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Thread: My Escort XE Project!

  1. #81
    Racer Decade Plus User Forest_rallying's Avatar

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    Re: My Escort XE Project!

    Nice work skmotorsport!

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    Re: My Escort XE Project!

    Looks stunning

  3. #83
    Racer Decade Plus User wildo105e's Avatar

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    My Escort XE Project!

    Great work 👍

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    Re: My Escort XE Project!

    Gearbox bracket finished!
    The normal T9 Gearbox bracket is too short if you fit a big tunnel!
    Gear1.jpg Gear 2.jpg
    Gear 3.jpg Gear 4.jpg

    Maybe I will attach some triangled plates to stiffen the outer wings...


    Next job was my Ingnition Coil pack.
    Normally it sits near the heater bowl. But I decided to screw it to the engine.
    After make some paper mockups I ordered a 10mm thick alloy plate. To reduce vibrations I will add some rubber washers.

    Igplate 1.jpg Igplate 2.jpg
    Igplate 3.jpg Igplate 4.jpg

    Now it sits under my Throttlebodies and the Ignition cables are not visible...



    Stay tuned

  5. #85
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    Re: My Escort XE Project!

    Not much done due to a lot of private appointments...
    BUT... I finished my Rims!!!
    Look at this beauties!!
    34669887_1766868320044229_8174438704165683200_n.jpg

    34343771_1766902110040850_1166790267538243584_n.jpg

    34133591_1766868300044231_913677365064761344_n.jpg

  6. #86
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    Not much done due to a lot of private appointments...
    BUT... I finished my Rims!!!
    Look at this beauties!!
    Attachment 82845

    Attachment 82846

    Attachment 82847
    very nice...keep the pics comimg..cheers mark

  7. #87
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    Re: My Escort XE Project!

    Next job done...Closing my huge gearbox tunnel hole. My intention is to keep the escort as original as possible inside! To keep the original center console in place with the big gearbox tunnel it was nescessary to build my own cover and weld it together. Just some small tuning underneath the center console with the grinder and here we are...it fits nearly perfect with the IP/ ashtray cover. There ist a small 8mm gap which i can close with the anti noise foil and the carpet!
    IMG_9258.JPG Mittelkonsole 1.jpg
    Mittelkonsole 3.jpg Mittelkonsole 4.jpg
    Mittelkonsole 5.jpg Mittelkonsole 7.jpg


    stay tuned....

  8. #88
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    Re: My Escort XE Project!

    The tyre nightmare. After fitting the BBS it shows that the fenders need more work...and the tyres more space...
    Front 5.jpg Front 2.jpg

    Rear 3.jpg Side 2.jpg

    Maybe I need to mill the alloy front hubs by 10mm to get the wheels under my fenders. Tomorrow I will check the clearance between the tyre and the front springs. If there´s enough clearance I can move on...
    The rearside fits perfeclty.

  9. #89
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    Re: My Escort XE Project!

    Last week I finished the welding on the watts linkage (pre welded, final welding will be done on the roller Jig)
    Both Watt domes are now in place.
    watt 5.jpg watt 6.jpg

    Watt 1.jpg watt 83.jpg

    I also mounted the alloy radiator to prepare the cooling hoses.

    Kühlschlauch 1.jpg Motor mit Kühler.jpg

    And I sarted to check the routing of the exhaust system. It seems to need abit love an time to get more clearance to the Steering column shaft.

    Auspuff.jpg

    To get more clearance at the front fenders I ordered again new alloy hubs with standard measurements. The ones I used at the moment are the GRP4 Style hubs with a plus of 10mm per side! Together with some slight modifications at the fenders together with some spacers between the BBS outer Rims it will produce about 15mm more clearance! That should be enough to go lower at the front!!Next Job will be the brake lines.

    Stay tuned...

  10. #90
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    Re: My Escort XE Project!

    Last week I´ve checked the bias paddle box...what else...the throttle pedal goes straight through my steering column shaft.
    After redesign it looks a bit funny...but it works perfectly.

    Gaspedal.jpg

  11. #91
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    Re: My Escort XE Project!

