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Thread: My Escort XE Project!

  1. #161
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    Re: My Escort XE Project!

    Hi, some more Updates:
    Center Console updated with Carbon and Gauges

    1032A4C1-D32E-4C54-8A08-236EA5B2701D.JPG CCED36ED-6BE4-4B96-8C12-F0AED475986F.JPG



    The center caps are now cabonised and the new wheel nuts arrived

    IMG_2507.jpg

    After the first test drives i noticed some issues with the rear wheel arches...time to create more space

    679592e6-6883-4e28-adda-8cfcefee3a0e.JPG

    And the Willwood rear brakes were kicked out! Less Power, no handbrake performance and not enough space between rim an calipper. Time for Cosworth calippers!

    IMG_3064.jpg IMG_3082.jpg

    IMG_3085.jpg IMG_3074.jpg

    At the moment the shell is back on the Roll over Jig, so the final bodywork can be done.

    IMG_2978.jpg IMG_2979.jpg

    IMG_2980.jpg IMG_2923.jpg

    IMG_2926.jpg IMG_2994.jpg

    IMG_3091.jpg IMG_3094.jpg

    Latest work from yesterday was the relocation of the window washer bottle under the left front wing.

    IMG_3189.jpg IMG_3190.jpg

    IMG_3191.jpg


    stay tuned...
    Attached Images Attached Images

  2. #162
    Bodger

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    Re: My Escort XE Project!

    Those guages look awesome and well fitted, what size are they? 52mm?

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  4. #163
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    Re: My Escort XE Project!

    Thank you, yes 52mm.
    I´ve tested several designs (Stack, Tripmaster...) but in the end the VDO looks very harmonised with the RS speedometer.

    IMG_3295.jpg IMG_3296.jpg

  5. #164
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    Re: My Escort XE Project!

    Some more updates with the GRP4 metallwork done. The C-Pillar stiffening plates are now finished.

    IMG_3230.jpg IMG_3234.jpg

    and the trunk is ready for the sandblasting.

    IMG_3241.jpg IMG_3245.jpg

    The body is now on its way to the sandblasting. But only for the places were I can´t get in with a grinder ore something else.


    Stay tuned...Dennis

  6. #165
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    Re: My Escort XE Project!

    God bless the Homeoffice!

    C1B80623-5C82-4E57-95B1-305B0C0B13D4.JPG

    A few month ago I bought a pair of RS doors. Time to restaurate...
    The door latch fixing points of the driver door was in a terrible condition

    IMG_3329.jpg IMG_3353.jpg

    IMG_3357.jpg IMG_3361.jpg
    And the lower section as usual full of rust

    IMG_3338.jpg

    The carbonised hood "Aerocatch"

    IMG_3362.jpg IMG_3363.jpg

    IMG_3364.jpg

  7. #166
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    Re: My Escort XE Project!

    Still pushing...

    The throttle pedal was quite too near to the brake pedal. With the original pedals as reference...

    IMG_3420.jpg IMG_3422.jpg

    IMG_3424.jpg

    due to the relocation of my Ignition coil under the throttle bodies it was necessary to protect it against the heat and optimize the ground...

    IMG_3470.jpg IMG_3479.jpg

    IMG_3482.jpg IMG_3484.jpg

    IMG_3488.jpg IMG_3489.jpg

    Stay tuned...Dennis

  8. #167
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    Re: My Escort XE Project!

    Now I also ready to restore a Transit!After checking some leakages 4 holes needs to get new threads

    IMG_3530.jpg IMG_3527.jpg

    IMG_3534.jpg

    And i started to build my own Roll over Jig!

    IMG_3599.jpg IMG_3605.jpg

    IMG_3607.jpg IMG_3616.jpg

    IMG_3618.jpg IMG_3608.jpg

    Now I also ready to restorate a Transit!

    Stay tuned...Dennis

    IMG_3626.jpg

  9. #168
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  10. #169
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    Re: My Escort XE Project!

    A lot of details could be finished throught the corona shutdown!
    First of all the Roll over Jig fixing bolt wa a bit too weak. Now I use a 12mm bolt and Some stiffening plates.

    IMG_4671.jpg IMG_4676.jpg

    To get the trunk painted in ALL areas it was necessary to get the paint under the fuel tank mounting. So I decided to make it screwable instead of weldings...

