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Aaron's 2nd Festiva Build Thread

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  • Aaron's 2nd Festiva Build Thread

    Unsure of exactly what it might entail or be used for, I made the decision a few weeks ago that it was time for another car. Finances are in good stead, and it was time for something different. Whether it be a personal project, a car for my sisters, a new daily driver, or a flip-and-sell project, this new vehicle was to be a summer time-waster for me and an opportunity to continue my journey of automotive discovery and discipline so that I would have an excuse to spend as much time as possible basking in the mild Victoria summer whilst I cool the jets from a tough couple of semesters of school.

    The white car's loyalty, though admirable, has begun to wear on me. Though it is absolutely a spot-on shooter, it does begin to erode you emotionally in certain circumstances. Whether you've been driving all day, have just gotten out of the gym, or are otherwise very tired, there are times when having a custom modified sports monster is not opportune. The suspension, though crisp, is really quite firm. The exhaust, though harmonic and throaty, is very loud. The smell, though indicative of performance, is a little too strong. In short, the car has potential to be more than just a daily driver... and the fire-breathing turbocharger knows it.

    Conscious of both my need for a fresh start and my car's need to be worshiped appropriately, I set off on a journey for alternative transportation. My as-of-late posting history will tell you quite directly that I had my sights set and locked on the procurement of a 1987 Suzuki Forsa 1.0L Turbo. I was committed to purchase, and with the agreement of the seller, had purchased a few hundred dollars worth of parts and prepared myself for the road-trip to pick it up from Nanaimo, a couple hours north of Victoria. Regrettably, the sellers decided that the car wasn't worth my trouble, and sold it behind my back to someone else. Shame really, as I had plans to make that car an absolutely amazing feat of automotive engineering by the time I was done with it.

    Knowing there was a lesson to be learned, and a silver lining to be found eventually, I held my tongue in hopes that my truthfulness and integrity would reward me for not lashing out against some people I barely even knew for doing something they felt was in their best interest. After all, another project car was surely just around the corner... and stuff is just stuff. It seems I have found a buyer for the majority of these parts I purchased for the car anyway, so no harm, no foul short of my fading disappointment and inverted excitement.

    The subsequent morning, I continued my search for another vehicle on the local classifieds and such by emailing almost a dozen various cars. All of them had something wrong with them, the vast majority were quite shy of $500, and some were even branded the stigmatized title of being mechanic's specials. Disheartened by the lack of email response, I refreshed the automotive listings only to find the absolutely perfect project car. I knew from the second I saw the photo that it had to be mine. I hadn't seen the price, read the ad, or evaluated the car at all... but I knew it was the one.

    It was a Festiva. An LX-model Festiva. One of the rare 1989 fuel-injected combinations, it carried with it the orange-themed interior and an automatic transmission. It was silver in colour, and was billed as being all original and never rebuilt. With the special and rare aluminum mags, some economical window tint, and a dent-free body, I knew there was serious potential here for me. In short, it was exactly what I was looking for and exactly what I had hoped to find. After all, I loved the vast majority of the things about my white Festiva... but longed to feel that sense of satisfaction brought about only by what the Ford factory and dealerships had delivered from 1988-1993.

    I emailed him as quickly as my fingers would carry me, all but demanding a spot in line to see and potentially buy the car and inquiring for more photos and information about the car's history. Shortly thereafter, I ran the VIN number through a database checker to determine the history of the vehicle and see if I had really found a winner. Fortunately, after weeks of searching, I finally had found one. The first great sign was seeing a string of green lights and check-marks down the page through every column and category. The second was the conclusion that the car had never been registered outside of Vancouver and Vancouver Island, which of course is indicative of very mild winters without much in the way of road salt (read as: rust). The third piece of telling news was that the car's VIN had a perfect score for a 24-year-old car, putting it at a tie with my white Festiva with a 32/37 performance rating. Not bad for a 24-year-old car with 310,000KM (193,000 miles) on it.

    The seller was quick to inform me that the car would even qualify for collector plates in the province in the subsequent year should I keep her all-original and insure another vehicle full-time. This of course, as an under-25 male and high risk driver, is an absolute delight to hear - I will take anything I can get when it comes to insurance reductions and cost minimization on my auto work. The only issue with the car was that I was not first in line... the ad had barely been up for an hour, and I had to patiently wait to see how things would turn out with the first potential buyer.

