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Thread: My Escort XE Project!

  1. #121
    Spanner Monkey

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    Re: My Escort XE Project!

    The cylinder head is now at the chemical cleaning...
    against boring, some more from the interior design is done!
    I´d like to add some carbon to my interior! The lower section of the original Ghia door panels looks like a perfekt spot. And by the way it protects against scratches from my shoes when get out the the car.

    Step one: cutting an OLD door panel to check the design and get a proper mockup part!

    Türpappen 1.jpg Türpappen 2.jpg

    After cleaning the leather from the foam along the seam , the carbon plate fits perfecly under the leather!

    Türpappen 3.jpg Türpappen 4.jpg

    Stay tuned....

  2. #122
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    Re: My Escort XE Project!

    Next goodies arrived ... aerocatch laminated with real Carbon Fiber!
    They look better than the the water transfer version...

    CAFAE822-19BA-4B81-85C6-5871B38C75D1.jpeg 98BCD9D4-1B35-4CE9-920D-85201214A53A.jpeg

    Stay tuned...
    Last edited by skmotorsport; 26-02-2019 at 22:09.

  3. #123
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    Re: My Escort XE Project!

    Back from chemical cleaning!! Looks like a bloody new head!!

    new head 1.jpg new head 2.jpg

    new head 3.jpg new head 34.jpg

    Today he goes to the engine maker for porting!



    Stay tuned...

  4. #124
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    Re: My Escort XE Project!

    Today i spend some time to relocate the fusebox to the A Pillar.
    I‘m very happy with the alloy box. The cables are now well protected.

    1435B1F3-13BF-4B18-B570-71D824F72AE2.jpeg 29D28282-9C7B-468B-8176-61AFFC91AEB8.jpeg

    889F4B32-06DB-41E6-9AB7-8B4D3036ABDC.jpeg 8DD50D39-C456-4C88-8DF8-DE20E8FCD88F.jpeg

  5. #125
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    Re: My Escort XE Project!

    Seconds ago my new mirrors arrived!
    Laminatet with Carbon...enjoy...
    9D52E585-5F98-45FD-9D0E-A775B9384E60.jpeg 64CB1CBF-44EF-4732-8354-1C605474D972.jpeg


    Stay tuned...

  6. #126
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    Re: My Escort XE Project!

    Some more updates... Good news from the engine maker! The new head passed the preasure test and is now hopefully without holes.
    Both front door trim panels are finished.

    Door front 1.jpg Door Front 2.jpg

    The rear door panels came up with a lot of work. First step was to clean the original leather.

    Door rear 1.jpg door rear 2.jpg

    the carbon plate need some fixing srews, so i tried to glue them on the carbon backside. It works.

    door rear carbon.jpg Door rear 22.jpg

    last step was the glueing with the UHU adhesive spray.

    door rear 33.jpg door rear 3.jpg

    The Idea to glue some chrome around the rear door panel armrest failed. The rubber didn´t stay in the form of the small corners. Maybe I need to cut something out of one part and polish it. It would be lovely to get the same design as on the front door panel.

  7. #127
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    Cool Re: My Escort XE Project!

    Still waiting for my engine coming back from the engine maker...
    i used the time being to clean my front end.

    links 1.jpg recht 3.jpg

    links ready.jpg

    I also managed my new escort garage.

    Garage alt.jpg Garage neu.jpg

    Now it is getting a real homebuild Escort!!#

    Last job in the last weeks was changing the tyres!

    195er 1.jpg 195 2.jpg

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  9. #129
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    Re: My Escort XE Project!

    Here we go.
    Trolley and rollover jig ready

    Trolley.jpg Roll over Jig.jpg

    Time to start cleaning the underbody.
    Surprisingly I could clean the middle section of the underbody just with brakecleaner!

    Wash.jpg wash 2.jpg

    heck 2.jpg heck.jpg

    the rear end needs some sandblasting due to too much rust in unreachable corners!
    The gear box tunnel shows some sharp edges an holes wich I covered with some plates.

    Gear 1.jpg Gear 2.jpg

    Verstärkung.jpg

    At the end of the day the underbody (without the tail) is ready...

    paint 1.jpg

    Also the new trimmed rear seats came back!!

    seats ready.jpg ausstattung 2.jpg

    The combination with the carbon parts is brilliant!
    Last step which was done is bring the Escort back home to my Garage. By end of July I closed my Shop. Now the real "homebuild" is going on!

    Ready 1.jpg Ready 2.jpg

  10. #130
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    Re: My Escort XE Project!