    IMG_4677.jpg 891E29C6-9AAB-4653-B577-FE58B21228EC.JPG
    2A21B335-67F4-4BC1-B82B-D7522C2B1464.JPG 3B5776F2-3367-48B0-9E84-44788598AAB8.JPG

    The Carbon cover is now also nicely fixed with screws...

    IMG_5080.jpg IMG_5079.jpg

    and the oil cooler is now better fixed without touch to the Body!

    IMG_5158.jpg IMG_5160.jpg

    And finally i started with sealing the body...

    IMG_5157.jpg IMG_5048.jpg



    stay tuned....

  11. #170
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    Re: My Escort XE Project!

    Update. The Body came back from the bodyshop with the new rear arches in. I could not belive what the last "master" did. He welded the new arches over not fully cutted old ones!!
    There was no chance to kill him because he´s in jail for other reasons!

    Radlauf.jpg

    Radlauf 2.jpg Radlauf 3.jpg

    the left rear side is also cleaned and painted...

    Seitenwand.jpg

    The backpanel is now cleaned and primed

    Heck 1.jpg Heck 3.jpg

    Second picture shows the Brunox Epoxy

    Heck 4.jpg

    And the washer bottle is now stiffer due to the alloy bracket behind. We weld on studs to route the cable and the washer hose properly under the wings!

    wascher 2.jpg Wascher 1.jpg


    Stay tuned...Dennis

  12. #171
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    Re: My Escort XE Project!

    more paint prework done
    Left side...
    seitenwand 2.jpg seitenwand 3.jpg

    right side
    seitenwand rechts 3.jpg seitenwand rechts 2.jpg

    Stay tuned...Dennis

  13. #172
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    Re: My Escort XE Project!

    Exciting news!!! June 5th. the car will go into the paint shop!!
    With this news it was necessary to create a Plan!


    IMG_5673.jpg

    The hole family is now helping do be done the grinding jobs!

    IMG_5655.jpg IMG_5666.jpg

    0a14797d-c022-4588-92d6-3ca51696c871.JPG


    Stay tuned...Dennis

  14. #173
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    Re: My Escort XE Project!

    I'm looking forward to it

  15. #174
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    Re: My Escort XE Project!

    The busy week is going on. 7 Days left and still a lot of open points on my to do list...
    Yesterday I finished the rivet nuts on my heater Bowl an on the rear seat for the carbon parcel shelf

    IMG_5700.jpg IMG_5699.jpg

    and again, my wife and my oldest son support me with some grinding jobs!

    IMG_5698.jpg

    Stay tuned...Dennis

  16. #175
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    Re: My Escort XE Project!

    next steps done...as usual still waiting for the paintshop!
    I found a "rat hole" along the door gap from about 3 mm. So I decided to weld on some material!

    Door weld.jpg Door weld 2.jpg

    Door weld 3.jpg Door weld 4.jpg

    the same issue was visible at the right front wing in the upper corner to the window...

    wing upper 1.jpg wing upper 2.jpg

    and the gap between bonnet and front wing...

    wing front 1.jpg wing front 2.jpg wing front 3.jpg

    after sealing all holes...

    Sealing.jpg

    i sprayed the stonechip protection!

    Stonechip 2.jpg Stonechip.jpg

    next small project was the adjustability of the watts linkage.

    Watt Mod 1.jpg watt mod 2.jpg

    watt mod 3.jpg Watt Mod 4#.jpg

    Watt Mod 5.jpg


    Last job was the cleaning and in the end the sandblasting of all srews...now the can go to the galvanizing center!

    Schrauben.jpg Schruben blast.jpg


    Stay tuned....Dennis

  17. #176
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    Re: My Escort XE Project!

    Looking forward to seeing the final product

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    Re: My Escort XE Project!

    Going well, looking good.

    I like the idea of the bolt on Heater Plenum cover, are they just rivnuts or little weld on captive type nuts?

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  21. #178
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    Re: My Escort XE Project!

    Thanks rallyrob! The M5 rivnuts are made of alloy. I hope that it will not cause some rust, due to chemical reaction with the metal! But I used red/brown paint and some drops of sealer to avoid.
    I bought not the cheapest ones from china!

    Cheers Dennis

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    Re: My Escort XE Project!