    The first buyer was obviously insane to turn down the car. The seller told me of his negotiating tactics, claiming that he was both rude and insulting in an attempt to dilute the car's cost and value. It was apparent to me what little I knew about this supposed buyer that he couldn't see the diamond in the rough that I saw. That's where we differed: though I knew full well and saw the car for what it is, having owned one and worshiped one for the past five years, I knew too what it could be with enough patience, time, and effort.

    The following morning, I dropped by to take a look with cash in hand and every intention of buying the car key unturned and hood unpopped. My heart raced when I saw the car, even though it was far from perfect. Cosmetically, it is much more beat up than the pictures would tell you. The paint job was fair, but details degraded its overall appearance. The original old hood had obviously flipped up and broken the cowl and windshield, requiring a new hood and a new windshield recently. Rust spots, deep scratches, and bubbly patches of paint plagued the car as if it were a seasoned war veteran. Duct tape held elements of the car in place, the interior was stale to put it politely, and the engine bay was absolutely filthy.



    It was apparent to me from the start that the factory paint had been over not once, but twice. Highlights and over-spray of a magenta/purple were tucked away in places you would expect to find over-spray, and aspects of the hatch, door jams, and fenders indicated a silver re-spray on top of that. And it was quite a good quality job at that. I was told by the previous owner that the car had been sitting for quite a while since he had received a free new car from his mother-in-law and opted to park the Festiva until such a time as he needed the money more than the car. That time was now, and I was ready to sink my teeth right into the project.

    The outside told me a story, but under the hood told me quite a different one. I loved what I saw under the hood of the vehicle. I had forgotten the calmness and simplicity of the factory motor setup. Compared to my testosterone infused turbocharged lion in the white car, I found a very adorable and well-mannered house cat in the silver car. How compact and quiet it was when it ran! But of course, it wasn't perfect mechanically either... what 24-year-old car is, right? The engine bay was spattered with dried gunk and oil, highly indicative of a valve cover gasket needing replacement. Further, the brake light was on and the owner claimed they needed immediate replacement both front and rear. Tack onto this a stale interior, a noticeably absent and forcibly removed stereo along with some factory Mercedes-Benz floor mats and you've got a unique little project there.

    1988 Chevy Sprint Turbo 997cc

  • #2
    As I said, my front-of-the-line comrade was nuts to turn down this car. I had zero criticisms of what I saw. With my heart still racing and doing everything I could to maintain my excitement, I tried my best to find any reason not to buy this car then and there just to ensure it wasn't an impulse buy I would regret. But there was no time for this process as I drew out my tattered burgundy wallet and presented my offering in exchange for the keys. He was a very honest and caring gentleman too, which only made the exchange that much more seamless and inevitable. Initially asking $500, we had settled on an agreeable $400 for the cost of the car in exchange for my quick few-questions-asked cash purchase. With the title transferred, temporary plates purchased, and insurance for the day covered, it was time to drive it home for a grand cost of $515.



    The car's first drive since 2010-2011 and my first behind the wheel was very memorable to say the least. For those 15 minutes or less, I was free. The car beckoned with anticipation to be driven again, and it quickly reminded me of the simple joys I once felt and appreciated for the Festiva franchise when my car was relatively unmodified several years ago. As soon as I fired her up, I instantly felt once more the simple joys of the factory vehicle Ford/Mazda/Kia released many years ago. What was it that made this particular car so special for me?

    The response and feedback from the steering wheel was as if the rack and pinion were soaked in hot butter as I slid through the twists and turns of the local streets. The response from the 12" aluminum wheels and 155/70-12 tires was superb. The suspension was loving for both the chassis as well as the driver. But most of all, that satisfaction and pride of driving an economy sub-compact was there again... and I forgot how intoxicating it really is. I felt all this in conjunction with a great degree of liberation compared to the white car. No longer would I fear blowing my intercooler piping, shattering my transmission, or being frustrated by electrical shorts. I listened closely to the symphonic 1324cc motor blaring away out of the exhaust hole as the three speed automatic shifted with a little bit of sluggishness.

    Most of my friends and family will be quick to tell you that I'm not really one for automatic transmissions. I was born and raised into a family of standard drivers, and I can count the number of times I've driven an automatic transmission vehicle on three fingers. Though I typically loathe the lack of control and precision, I was pleasantly surprised by the Festiva's transmission. It was actually quite a bit of fun. The exhaust problem didn't bother me all that much because it was still quieter than the white car, and the mushy brake pedal was manageable once I got used to the missing pedal for my eager left foot to mash between gears. From time to time, I found myself resting my hand on the gear lever anyway as if to respect the car's willingness to do the work for me.