    Time for changing the good old stuff to good modern stuff!
    After some bad shots i came to the conglusion that my old Messer Grießheim Welding mashine is at the and of his lifecycle!
    Now I can move on with the latest technic!
    Welcome ESAB MIG Caddy C200i an the God of Automatic helmets itself ESAB Sentinel

    ESAP GEräte.jpg

    Stay tuned...

  11. #131
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    Re: My Escort XE Project!

    Hey mate this is coming along very well.

    What specs did you bbs end up at, 13x?7 with what offset/dish ?

  12. #132
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    Re: My Escort XE Project!

    The inner and outer rims are 3,5
    7Jx13

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  14. #133
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    Re: My Escort XE Project!

    And some impressions from the new welding machine

    BF87F941-6E29-4509-A1B2-798E2F4A0E11.jpeg FB7CE19B-AC41-47EE-BD56-BADA11995512.jpeg

  15. #134
    Racer Decade Plus User Forest_rallying's Avatar

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    Re: My Escort XE Project!

    A nice weld there SK.

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  17. #135
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    Re: My Escort XE Project!

    Thanks a lot! It realy made fun wich such a machine! Welding next level!
    Today I finished the underbody reinforcement welds.

    0B59E585-E1C9-4038-A360-CCD2571FB52F.jpeg A50CBDD6-0A96-45E0-AFFA-E5DCA65D9FDA.jpeg

    Now I can start with „cosmetical“ part at the engine bay


    Stay tuned... Dennis
    Last edited by skmotorsport; 03-08-2019 at 20:23.

  18. #136
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    Re: My Escort XE Project!

    Today My new Battery arrived! This is not just a battery!
    This is the answer of the combination from weight saving, kill switch implementation, power controlling
    And by the way an Carbon beauty!
    0C7E4EFC-C92F-4EAD-8F57-B25DB0386642.jpeg

    The missing puzzle in the boot of my Carbonqueen!

    80EF8D58-E7BA-42AE-8B7F-894AE573A546.jpeg C8E53E9E-6E68-4EDD-85CE-93E869CD4EB2.jpeg

    Tech specs.
    1.4 kg
    450 A
    20-35Ah

    DMSB homologation
    Intelligent Kill Operation Switch
    Active Vehicle Anti Theft

  19. #137
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    Re: My Escort XE Project!


  20. #138
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    Re: My Escort XE Project!

    Now the battery tray is removed and the battery directly fitted to the Body and the bracket which I build to Support the old tray.

    D80959E3-2816-4E1F-AEEE-3E1493FCCB9C.jpeg. D1DB5917-7EB9-4EBB-A87D-B976AEEDCBC8.jpeg

    And the Engine is nearly ready!!

    E885CD9A-03FD-4BB2-AC78-CACCAEC94555.jpeg 8B943394-19B5-48AC-85D8-4C0D03B521E4.jpeg

    The pistons are coated now and the Pistons rings reworked! That was the reason for the marks!

  21. #139
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    Re: My Escort XE Project!

    Today I have spend some Time with the headlights!
    I bought some Golf MK1 lights with a black cross inside.
    I Love the look of theese lights. I trimmed the frame to a pair of plastic bowls.
    Now they fit perfektly into the front.

    8DD48043-683D-4A9D-A89D-F39A4C718D32.jpeg 402E7FE3-9490-4707-9757-CCD76E6726CE.jpeg

    C96B032A-BCBD-4F26-9337-F2299C02602A.jpeg 36DF3D67-064C-40AE-B585-58FB28FD90F1.jpeg


    Stay tuned...

  22. #140
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    Re: My Escort XE Project!

    Refreshing of the headlamp cables is ongoing. Before the engine goes back in the car I need to sort out how and where to route the main loom. It hurts too much to drill holes in a fresh painted car...

    Lampenbau alt neu.jpg Lampenbaum detail.jpg

    And the best news..........THE ENGINE is back!!
    After six month I´m very happy with the results! The compression is now 11.8:1 - 0.6 better than expected. Oilpressure is constant at 6 bar. Time to speed up the bodywork to get this beauty back in the car!

    New front.jpg New out.jpg

    Also the wrapped manifold still fit.

    New Exhaust.jpg

    Stay tuned...

  23. #141
    Pit Crew Decade Plus User onecamohv's Avatar

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    Re: My Escort XE Project!

    looks great keep up all the good work! engine looks really good, what colour are you going to paint it?
    p.s how much was the battery?

  24. #142
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    Re: My Escort XE Project!

    Thank you...a lot of traffic but no comments...a bit scary
    It will be silver! My master is the silver Harrier Escort from the legendary dangerousdave.