    Small steps...
    Cooling hose.jpg cooling hose 2.jpg
    Adapter found from Motamec to get water hoses in the perfect angle!

    Brake fluid bottle 1.jpg Brake fluid bottle 3.jpg
    Also found a place for my two brake fluid bottles...(not the alloy bumper brackets!!)

    Next step is to complete the brake system. With metal hoses, adapters for the Wilwood calipers...

    Brake lines.jpg
    And I received a funny pic from a friend...he modifiyed my trumpets!

    Trumpets.jpg

  12. #92
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    Re: My Escort XE Project!

    Looking great, keep at it

    Matt

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    Re: My Escort XE Project!

    This week I started with the gearbox. I ordered a new alloy top plate with breather from JT.

    740A858E-36EE-4D74-A471-2C9F56B97ACF.jpeg

    And I made some wings to stiften the gearbox mounting

    03A71342-D84F-4EC8-960F-29583421D848.jpeg D6AC356D-DB21-4ECE-9328-B60BA2E873A0.jpeg

    And I started to find out the best Seat position. One issue to fix is the bias Pedal Box brake Pedal position.
    To get it in the right Position i have to cut the thread from the Pistons an made two 6 mm thick spacer

    960E63F7-758A-427B-B886-902C34C93ED6.jpeg

    Also the fuel pump bracket arrived. Now all parts can go to powder coating.

    Stay tuned...

  15. #95
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    Re: My Escort XE Project!

    Engine and Brake fluid reservoir brackets came back.

    3549457.jpg

    Yesterday i started to finish the trunk. It seems that I need to cut the top of the tank bracket to get silver paint behind the punched holes!

    trunk 1.jpg trunk 2.jpg trunk 3.jpg

    next step is creating the bracket for the battery and the fuel pump/filter galery.

  16. #96
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    Re: My Escort XE Project!

    Next stop, fuel Tank sender for my RS cluster.
    The cluster is now ready with the carbon foil. The rev.couter is Now getting to a specialist to expand the rev Range from 7000 to 8000 rpm.
    DF371D86-ED75-431B-AF2E-A19A80E5AEFB.jpeg

    Final solution for the fuel sender unit was the original one, which is used in standard escorts. To fix it I used alloy rivet nuts.
    B06E3D0B-54AA-4F5A-8B52-024B4BB7849A.jpeg A79984BD-BD34-41EF-BC41-EBF4FEECF99E.jpeg

    To get a balanced presure to the unit I used a alloy ring. Now it looks perfekt.

    82950BD0-2CD4-42D9-89F2-170F7AE6EE27.jpeg 09A9A863-8A2D-4B4E-9CCB-D5513692F2D7.jpeg

    Now it will take some hours of cleaning the tank !
    Also the wet sump came back from welding.
    Now it‘s Time to finishthe engine.

    Before and after...

    74DD057E-3F4E-4B66-BA46-E77AF94171DA.jpeg 8B656757-5EAC-4247-B6F8-F00A301B7C72.jpeg

    Stay tuned....

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    Re: My Escort XE Project!

    Still pushing ...
    After hours of searching I came to the conclusion that someone scrap my blody Oil pickup pipe! So I bought again 2 used pipes to modify them for the Wet sump according Steve´s manual (SBD).

    Pickuppipe1.jpg

    After cutting I went to an old friend who builds custom bikes. He made two sleves and brazed the pipe together!

    Pickuppipe.jpg

    To get a Oil temperature signal from the XE, I used the plug screw from the oil pump. Just bought an VDO sensor in M14x1,5 and cut a thread in the plug...now here we are...

    Oil temp.jpg

    To get the oil presure signal I bought an original Oil presure pipe for the RS cluster.
    Last job yesterday was to create a battery tray. I used a 3mm thick metal plate, to support the battery tray from below.

    Battery Tray.jpg Battery Tray2.jpg

    Batterytray support.jpg

    Stay tuned...

  18. #98
    Racer Decade Plus User wildo105e's Avatar

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    Re: My Escort XE Project!

    Great progress as usual keep the updates coming.

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  20. #99
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    Re: My Escort XE Project!