    As soon as I got it in the driveway, I set to work on running a few minor diagnostics and major cleaning. After all, learning from my past experience with the Forsa Turbo, I vowed to not purchase or order any parts for this car until it was safely in my driveway. So, without any parts, there's only so much one can do to a car... especially in the pouring afternoon rain one typically finds in May weather. I started with the basics that I do on every car that ends up under my care by ensuring that the electrical, ignition, and charging systems were all running up to spec. The alternator was perfect, all of the ignition components looked fine, and the battery was still relatively charged up. I threw some Seafoam cleaner into the oil and fuel tank to help clean things out a little bit, tested some parts with my multimeter, and did some major cleaning of anything I could get my hands, brush, and degreaser on.

    I discovered a few little gems in the process. For one, once I washed them, it became apparent that I had almost new tires. Also, my brakes were just fine and required only a little extra brake fluid in the reservoir to firm right up. The exhaust issue was simply the pipe rusting through and detaching from the muffler, which should be an easy one hour fix from the local exhaust shop or a nearby friend. All in all, the so-called major issues I was presented with proved quite inexpensive and easy to fix. The car is now perfectly safe and ready to drive, and I'm likely to transfer my plates from the white car to this one relatively soon.

    After a couple of hours of labour on the car fixing and adjusting everything I could get my hands on, I got cleaned up and ordered a big pile of parts. It will probably be a couple days until I finish all of the cleaning inside and out, but I'm totally okay with that. Once my ordered parts arrive, I'm going to be doing a full maintenance overhaul and tune-up on her just to ensure things are in peak and optimal condition. All in all it has been a wonderful adventure so far with Festiva #2, and thank you very much for reading. I hope you enjoyed it.
    1988 Chevy Sprint Turbo 997cc

    Comment


    • #3
      Where's the like button? I saw that Festiva in my daily dose of www.searchused.ca and even thought about bringing it to your attention! Obviously that wasn't necessary.

      Sent from somewhere west of here via Tapatalk!
      Last edited by fastivaca; 05-28-2013, 11:59 AM.
      Ian
      Calgary AB, Canada
      93 L B6T: June 2016 FOTM
      59 Austin Healey "Bugeye" Sprite

      "It's infinitely better to fail with courage than to sit idle with fear...." Chip Gaines (pg 167 of Capital Gaines, Smart Things I Learned Doing Stupid Stuff)

      Link to the "Road Trip Starting Points" page of my Econobox Café blog

      Comment


      • #4
        Likedy like like!!


        -Scott
        Aqua 93 L
        Razor Red 09 F-150 XLT
        White 06 Ford Escape XLT

        Comment


        • #5
          I woke up this morning really happy with my purchase and anxious to keep working on her. First thing, I went down to the insurance broker and swapped the plates over from the white Festiva to the new silver one. It's ready to drive as my daily, and I'm really looking forward to having it on the road for a while at least. I gave her a very much needed wash which removed a lot of imperfections in the paint I assumed would need wet-sanding or touch ups, much to my satisfaction. I'm not going to start on any cosmetic bodywork however until I can confirm that there is a Dupli-Color Perfect Match spray can for this silver, for which I'm trying to track down the Ford paint code for cross-referencing purposes.

          That aside, today was essentially more cleaning, de-greasing, and deodorizing. First I shampooed and steam cleaned the front seats. Here's a before and after with the top obviously clean and the seat base dirty. To go with it, I gave the car's interior a bath of Simple Green to help with the odor and staleness, and vacuumed it a couple times over to get the carpets back up to spec. The headliner is going to need some more scrubbing though I think. With the seats reinstalled again, I was pretty pleased with the interior of the car. I still have to do the rear seats, but I'm a little bit tired and busy with other things. On a minor note, the ignition switch was a bit sticky and wouldn't turn to LOCK without a lot of persuasion, but it freed right up with some lubrication fortunately.


          On the performance front, I was a little concerned yesterday about my ignition performance and a touch of a rough idle as well. I figured it would be easily repaired though with some light maintenance work. I threw half a can of Seafoam through the brake booster line, which caused quite a smokescreen as is often the case on a car receiving it's first dose of the stuff. That helped somewhat with the idle. But beyond that, I could hear a little clicking/zapping noise while the car was running, but was too dirty and lazy to take a good look at the spark plugs to be certain of what was up. Sure enough, a plug wire was loose and the plug gap was excessive in all four cylinders due to aging. I of course have new ones in the mail, but I made the necessary adjustments just for now. They of course also needed cleaning from all the carbon deposits and soot that was built up on them from the Seafoam just prior, so I was sure to do that as well.