    Daves MK2.jpg

    Together with "modern Spec." carbon parts it will be a cracker!
    The battery is not a snapper!Official price is 790€. But it will safe minimum 14kg. And the fact that it came up with the internal kill switch, anti theft is a argument for me...and she looks fantastik!
    At the moment I´m checking the main loom to see wich holes I can close and which closed holes I need to drill again
    It is a nightmare! Oh the horn cable...oh the fan switch cable...oh the washer bottle cable...Its uncountable how often I start again packing the wire together... but in the end I will be a cable specialist with hundreds pictures. So I can support generations of Escort rebuilders!

    Cheers
    Dennis

  25. #143
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    Re: My Escort XE Project!

    Really like what you’ve done with the carbon trim. I’ve been thinking of introducing some carbon trim to my Mk2, keeping the over all classic look but with a light modern touch. Cable sleeves look good to, some nice attention to detail here.

  26. #144
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    Re: My Escort XE Project!

    Thanks.
    And the wiring goes on...
    before.jpg After.jpg

    And I found the holy grale of Cable routing questions!! A complete Schematic drawing.

    Schemema - K000opie.jpg

    I can send it in a better solution!! PN me...


    Stay tuned

  27. #145
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    Re: My Escort XE Project!

    Cable Guy...to check the length of the flasher cable it was necessary to assemble the Flash light in the bumper!

    Blinker.jpg Blinker 2.jpg

    now both sides looks quite better than before...

    Blinkerkabel2.jpg Blinkerkabel.jpg


    Stay tuned...

  28. #146
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    Re: My Escort XE Project!

    Some more steps done...
    It was necessary to buy a new pair of front struts. Luckily I found a set of new remanufactured RS dampers.

    Front new.jpg 72048916_2511128145618239_6138555353240961024_n.jpg

    the GAZ inserts are adjustable, so I made a adjuster who fits a bit more than the old one!

    Versteller.jpg

    There was also some rework needed at the steering rack. But now it fits perfect!

    71350881_2511127852284935_746739433742532608_n.jpg stabi.jpg

    The carpet fits now perfect to the seat rails.

    71533422_2511128298951557_6918328213680685056_n.jpg 71892906_2511128245618229_9051845937999118336_n.jpg

    And the spacer to fit the carbon strut bar came after a long journey...

    spacer.jpg

    The front and rear bumpers are installed ... i love the back of the car with the carbon spoiler! For the exhaust pipe I need to cut out the metal at the lower rear end !

    70589891_2479196368811417_2610026401436270592_n.jpg 70706932_2479196362144751_1558461529400016896_n.jpg

    70840834_2488683704529350_974595592053325824_n.jpg

    Next step is to fit the rear axle again. But I lost one rubber for the hangers...so I can spend some time with the braking system!

    Bottle.jpg Bottle2.jpg

    Stay tuned...
    Attached Images Attached Images

  29. #147
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    Re: My Escort XE Project!

    Touch down. Since my last post several more steps done!

    72762457_2550132895051097_1615499360810827776_n.jpg 73158195_2550132905051096_7959426018488352768_n.jpg

    74324814_2550134598384260_7654216601528434688_n.jpg 74459274_2550156971715356_2006130093830701056_n.jpg

    This weekend I pushed the works with the brakesystem. Due to the verry hot exhaust it is necessary to re route the brake pipes outside the engine compartment.
    The first prototype wasn´t ok because there was a slight risk to get in touch with the tyres the wheel arch area.So I created a mockup at my woodn workbench. So it was very easy to create some prototypes.

    72635274_2554279734636413_1905414798661648384_n.jpg 74236003_2554280107969709_2834192877897121792_n.jpg

    73265398_2554279874636399_8992017992753610752_n.jpg 72824110_2554279934636393_539267550995808256_n.jpg

    74344924_2554279974636389_3573124125520035840_n.jpg 75610900_2554280247969695_8500235613067280384_n.jpg

    Stay tuned...

  30. #148
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    Re: My Escort XE Project!

    everything is looking fantastic on this project, keep up the great work!

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  32. #149
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    Re: My Escort XE Project!

    This weekend I started to build my Wheel alignment tool. Just for the first adjustment (open spread 80mm ). The final adjustment will be done after the car is finally completed.
    But it works that easy...

    73306682_2564826590248394_1418624498118164480_n.jpg 76769646_2564826463581740_6523242658977021952_n.jpg

    75446820_2569505529780500_7704389971393642496_n.jpg 74667384_2569505693113817_9102959682363850752_n.jpg

    Step by step...stay tuned...

  33. #150
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    Re: My Escort XE Project!

    Last week I drove the Car for the first time on the road!
    The exhaust Muffler cover is now ready and just needs 2 rivets.

