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Thread: My Escort XE Project!

  1. #201
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    Re: My Escort XE Project!

    Thanks mate, I found a small company in Germany. They told me that they designed their own Rev counter which they can calibate to whatever you want! V8 engine, V6 Engine, 7000, 12000 UPM, every signal is possible! for just about 250€.

    But due to fckn covid they kicked out the half of their Team. So they can´t fabricate the speedo disk anymore. Thats why I had to do it by myself.
    http://www.wsm.de/

    Never the less you´re right, I should not look at the rev counter! But as you mentioned "attention to detail"

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  3. #202
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    Re: My Escort XE Project!

    Today we start to scan the Cluster bezel with modern 3D technic.

    3D2.jpg 3D4.jpg

    3D1.jpg 3D3.jpg

    Now we will start modelling a CAD File out of that scan.

    Stay tuned....

  4. #203
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    Re: My Escort XE Project!

    Some more Pictures from the 3D scanning. It took 3 hours.

    3D4.jpg 3d5.jpg

    And the creating of the CAD model is already finished!

    Plate 1.jpg Plate 3.jpg


    Have a nice Weekend!


    Stay tuned...Dennis

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  6. #204
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    Re: My Escort XE Project!

    Good morning,
    to protect the finished Car in the garage it was necsesary to search for some heater or dryer. I found a great solution from Trotec, but in the end absolutely over the top an too expensive.

    The best humidity value should be betweet 45% and 55% as shown in the picture below.

    dh-vpr-chart-hs-002-de-3ec0.jpg

    State of the Art is the DH 15 VPR+from Trotec...but very expensive with 2500€

    Trotec.JPG

    In the end I found a cheeper solution but never the less with high tech. Klarstein DryFy40. An portable DRyer with WiFy and app for easy access and full controll werever you are.

    Dryfy40.JPG dryer3.jpg

    At the beginning there was a humidity about 75 -80%. It took just 3 hours to dry it down to 56%

    dryer1.jpg dryer2.jpg

    Now it runs stable with 50% Humidity, which is a quite good number to safe the parts which are stored there before the go back to the car...hopefully soon! The garage have about 27qm.

    65759119_2346392368758485_524757210144702464_n.jpg 65753313_2346392445425144_5362331037730865152_n.jpg

    Stay safe....stay tuned....Dennis

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  8. #205
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    Re: My Escort XE Project!

    Some Nice weight reducing tips:
    Alternator -1850g :
    Old part 4750g for the Alternator and 500g for the bracket

    Lima alt.jpg Bracket old.jpg

    New Part 3100g for the alternator (Daihatsu Cuore 60 Amp. Referenznumber OE:2706097202) and 300g for the bracket (Opel 9129426 41519)

    Lima New.jpg bracket new.jpg

    ALternator 1.jpg Alternator 2.jpg

    Ignition Coilpack: -600g :

    Old Part 950g/New Part 350g (BOSCHF01R00A025)

    Stay Safte....Stay tuned...

    Coil old.jpg Coli new.jpg

    Coil 1.jpg Coil 2.jpg

  9. #206
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    In Saarland , the region were I´m from we have an great Series only for Oldtimer. Saarland Classic Cup. Thats my personal target! First event is on May 13th 2018. Would be great to start there.
    The ECU came from SBD Motorsport. It is an MBE Ecu. the Series is an MBE9A9 with a ready to start engine loom.

    There is also another great event in Belgium this year. For the 50th Birthday of the Escort MK1
    https://www.escort-rally-special.com/english-1/
    Very optimistic at that time!!!four and a half years later and still no visible end...

  10. #207
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    Very optimistic at that time!!!four and a half years later and still no visible end...
    Finding the same thing myself.

    Probably about 200 hours into the rebuild now and if you looked in my garage you'd think I've done nothing other than slapped a bit of paint on a few suspension parts!

  11. #208
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    Re: My Escort XE Project!

    I filled another checkbox in my to do list:
    The Old Steering boss hub was a bit too big to fit under the Steering column shroud. So I ordered a new Steering boss hub for "Escort MK2"...and what else...Problems!
    The lower end is not long enough to push the turn signal reset ring (dont know the right word) deep enough against the spring. So I decided to create a spacer.

    Boss 2.jpg Boss 5.jpg

    All good plans start with a drawing...