          I'm going to drive it consistently until all of my parts arrive, by which point there should be a few hundred kilometers on the oil with the Seafoam in the crankcase that I dumped in yesterday. That should soften and loosen some or most of the sludge in the motor, making the removal process much easier. I of course expect that with a fresh high quality filter and good oil that things will improve in the motor over time as fresh detergents eat away at any gunk in there as well. Chances are I will drop the oil pan and valve cover just to ensure everything's all cleaned out though and nothing's clogging the oil pickup tube.

          After making some quick adjustments to the accelerator cable and the parking brake, it was time for a much needed engine bay detailing. Here's my before and after... the majority of the work was done by Simple Green, Engine Brite, and a garden hose... though I did get down and dirty quite a bit to get most of the engine oil gunk off of the head and valve cover.
          1988 Chevy Sprint Turbo 997cc

          Comment


          • #6
            Its a Diamond in the rough.Good find!
            Some people like to read fiction,I prefer to read repair manuals. Weird I know-
            Henry Ford: "Failure is the opportunity to begin again more intelligently"
            Fuseable Link Distribution Block repair link

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            • #7
              I cannot wait to see it. Are you bringing it or the white one to Westiva?

              Comment


              • #8
                Wow, that is a perfect project car, the fun is starting! Sweet!
                Reflex paint by Langeman...Lifted...Tow Rig

                Comment


                • #9
                  The job of the day was deep interior cleaning and insulation. I've done similar jobs on previous cars, and knew that this was to be a comfort modification on a comfortable car. I picked up all of my supplies at the local Home Depot. Though I'm sure brand name stuff works far better, my needs are met by my sub-$100 purchase. Today, I just did the flooring from the front seats back. I will, in the near future, tackle the headliner, doors, and maybe the cabin-side of the firewall as well. This is a multiple person job if you can find a friend to help, but it's doable with a loud radio and Gatorade if you're stuck doing it alone as I was today.



                  Here is what I started with... a familiar rusty site to most Festiva owners. This was during a very involved cleaning process in an attempt to make the cabin smell a bit less prominent. It has been continuously improving since I got the car and started cleaning things repeatedly... and I'm not likely to stop until it is pleasant once more.



                  The supplies shown are a roll of cork-based carpet underlay, 2.5 rolls of Blueskin Flashing, three bags of Polyfill, a couple cans of Great Stuff, and heavy duty cleaner. That's pretty much all you need to get down and dirty on your insulation project. The Blueskin is the main sound-eater, with the rest serving supporting roles in various crevices large and small.



                  It was probably good that I chose to do this so early. There was so much moisture, gunk, and potential for mold underneath the carpet. I made quick work of it all with heavy duty cleansers, wire brushes, and a shop vacuum before applying the base coat of Blueskin for insulation. On top of that, I applied a layer of carpet underlay. Then the carpet went back in, followed by the seats.
                  1988 Chevy Sprint Turbo 997cc

                  Comment


                  • #10
                    Originally posted by fastivaca View Post
                    Where's the like button? I saw that Festiva in my daily dose of www.searchused.ca and even thought about bringing it to your attention! Obviously that wasn't necessary.

                    Sent from somewhere west of here via Tapatalk!
                    Be sure to shoot me a text the next time you see one come up!

                    Originally posted by leapin View Post
                    Likedy like like!!
                    Originally posted by nitrofarm View Post
                    Its a Diamond in the rough.Good find!
                    Thanks, gents!

                    Originally posted by bolokid View Post
                    I cannot wait to see it. Are you bringing it or the white one to Westiva?
                    Hard to say. Not sure whether I'll be making it this year just yet. Currently the grey one is licensed, but I suppose we will see.

                    Originally posted by Movin View Post
                    Wow, that is a perfect project car, the fun is starting! Sweet!
                    Yes indeed! Stay tuned... gonna move as fast as I can on this one.
                    1988 Chevy Sprint Turbo 997cc

                    Comment


                    • #11
                      Whoa...you are taking this clean up, smell good and insulation to epic levels, and making it sound inexpensive and easy!! Thats awesome, stay with the pics and share, we love it!!!
                      Reflex paint by Langeman...Lifted...Tow Rig

                      Comment


                      • #12
                        Day four... a busy one thus far. Two main jobs so far for the morning and the afternoon. I started with deodorizing and degreasing the door panels. The vapor shields were tattered, in pieces, and very messy. My heavy duty citrus cleaner made quick work of the panels though and removed a lot of smelly dirt and grime. Then I took yesterday's remaining window flashing and lined the door panels in it. I figured this was smarter than coating the actual door so that I can remove it easily if needs be to install power windows or doors in the near future. On top of that, a 1/4" thick layer of cork underlayment with a new plastic vapor shield.