    IMG_6347.JPG IMG_6348.JPG

    The Carbon Pipe came from an Superbike company...looks cool!

    Next step is to check the door panels how they fit and how they look. There are some plastic/chrome parts which needs to be renewed. Over the years they got some cracks.

    IMG_9734.JPG IMG_9736.JPG

    IMG_9740.JPG IMG_9769.JPG

    Yesterday I ordered some special leather paint to change the headrest color to black like the rest of my trim. The rear door panels needs to be retrimmed again because the glue which i used for wasn´t that good... the comlpete leather came loose and fall of. BUt never the less the doors are assembled with its mechanism parts. Next step is a visit at the body shop to get all parts in the right direction before the car goes to the paint shop.

    IMG_9773.JPG

  34. #151
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    Re: My Escort XE Project!

    Still pushing...
    The Headlights are now finally fixed, at the first tryouts I used some glue to fix the screws. Now I used some alloy rivet nuts! Works perfekt.
    After installing the lamps i drilled the big holes for the prepared looms. It looks fantastic and its invisible in front of the radiator.

    IMG_4636.JPG Lamp.JPG

    The mirrors are now on its place and looks also great.

    Mirror.JPG

    Stay tuned....
    Attached Images Attached Images

  35. #152
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    Re: My Escort XE Project!

    Nice work.

    I'm loving the Recaros

  36. #153
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    Re: My Escort XE Project!

    This starting to come together nicely, trim looks great but i bet those front seats weigh in heavy but they do look good tho.

  37. #154
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    Re: My Escort XE Project!

    Well after long days of searching for matching materials I finally found the right stuff to complete the oil cooler setup!
    Biggest problem was the space between the oil filter and the anti dive kit!
    But with a threat adapter from M20 to M18 it works fine with the MANN W7003 Filter!

    78244539_2639381739459545_1270963385042731008_n.jpg 79369549_2639381752792877_819334487102980096_n.jpg

    79378827_2639381859459533_2904126683621621760_n.jpg 78790571_2639381926126193_8928152980113326080_n.jpg

    78158996_2639381956126190_6074640398720958464_n.jpg 74473192_2639382089459510_7871182045626499072_n.jpg

    78932471_2639381826126203_8099221105119592448_n.jpg 78664081_2639382019459517_1337182241624686592_n.jpg

    Another big milestone is done. Connecting the handbrake lever to the wilwood calipers!
    Days of thinking...but in the end it works!

    Plan.jpg fixing.jpg

    lever.jpg cable.jpg

    brackets.jpg

  38. #155
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    Re: My Escort XE Project!

    time for some details at the inner trim parts. the original window cranks are in a bad condition after 40 years of usage. Time to carbonise...

    kurbel 1.jpg kurbel 3.jpg

    Kurbel 6.jpg Kurbel 7.jpg

    kurbel 5.jpg kurbel 4.jpg

  39. #156
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    Re: My Escort XE Project!

    hi mate where did you get the thread adapter from got the same problem any links keep up the good work

  40. #157
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    Re: My Escort XE Project!

    Hi Hossman,
    the original Bolt is big enough. So we could cut a new thread on it with M16 x 1.5 . The adapter is from the folowing link. I thought it is M20 to M18 but it is M20 to M16!! My fault...
    https://www.conrad.de/de/p/hellerman...st-605769.html

    We shortened the bolt and the adapter at the marked ares by -1mm to get enough clearance between housing and the filter. I was a bit scared with the compression of the O-ring of the oil filter...

    InkedBolt_LI.jpg

    The fittings and the pipe came from WISH...and yes they are not rubbish! I ordered some "expensive" parts...and surprise surprise...absolutely the same!! Just for 42quit!
    https://www.wish.com/product/5c91b18dcaedb76921230a5e

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  42. #158
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    Re: My Escort XE Project!

    thats brilliant thank you

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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    Touch down. Since my last post several more steps done!

    Attachment 84720 Attachment 84721

    Attachment 84728 Attachment 84722

    This weekend I pushed the works with the brakesystem. Due to the verry hot exhaust it is necessary to re route the brake pipes outside the engine compartment.
    The first prototype wasn´t ok because there was a slight risk to get in touch with the tyres the wheel arch area.So I created a mockup at my woodn workbench. So it was very easy to create some prototypes.

    Attachment 84723 Attachment 84724

    Attachment 84725 Attachment 84726

    Attachment 84729 Attachment 84727

    Stay tuned...
    i would put the helper spring to the bottom as the main spring wont locate on the top cap with it there

  44. #160
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    Re: My Escort XE Project!

    Any update?

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