    Boss 3.jpg Boss 4.jpg

    followed by a good readable drawing...

    Boss 6.jpg

    and ended up in a perfect part...

    Boss 8.jpg Boss 9.jpg

    Now the spacer pushs the reset ring in the right position and the Turn signal can be resetted, and the Column shroud fits like a new one!!

    Boss 10.jpg

    Boss 12.jpg

    Stay safe...Stay tuned...Dennis

  12. #209
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    Re: My Escort XE Project!

    The rear ashtrays were in a bad condition and he chrom effect is gone. So I decided to Carbonise them...

    Ashtray 3.jpg Ashtray 1.jpg

    Ashtray 4.jpg Ashtray 2.jpg

    Maybe I will, add a chrome edge around the carbon plate with a foil...


    Stay safe...Stay tuned...Dennis

  13. #210
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    Re: My Escort XE Project!

    Finally my Carbon Plate arrived at saturday. A very thin carbon layer with glue on the rear side. Now it looks really nice!

    carboncover 2.jpg Carboncover.jpg

    Thanks to team-jollify for the great work!

    Stay safe...stay tuned...Dennis

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  15. #211
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    I filled another checkbox in my to do list:
    The Old Steering boss hub was a bit too big to fit under the Steering column shroud. So I ordered a new Steering boss hub for "Escort MK2"...and what else...Problems!
    The lower end is not long enough to push the turn signal reset ring (dont know the right word) deep enough against the spring. So I decided to create a spacer.


    Now the spacer pushs the reset ring in the right position and the Turn signal can be resetted, and the Column shroud fits like a new one!!

    Stay safe...Stay tuned...Dennis
    If you scan the indicator cancel cam and get it reproduced in aluminium, I think you would sell a lot of them.

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  17. #212
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    Re: My Escort XE Project!

    I can ask my friend to scan it to create an CAD. I saw some 3D printed parts...but i will do!
    Maybe in aluminium a good business to get some money back which i killed in my Money Pit!

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  19. #213
    Racer Decade Plus User wildo105e's Avatar

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    Re: My Escort XE Project!

    Quote Originally Posted by dt36 View Post
    If you scan the indicator cancel cam and get it reproduced in aluminium, I think you would sell a lot of them.
    put me on the list

    More great work here.

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  21. #214
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    Re: My Escort XE Project!

    Quote Originally Posted by wildo105e View Post
    put me on the list

    More great work here.
    I'll have one too. ��

  22. #215
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    My Escort XE Project!

    Quote Originally Posted by wildo105e View Post
    put me on the list

    More great work here.
    Me too!!
    Great work going on here.....👍👍

    Sent from my Hammer_Energy_18x9 using Tapatalk

  23. #216
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    Re: My Escort XE Project!

    Yesterday I blasted my Speedo dials. The new sandblaster Box works perfekt. With very low preasure the didnt bent. I painted them in black, now i have to wait for the stickers from the stickermaker.

    dials.jpg Dials black.jpg

    stay safe...stay tuned...Dennis

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  25. #217
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    Re: My Escort XE Project!


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  27. #218
    World Champion Decade Plus User alladdin's Avatar

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    Re: My Escort XE Project!

    looking good i notice your screwing on the heater bubble rather than welding ? - i was thinking of doing this myself to avoid a possible corrosion trap on the welds.

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  29. #219
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    Re: My Escort XE Project!

    Thank you alladdin, the only reason for me to doing this, now I can use my carbon bowl and , the best reason, I can paint the whole area an I can dismantle it just for cleaning once a year to check for corrosion...

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  31. #220
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    Re: My Escort XE Project!

    Work of art and will be nice once done

  32. #221
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    Re: My Escort XE Project!

    After 5 long Years...painted in Strato silver in a perfect condition!

    f7f0ecc9-8390-4d20-b49d-5ddfd3943552.JPG IMG_1535.jpg

    First of all....start with a plan!
    1A89E286-1B17-4712-A94F-D2DC5C48208A.JPG


    IMG_1548.jpg IMG_1549.jpg

    IMG_1564.jpg IMG_1565.jpg

    IMG_1566.jpg IMG_1568.jpg

    IMG_1593.jpg IMG_1595.jpg

    After Assembly the brake lines I found some leakages at the firewall at the front brake system. The rear system is ok. So I have to order some parts to fix it!