    Some more fit and finish done....
    Left front wing. Massive gap along the lower section to the front.It was necessary to extend the radius.

    left wing 2.jpg left wing 3.jpg

    left wing 3.jpg left wing 4.jpg

    same for the left side!

    right wing.jpg right wing 2.jpg

    right wing 3.jpg right wing 4.jpg

    and...what else....STILL waiting for the paintshop!!


    Stay tuned...Dennis

  23. #180
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    Re: My Escort XE Project!

    quick update on my reworked parts and srews...they´re back from galvanising!

    screws 3.jpg srews 2.jpg

    screws 1.jpg

    Amazing results! better than new!

  24. #181
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    Re: My Escort XE Project!

    Some more Updates done over the weekend!

    I continued to search nuts and screws from every part of the car which can go for galvanising. so with that I found another big box full of screws an fixings. Time for sandblasting!

    Attachment 85723 Attachment 85724

    Another job were the rear lamps. They were in a bad condition. Time to strip them down...

    Attachment 85725 Attachment 85726

    Attachment 85727 Attachment 85728

    The connectors were coroded over the years.

    Lamp 5.jpg Lamp 6.jpg

    Lamp 7.jpg Lamp 8.jpg

    Lamp 9.jpg

    Last job on saturday was the heater bowl.

    Bowl 1.jpg Bowl 2.jpg

    Yesterday was just a "cleaning day"
    The TCA´s are together again with the refreshed nuts and bolts. I also changed the dust covers of the ball joints.

    TCA 1.jpg TCA 2.jpg

    and the Top mounts are cleaned again...

    Dome.jpg

    AND...I´m STILL waiting for the paintshop!

    Stay tuned....Dennis

  25. #182
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    Re: My Escort XE Project!

    The missing files...

    Screws 1.jpg Screws 3.jpg

    Lamp 1.jpg

  26. #183
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    Re: My Escort XE Project!

    Exiting news!! The car will go to the paintshop tomorrow!!
    More than happy about this news!
    And the screws came back from galvanising with again great results.

    Srews 6.jpg

    Time to built the rear axle together again!

    New 1.jpg New 2.jpg

    New 4.jpg New 3.jpg

    New.jpg

    And the screws are going back to the engine...

    New.jpg New screws.jpg



    Stay tuned...Dennis

  27. #184
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    Re: My Escort XE Project!

    Another hours spend assembling the front axle parts.

    Stabi New 1.jpg

    Dämpfer neu beide.jpg Dämpfer neu links.jpg

    And the last journey with that bloody re/brown color starts!!

    way1.jpg way 2.jpg

    At the last galvanising job something went terribly wrong with the watt pipes.
    I told them that these two parts do not demonstrate their amazing work and they need some rework!

    Watt mod scrap 2.jpg

    They only needed one day to do that! And they did again a brilliant job!!

    Watt final 2.jpg

  28. #185
    Racer Decade Plus User wildo105e's Avatar

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    Re: My Escort XE Project!

    I bet you can't wait to get it back. Great work. Did you send the rear willwoods back in the end ?

  29. #186
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    Re: My Escort XE Project!

    Hi, no I sold the rear willwoods because of space issues with my split rims. there was only 2mm gab between the brake mechanical brake lever and the inner srews of the rim. So I had to adapt the wheels to become more clearance. But that was to wide out for the rear arches...Long story short...
    But I think in the end I will be more happy with the performance of these calipers! With the wilwood it was impossible to block the rear wheels without hydraulic handbrake!
    Last edited by skmotorsport; 03-07-2020 at 10:24.

  30. #187
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    Long story short...

    But I think in the end I will be more happy with the performance of these calipers! With the wilwood it was impossible to block the rear wheels without hydraulic handbrake!
    I know what you mean. I have bought so many things that then mean i have to modify 2 more things to fit it.

    TBH a lot of time i think people overbrake rears, I have sierra rear calipers and they were good enough for a sierra cosworth. I am sure you will have more than enough rear braking with yours rear brakes.

    keep up the updates.

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  32. #188
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    Re: My Escort XE Project!

    [QUOTE=wildo105e;3679148]I know what you mean. I have bought so many things that then mean i have to modify 2 more things to fit it.

    NOTHING...rearly every bloody part which goes in that car needs to be modifiyed...

    and for the balance I have the Bias pedal box!

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  34. #190
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    Re: My Escort XE Project!

    Decking lovely, cracking job and will be good to see it going together after paint

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    Re: My Escort XE Project!