    New day , new issue, as usual.
    we brazed the oil pickup pipe together. But the angle of the pipe was 5 degrees wrong. My fault.

    wrong pipes.jpg

    To get it to the right angle I screwed both pipes together on a peace of Wood.

    wrong pipes 2.jpg

    And some new Christmas goodies arived yesterday...
    My Alloy Firewall

    firewall.jpg

    and my Carbon Strut brace

    Strut bar carbon.jpg

    Nice work !
    Stay tuned...

  21. #100
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    Re: My Escort XE Project!

    Just a picture...

    Bar2.jpg

    one step forward...3 steps back...
    There is absolutely NO part which I can put at the car from the box! Bloody rework on every single piece!

  22. #101
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    Re: My Escort XE Project!

    Hi, good work! That will be a nice car when finished. Which gold tone did you use for your bbs centers? Do you have a color code? Looks very close to the original.
    Have a nice Christmas!
    Best Regards
    Lars

  23. #102
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    Re: My Escort XE Project!

    Der Lackierer ist im Urlaub. Muss ich anfragen.

  24. #103
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    Re: My Escort XE Project!

    Next stop...exhaust. The Tony Law manifold runs straight throug my steering. Time to cut and redesign. 9F11D70C-E31A-47DD-A0CD-624E11709B26.jpeg BF226B65-2048-4CB0-8AE9-AB8D393495E0.jpeg FAA11676-44F4-46FD-AC52-D4DFEE956D24.jpeg 361F3F16-8391-4521-9A92-CC0D83FA89A0.jpeg

    And I spend some Time with the brake Lines...

    6D4B5581-68CF-46FE-B355-0AAE153A1B0C.jpeg A8BC9ABB-E91B-451A-A5E0-3DAF3A1DE2C8.jpeg

    Finaly some easy stuff...

    084BAF17-F289-4EC3-9098-C0609AAF0CCE.jpeg 7AD74E6C-2F18-4EE5-9F38-E196D2D5B60B.jpeg

    On thursday we will weld the new routed pipes together with WIG

  25. #104
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    Re: My Escort XE Project!

    Shame you have to cup up TLE but I understand you have to. Mine just arrived today to allow me to mock up the engine but mines RHD so can't foresee any issues.

    Keep up the good work. I'm a little behind your progress so I look forward to the updates.

  26. #105
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    Re: My Escort XE Project!

    I‘m with you...the First cut in this nice peace of work was the hardest! I called TLE to get some Support for an left hand drive Version it. Nooooooo...
    Before cutting we have done „the paper blow test“ ...tomorrow I will try it again.
    (Put a peace of paper at the to of 3 pipes and blow air in the fourth , If the paper get sucked to the pipes on all four pipes you have a great exhaust...more or less  )

  27. #106
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    Re: My Escort XE Project!

    Heater pipes done. A lot of clamps, but with a perfekt routing now, and no touch condition to the coil which is Now located under the throttle bodies.

    BFF43125-7BB0-4ADA-BE9D-EA69E8E3C34E.jpeg. 5AABB14E-4B73-478D-800C-2288698EF8CD.jpeg

    I just need some more space for the small pipe and tube at the rear end.

    20B7EFBD-139C-4F63-AFAD-BBDDEE8A2949.jpeg

    Also the Tony Law Exhaust „Dennis Edition“ is finaly welded.

    FBE671EF-2373-4C0E-8878-6F74850A2E7D.jpeg

    Next step is the fuel pump, pipes etc.
    Yesterday I ordered a lot of dash06 fittings at Bat Motorsport. The prices are not that bad and they are very good sorted.
    Stay tuned...

  28. #107
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    Re: My Escort XE Project!

    Due to some delivery issues for my fuel system parts I started with the electric.
    The new fuse Box will be mounted to the passenger footwell at the A-Pillar. To protect the cables against passenger feets I´d like to use a cable channel out of alloy.
    first mockup done.
    KAbelkanal 1.jpg KAbelkanal 2.jpg

    The plastic covers are easy to remove.

    The MBE Box for the Jenvey TB´s is fixed above the fuse box and will be covered from the glovebox.