    With that, I wish you and your families just the best! Stay Safe

    Dennis

  33. #222
    Racer Decade Plus User wildo105e's Avatar

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    Re: My Escort XE Project!

    Looking lovely now great to see all the harrd preparation paying off.

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  35. #223
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    Re: My Escort XE Project!

    Some more Updates...
    Sound and heat isolation is now in.

    IMG_1717.jpg IMG_1730.jpg

    the rear cable loom is finished and I started with my fuse box...

    IMG_1770.jpg IMG_1735.jpg

    The washer bottle is back in and electric done

    IMG_1791.jpg

    Time for the marriage

    IMG_1873.jpg

    IMG_1881.jpg

    But in the end I got some bad news with the removable heater bubble/bowl. The bowl is an elementary part of the front structure and it is necsessary to glue it back in (strengten with screws) to make the front stiff again. So hopefully it is not too late and the front is bented like a banana.

  36. #224
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    Re: My Escort XE Project!

    and two more pictures ... One with "MY Engine"

    IMG_1862.jpg

    and the fresh rerouted engine loom is now a bit lower, some more space to install a big Airbox!

    IMG_1823.jpg


    Stay safe, stay tuned...Dennis

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  38. #225
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    Re: My Escort XE Project!

    Looking really good, keep the updates coming it does help me with my project

  39. #226
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    Re: My Escort XE Project!

    Fuel Lines and Oil cooling lines finished yesterday..

    IMG_1929.jpg IMG_1931.jpg

    IMG_1935.jpg IMG_1934.jpg

    IMG_1936.jpg IMG_1937.jpg

    IMG_1941.jpg

    Step by step...


    Stay Strong, stay tuned...Dennis

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  41. #227
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  43. #228
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    Re: My Escort XE Project!

    After a good Tip I found out that the brake mastercylinders were sortedin the wrong way. I used the 0.70" for the front and 0.625 for the rear brakes.
    After the change, the rear one is leaky at the piston side for unknown reasons. Now I decidet to change both (front and rear) for new one due to the reason that both are more than 8 Years old.
    I did some more steps with the Instrument panel.

    IMG_2036.jpg IMG_2037.jpg

    IMG_2039.jpg

    IMG_2004.jpg IMG_2002.jpg

    I decided to use the CUSTOM sticker. This Escort will be an Custom Escort!

    IMG_2001.jpg IMG_1998.jpg

  44. #229
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    Re: My Escort XE Project!

    New day, new issues.
    Yesterday I assembled te Heater Air duct pipes. At the right side without any Issue.

    IMG_2130.jpg IMG_2129.jpg

    But at the left side (my driver side) the Brake Bias Box is right in front of the Air outlet!

    Air out.jpg

    The center console brackets are back in place.

    IMG_2133.jpg IMG_2131.jpg

    And I refreshed the chrome at the Valves...

    IMG_2122.jpg IMG_2129.jpg


    Stay safe...stay tuned...Dennis

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  46. #230
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    Re: My Escort XE Project!

    The heater issue is fixed. I used some caravan heater pipes.

    IMG_2229.jpg IMG_2222.jpg

    The rear cards came back and they look very nice...

    IMG_2224.jpg IMG_2226.jpg

    After protecting the throttle cable i decided to add a bracket to avoid touch condition to the manifold.

    IMG_2295.jpg IMG_2299.jpg

    Last job was the assembly of the fuel tank and the fuel sender. The fuel feeding line which goes to the fuel pump needs to be a bit longer

    IMG_2300.jpg IMG_2309.jpg

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  48. #231
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    Re: My Escort XE Project!

    Much more steps done...
    Sound and vibration insulation done at the rear side and at the roof.
    For the roof I used the butyl plates.

    IMG_2323.jpg IMG_2324.jpg

    For the roof I used the foam with heat isolation
    IMG_2326.jpg
    Also at the underbody along the Exhaust I finished partially the heat isolation

    IMG_2416.jpg

    Next big step was the finishing of the Electric. I had a bloody shortcut at the front lowbeam/parkinglamp just due to fit the bulb cables in the wrong way. I found it after killing roundabout 15 fuses.

    IMG_2332.jpg IMG_2333.jpg IMG_2335.jpg

    At the Interior I started a first trial to fit the rear side covers..but there is more work to be done. The middle section at the B-Pillar area has a big gap where you can look through.

