Stunning attention to detail mate, cracking build- a real credit!

Thanks for the nice feedback.

I like the Golf armrest as it's neat and solidly built. I'm fortunate as within reason I had free reign of height and mounting position due to modifying the mounting bracket to my own spec. I never really had a problem driving the old Mk4 Golf with an armrest, and I also had an old S3 years ago which was actually pretty much the same and I got on OK with that too. I know a lot of people didn't though.

A few more things ticked off the list:

Focus Centre Console
The used console I'd been using for mock up had picked up a few marks, so now I'm happy with the fit I purchased a new one.


I ordered this white multiplug from Vehicle Wiring Products and fitted it in line with the parking sensor display loom, so I can disconnect the display in future without the need to disturb the rest of the loom, most of which runs under the carpet.


Handbrake
The Focus console sweeps up towards the gear lever and meant that the Fiesta handbrake rest position was too low and let the lever hit the console. I'm now using a Focus handbrake which is shaped to suit, but obviously there are differences in the Fiesta and Floor pan so it still doesn't sit perfectly. To correct this I added a screw to the handbrake lever so I could fine tune the rest position.


Console fitted,lever adjusted, and gear lever surround trim temporarily fitted. The surround trim is black at the moment but that will change.


Armrest Mounting
I made use of the handbrake to create the front armrest fixing point as the shell under the handbrake mounts is already suitably reinforced. I welded a raised stud on to the rear of the handbrake (top) to achieve this. In the foreground is the reinforcement plate I made to fix under the exhaust tunnel in order to provide captive fittings for the other two armrest mounting points.


Armrest bracket mounted. I can't provoke any flex in the bracket or shell using my hands, so I'm pleased.


I mounted the armrest so that the bracket protruded out from the rear cup holder mount in the Focus console. I've trimmed the rubber cup holder insert to fit perfectly around the bracket.


All that remained was to bridge the gap between the Golf armrest shroud and the Focus console. To achieve this I cut up some Kitchen extractor fan ducting and bonded it to the Golf trim. Once it's dry I can trim to suit and paint to match the Fiesta trim colour.


Lexus IS200 Door Loom Gaiter
Here's the additional door gaiter in place (top) for which I added to house the new speaker cables. There was a spare blanking plug in the A Pillar which I made use of on the car side, I used a Dremel to remove the centre of the plug and then bonded the Lexus gaiter to the end of that. SMS made the corresponding hole in the doors whilst the car was with them for paint.


The gaiters have a slight overhang on the inside which means cables are kept clear of the Fiesta's secondary inner door skin.


Door Misc
Door lock position sensors fitted. These are for the deadlock and alarm system.


New door lock shields/window runners were then fitted in place and sealed with Sikaflex 221. I sprayed these with Dinitrol once fitted as they have a tendency to collect moisture and rust.


The last of the cable clips fitted to the doors, and also the mounting brackets for the door cards. I'm waiting on another delivery of vibration damping for the inner door frame and then the door cards can finally go on.

Just wow. A stated before, I almost don't want you to finish this!

Ive been dipping in and it of this build thread but read it in its enitiry this morning. My god how mad! A 500bhp Ford Fiesta lol! I love the attention to detail, the interior is just fantastic

Can't wait to see the interior with all these modern touches.

Sunroof
New Ford Mk5 Fiesta sunroof ordered.


The new sunroof (top) has tinted glass whereas the old (bottom) version had a mesh of ceramic coating. The new version is nice because it lets a lot more light into the car but offers the same level of solar protection.


Fitted.


Armrest Complete and Fitted
Here's the kitchen extractor fan ducting trimmed to suit the Focus console.


I wanted to paint the armrest plastics to match my interior trim, so I used thinners to remove as much of the VW soft feel paint as possible, and then a Scotch pad to give a good key for the paint. I used plastic primer and then matt black as a base coat.


For the colour matched paint I found a company in the States called SEM who produce 'Classic Coat' flexible coating specifically designed to be applied to plastic, vinyl etc. I found out that some US market vehicles were produced with the same trim colour as the Mk5 Fiesta interior so I ordered a can to suit.


The results were fantastic, it really is a superb product that serves to show how far DIY paints and coatings have come in the last ten years or so.


Armrest fitted.



Mk 4 Golf armrest, Mk1.5 Focus console, and Mk5 Fiesta dashboard The handbrake handle isn't fitted here because I've just sent it and the steering wheel away to be re trimmed in Alcantara with a stitching to match the leather colour.


Interior Door Handle Illumination
I chose to use new interior door handles from a 'Ghia' model, as these are chrome rather than black plastic.


I drilled the bottom of the door handle mount to make an interference fit for the Audi A6 illumination LED.


The outer trim cover was also drilled, but with a smaller hole so that only the tip of the LED is exposed inside the handle recess.


I removed the standard Ford tweeter and enlarged the hole to fit the Seas tweeter.


Driver's Door Completed
Inner door skin vibration damped.


Midbass driver fitted and stainless screws painted matt black.


Audi wiring plugs soldered on to suit the A6 door illumination loom.


New Ford door 'foil' waterproof membrane.


Membrane fitted.


BMW trim clips fitted and door card cut to accept the Audi A6 puddle and marker lights.


I used self adhesive cable clips to hold the Audi door loom neatly against the Fiesta door card.


I tried an additional sound deadening layer behind the door card, but alas, it didn't fit.


Door card fitted.


Marker light. The puddle lights are out of sight on the bottom edge of the door card.


Close up of Seas tweeter and handle illumination LED.


Misc. Parts
RS Accessory light clusters are no longer available so I refurbished a second hand set. I put them in the dishwasher to clean the insides, and for the outside I used Epoxy resin to fill in the various mould indentations, and then sanded off the casting marks and excess resin with 120 grit. I finished with 1500 wet and dry, G7, T cut, and then Autoglym polish. I left the Ford logo in tact because these are rarer than Hella produced versions, and also an E Mark in the bottom corner to satisfy any strict MOT testers.


Now I know that cruise control will work, I ordered a new Ford CC retrofit kit for the Mk1 Focus.


I found out that the ST170 Focus had real leather gear lever and handbrake lever gaiters, so I ordered those.

Excellent update.

Rear lights look better than new, top work!

Hello! Long time lurker, first time poster

So I like what you've done with the lights, did you tint the black bit yourself? I ask because my Noble M12 uses Mondeo Saloon rear lights and I've been looking and pondering ways of making them look better. Do you think you could help?

Sent PM as well in case you want to discuss off the thread.

Superb, that arm rest assy really came up nice after you painted it. Top marks as per usual!