  29. #108
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    Re: My Escort XE Project!

    Some good news for everyone who struggles with too short or damaged clutch or throttle cables.
    My old T9 clutch cable was about 45 cm too short. After some research at google I found a nice page !!!
    The holy grale of cable manufactoring!
    https://www.bowdenzug24.de/en/
    Everything is possible... take a look !
    #bowdencable T9
    #throttlecable
    Cheers Dennis
    Last edited by skmotorsport; 11-01-2019 at 08:47.

  30. #109
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    Re: My Escort XE Project!

    Fusebox cover back from milling

    2348671F-671C-4077-B554-42A7419A90AD.jpeg

    And I ordered my new gear stick and the handbrake lever handle
    made of carbon.
    22C71D24-D7BC-4355-A266-2CDD64F30922.jpeg 996227AF-09BC-420E-8D07-E066007C2F46.jpeg

    Hopefully my 35mm square cable will be arrive today. So I can start with the electronic distribution!
    Last edited by skmotorsport; 15-01-2019 at 04:47.

  32. #111
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    Re: My Escort XE Project!

    great work going on, keep the updates coming!

  33. #112
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    Re: My Escort XE Project!

    Thank you! Still pushing hard tio get the engine running! I started with the routing of the cables. Need some new cables, but in total I´m verry happy with it... I closed too much holes in the engine compartment ! Now I need to drill new ones to get the loom to the headlamps again !
    The new position of the fusebox looks good. Just need to coat it satin black.

    Batterie.jpg sicherungskasten.jpg

    The small black box above the battery tray is an additional 100A fuse box. This should protect my interior against the 35mm² cable in case of an accident or whatever

    Also the Carbon handle looks massive...
    On saturday I will finish the engine compartment loom as well and start to wrap it again.

    motorraum first shot.jpg


    stay tuned...

  34. #113
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    Re: My Escort XE Project!

    handbremshebel.jpg
    ...and the Handbrake...

  35. #114
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    Re: My Escort XE Project!

    Yesterday I started crimping the big cables (35mm²) I borrowed a special press plier.
    Together with the black mesh cover and the shrink tube which I ordered from wish, it looks great!

    Cable 2.jpg

    Cable.jpg

    Each cable will be covered like this. Hopefully this week we can celebrate the first start of my monster!

    Stay tuned...Dennis

  36. #115
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    Re: My Escort XE Project!

    Looking great mate

    Keep up the great work, nearly there

    Cheers

    Matt

  37. #116
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    Re: My Escort XE Project!

    Bad news after first run yesterday...
    After few minutes running we found some coolant water dripping out of the Exhaust... After checking the spark plugs we saw that the 3rd. cylinder was showing some water. so we disasembled the exhaust... the tuner who modifiyed the head touched a water chanel at the exhaust side and created a small hole.

  38. #117
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    the tuner who modifiyed the head touched a water chanel at the exhaust side and created a small hole.
    Ouch that's going to hurt. Do you think it will take a repair or is the head going to be scrap...?

  39. #118
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    Re: My Escort XE Project!

    We still searching the defekt... Looks like a crack. I ordered some special paint to make the crack visible.
    310BF9EE-BD70-45F7-833C-BE76BBDD0048.jpeg

    F6C87771-F677-4F62-9404-F16ABA7B9C69.jpeg

  40. #119
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    Shit Re: My Escort XE Project!

    News... we found the hole in the outlet port of the third cylinder.
    Next step is to contact a specialist who can close this hole again!

    Head 1.jpg head 2.jpg

    Head 3.jpg Head 4.jpg

  41. #120
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    Re: My Escort XE Project!

    Back again. The engine builder told me that the water chanel is rotten from inside due to wrong cooling fluid over the last 10 years.
    Next step...ordering a "new" head
    2.kopf 4.jpg 2.Kopf 3.jpg

    What should I say...the "low mileage" head came with bent valves...
    Today I will check the head with a leakage test with my old valves...
    Against boring I´ve wraped my exhaust!

    Wrap 2.jpg Wrap 4.jpg
    Last edited by skmotorsport; 18-02-2019 at 10:00.

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