    IMG_2367.jpg IMG_2365.jpg

    Some funny stuff...I bought the headliner three years ago...NOW after hours of trying to fit it alone, my wife asks me to check the shape with an old headliner..
    and...surprise, surprise, I bought a MK1 headliner!

    IMG_2413.jpg

    The right one is now ordered and on its way!

    Last step at saturday...fit and finish for the body panels!
    It took 5 long hours. BUt in the end , I was very happy with the gaps...

    IMG_2471.jpg IMG_2469.jpg

    IMG_2482.jpg IMG_2485.jpg

    Now I can complete the doors with mechanic, rubbers and so on until the headliner arrives.

    IMG_2467.jpg IMG_2419.jpg

    Stay tuned...stay safe...Dennis
    Last edited by skmotorsport; 25-01-2021 at 10:26.

  49. #232
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    Re: My Escort XE Project!

    thats a nice looking car
    sideways is the best way to turn a corner

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  51. #233
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    Re: My Escort XE Project!

    Coming on leaps and bounds now, the car looks excellent you must be really happy with it

  52. #234
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    Re: My Escort XE Project!

    Some updates...
    The left door is well insulated and sounds great when slamed.

    IMG_2531.jpg IMG_2533.jpg

    The Zinc plated mechanism is assembled and the new painted door handle is in place.

    IMG_2524.jpg IMG_2528.jpg

    The next Picture is the lifehack for all high door handle users! I lost the small fixings were the bajonet fixing from the handle goes through.
    I cut a metalclip and drilled two small 3,5 mm holes to use rivet nuts. Just bend the edges a bit up... and here it is!!

    D31C9908-BCD8-4E49-8652-0BA855C1347A.JPG C5C6AC05-57A6-4E80-81EA-7C78FFCE2191.JPG

    IMG_2569.jpg IMG_2572.jpg

    IMG_2540.jpg

    The day ended with assembling of the first windows and the seals. The Brown tinted glass looks awesome with the carbon parts.

    IMG_2581.jpg IMG_2583.jpg+

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  54. #235
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    Re: My Escort XE Project!

    not long till your on the road bet you cant wait

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  56. #236
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    Re: My Escort XE Project!

    looks great Dennis, Keep up the good work and please keep the updates coming!

    wont be long until it is ready for the roads do you need to complete a TUV with this age of car?

  57. #237
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    Re: My Escort XE Project!

    Thanks for the door clip hack

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  59. #238
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    Re: My Escort XE Project!

    Thanks Mark, I have two options.
    1st. Drive with a so called Red 07 Number Plate:
    With this plate I´m able to use up to 10 Oldies (Bike and Car) But it is restricted for Events only. Trial and test rides and rides for repair and maintenance.
    2nd. Option is a full blown TÜV certification. If the TÜV register the engine, Exhaust and the brakes, I'll do that. Thats also the reason for me , to work as precise and clean as a can...maybe they can turn a blind eye!
    and a small update from yesterday...the right door is assembled

    IMG_2596.jpg IMG_2597.jpg

    There is one BIG Question! The trunk seal is still pushing the lid upwards...in which direction should the small lip at the seal?? Inwards or outwards

    IMG_2600.jpg

  60. #239
    Pit Crew Decade Plus User onecamohv's Avatar

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    Re: My Escort XE Project!

    how strict are the police on using the red plate? how can they prove you are not on a test drive? going to work perhaps or..?

  61. #240
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    Re: My Escort XE Project!

    Quote Originally Posted by skmotorsport View Post
    Thanks Mark, I have two options.
    1st. Drive with a so called Red 07 Number Plate:
    With this plate I´m able to use up to 10 Oldies (Bike and Car) But it is restricted for Events only. Trial and test rides and rides for repair and maintenance.
    2nd. Option is a full blown TÜV certification. If the TÜV register the engine, Exhaust and the brakes, I'll do that. Thats also the reason for me , to work as precise and clean as a can...maybe they can turn a blind eye!
    and a small update from yesterday...the right door is assembled

    Attachment 86503 Attachment 86504

    There is one BIG Question! The trunk seal is still pushing the lid upwards...in which direction should the small lip at the seal?? Inwards or outwards

    Attachment 86505
    i would say out
    sideways is the best way to turn a corner

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