    And the build goes on...
    time for some upates on my interior parts.

    The Heater core:

    heater core 1.jpg heater core.jpg

    I cleaned and polished the complete core

    heater core 2.jpg

    Next part was the blower...

    Blower 1.jpg blower.jpg

    ...and the heater... before and after polishing:

    heater.jpg Heater1.jpg

    heater 2.jpg

    ...the wiper motor:

    wiper.jpg steering wiper.jpg

    The ignition housing...

    column 1.jpg Column2.jpg


    and the last job for the weekend...the brake pedal box will be refreshed with coating and galvanazing...

    Pedalbox.jpg Brakezylinder.jpg

    now all srews and fixing are going to sandblasting an galvanising.

    screws 4.jpg

  36. #192
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    Re: My Escort XE Project!


  37. #193
    World Champion Decade Plus User alladdin's Avatar

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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    whats that little blast gun like ?

  38. #194
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    Re: My Escort XE Project!

    HI alladdin, the small gun is fine for smal parts, I blasted all the screws and small brackets with that gun. It works fine for me.

    https://www.ebay.co.uk/itm/1-4-Handh...sAAOSwEoNe5svm

    Attached the link to UK auktion!

  39. #195
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    Re: My Escort XE Project!

    Some more Updates from the paintshop!

    Heck 2.jpg Heckklappe 3.jpg

    haube 3.jpg Seite links 2.jpg

    Front 2.jpg


    This week they will finish the grey filler (The coat after the spray filler...however it is called). The pictures shows the "spray filler" . Next week the car stays untouched to let the filler setting down!


    Stay tuned...Dennis!

  40. #196
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    HI alladdin, the small gun is fine for smal parts, I blasted all the screws and small brackets with that gun. It works fine for me.

    https://www.ebay.co.uk/itm/1-4-Handh...sAAOSwEoNe5svm

    Attached the link to UK auktion!
    would it do something like a xmember ? and ebay failed on the link

  41. #197
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    Re: My Escort XE Project!

    It depens on the Compressor ! More power, better ( constant) solutions.
    For eBay, just search for „small sandblasting gun“
    But it works on all parts!

  42. #198
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    Re: My Escort XE Project!

    Next parts fitted together .
    Another shiny bling bling coatet screws and nuts came back from galvanising.

    925CB0B9-AB12-473F-BF40-8C96D920C30A.jpeg

    Time to Puzzle...
    Bias pedalbox and heater core

    219C586F-F18A-42AA-9E27-47292EE6EA87.jpeg. 4D0B3B3A-C4D3-49E1-816F-675A254E3DA0.jpeg

    Steering colum and the wiper

    6045B8AE-8F99-41DB-99F9-39F5058B0DD2.jpeg A8B794C2-0655-485B-A03E-33200163088A.jpeg

    5441F882-3F54-4CB1-B93C-D2BC4D9B087E.jpeg E1C1BA7E-7064-451A-B222-5C076EA69141.jpeg

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    Re: My Escort XE Project!

    Due to the fact, that my engine revs over 7000 UPM it was necsesary to extend the original Revcounter scale to 8000.
    My first idea was to let print a foil, but in the end it looks verry cheep and the original backround is mat instead of shiny black.
    And the external grafik maker made a fail with the radius, in fact too big! So assembled, you could not se the stripes AND he used the wrong Number design...

    Tacho falsche Folie.jpg tacho scheiss passung.jpg

    With this news I did it by myself...as usual...
    scanning, scaling....

    AND here we are (just a handy picture from my PC Screen as you can see at the picture )

    dzm scheibe.jpg Drehzalmesser.jpg



    and I did the same with the speedo. At some Numbers and stripes the paint peels of a bit.

    Tacho new Tina.jpg

    Now I will send it to an sticker maker that he can print out just the Numbers and the Scaling to transfer it to the plate!

    Next job will be the carbon foil removing! The cluster frame is going to friend who will make a scan and create a CAD from the Cluster frame.
    This file is going to another specialist who can cut out real carbon fibre with a "printer"...


    Stay tuned....Dennis

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  45. #200
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    Re: My Escort XE Project!

    Nice attention to detail.

    When my rev counter is pointing at 7000 its very unlikely I'd be looking at it so I probably wouldn't put the effort in to change it!

    How do you calibrate it so the needle is pointing at the correct number?

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