did my first track day at Castle Coombe the Marshall doing the noise test said to me "Your not trying very hard are you Sir " LOL
 
You deserve all my compliments, i very enjoy this types of transformation, specially done very smooth and clean like yours :grin:
Regarding the manifold directed to the air filter, this can take a lot of fresh air, but when it rains? It is a problem? I want to made this mod to my puma, but it is a daily drive, not a track car, and how many hp with an high performance filter this mod can make? Thanks
 
The Ram Filter will probably free up a few HP (Nothing noticeable however the induction noise is addictive lol) but more to allow the engine just to breathe a little better, With regards to the Rain - It is fairly well shielded by the bonnet and I've not had any issue with this.

Hope that helps.
 
Good morning to everyone, i was going to upgrade the brakes, with the front mk1 st170 focus discs can you see differences from the standard ones? Did you need to move the calipers, with a steel support or others? Because the new discs are bigger than the original, how can you move the calipers? Thanks :grin:
 
You need the calipers & pads from Mk3 Ford Mondeo for cheap cost & availability. Ideally need 16" or greater wheels to give room but some 15"'s can be used if you are also prepared to grind the calipers a little to give clearance (I wasn't)

Quick search brings up this "how to" guide:- https://www.projectpuma.com/viewtopic.php?t=7991

Some of it is slightly mis-written but people have corrected it where needed later on (hole/bolt sizes etc)

It's a really easy modification anyway and well worth it in my experience :thumbs:
 
Lorenzo Zaga said:
Good morning to everyone, i was going to upgrade the brakes, with the front mk1 st170 focus discs can you see differences from the standard ones? Did you need to move the calipers, with a steel support or others? Because the new discs are bigger than the original, how can you move the calipers? Thanks :grin:

Hi,

I used Focus ST170 Calipers with 300mm Discs, The only thing you will need is a slightly larger bolt which the calipers should come with (I would get new replacements though) You make the hole in the caliper mount slightly bigger of memory I thinks it's 12.5mm (But I maybe corrected Lol) Take your time drilling the holes as you want the bolt to pass through nice and tight and not a sloppy fit.

Or you can use Mondeo set-up, Plenty of good advice on this forum, and plenty of helpful members. :) I will try to get some more pictures up later of the car at Oulton Park.

Thanks to all the members for the compliments too it is much appreciated.
 
Thanks! Ok, so i have to drill for the new calipers position? And i need bigger bolts? :?: sorry its the first time i upgrade the brakes :lol:
 
Have a look here for some useful information https://www.projectpuma.com/viewtopic.php?t=7991
 

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