                        In all three of the doors (hatch too, which was stuffed with Polyfill), there was a noticeable improvement in the clunk noise and weight of the door. The sound is much deeper and more solid, kind of like a modern car. I look forward to testing it out on the road pretty soon. While I was in there, I had a great chance to lubricate all of the door and window assembly pieces and tighten up some very loose bolts that the previous owner's mechanic forgot to tighten properly, which caused a lot of shaking and rattling at speed.

                        The second job is one I did on my white Festiva and with which I was very happy. Julian has called this process "fender gooping", but technically it is lining the wheel arches with liquid rubberized asphalt used for roof patching and repair. Here's my how-to on insulating the wheel wells from my other build thread: http://tinyurl.com/8nkbnbd



                        Should do a number on tire and wheel noise... if not, another coat is in order! Stuff is very economical, and makes a noticeable improvement I must say. Highly recommended mod that costs you less than $50 to pull off if you do it cheaply with Home Depot brushes and goop.
                        1988 Chevy Sprint Turbo 997cc

                        Comment


                        • #13
                          How many miles were on it when you purchased it??

                          Comment


                          • #14
                            310,000KM / 192,000 miles as stated in the original post. Yesterday, I didn't get many pictures of my wheel cleaning and polishing unfortunately because it was pretty dark out which made the photos look all distorted with the work I was doing. I wanted to do a nice how-to on restoring the factory wheels, but it's pretty intuitive to be honest with you. Essentially though, I gave them all a very thorough degreasing/cleaning/polishing back to the factory aluminum look. It made a huge difference in the look of the car if you ask me.



                            To do it, I started with spraying Simple Green and Citrus Degreaser on them and giving them a solid wash. Then I used aluminum cleaner, some rubbing compound, and a drill with wire brush attachments to attack the brake dust and get them cleaned up really nice. Another couple cycles of degrease, wash, and wire brush... then I finished them off with some high grit sandpaper. Even though the rubbing compound was technically for paint, it worked really nicely in conjunction with the wire brush fittings for my drill. It ripped the brake dust to shreds and made a nice effect on the lip of the rims too.

                            I ran low on patience by the end of it, but they do look a heck of a lot nicer than they did. I can always do more with them later if I feel like it, really. I ended up messing up some threads mounting the fourth and final wheel back on, but I picked up a tap and die this morning (my set didn't have M12x1.5 unfortunately) and that fixed it right up. Lesson learned... always hand thread your bolts. Soon enough I'll convert this one to lug studs though, so that will be the end of my worries! Fortunately, I now have the tools on hand to fix it if it ever happens again. I did soak the lug nuts in heavy degreaser while I was doing the wheel cleaning, which helped clean them up really nicely... the threads looked much less rusty and gummed up when it was done soaking.

                            This morning's project was to improve my electrical grounds. On previous cars, I did it ultra-JDM style with wires running everywhere... but I decided to try my luck at mostly working with the factory equipment and see how much of an improvement I could make. Even though I've already cleaned up my ignition system twice now, it still didn't crank as strongly as I wanted it to. It did take a while to turn over when cranking, even though it always started. I shined up the contacts on the negative cable using electrical cleaner and a wire brush attachment on the end of my drill. This brought the terminals back to shiny conductive ones and the mounting points back to clean and bare metal. I also shined up the battery terminals to remove corrosion.



                            Once I was done with the cable, resistance had dropped from 0.7-0.8 ohms to 0.2-0.3 ohms. Not that it was bad or anything before, but it was still a significant improvement! Similar results were found when I replaced the factory engine ground that runs from the block to the passenger shock tower. I added two extra 10AWG wires from the valve cover to the firewall and the valve cover to the radiator support just for kicks.

                            The impact was noticeable right from the get-go. The car now cranks with serious attitude - more audible noise and a higher rotation speed. This makes the car now start a lot faster. Also, it actually improved my charging system by about 0.25V across the battery - I went up from 14.1V to 14.4V with the car idling. Sounds good to me!
                            1988 Chevy Sprint Turbo 997cc

                            Comment


                            • #15
                              Did some more work on the fenders to ensure that my wheel and tire noise is minimized. I ran out of goop and flashing after this passenger side one, so I buckled it all back together and will head off to Home Depot to acquire more of both to do the driver's side. I may do underneath the front bumper/grill/headlights as well if I feel up to it today.

                              1988 Chevy Sprint Turbo 997cc

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