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Thread: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

  1. #361
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Found an original engine splash shield. I don't even remember seeing one on a car back in the day, just that they are mentioned in a couple of my original maintenance manuals. (Just for anyone new, this isn't a sump guard ) I don't need a sump guard for a road / track day car but a splash shield to help keep the engine clean, yes please.
    Think the guy getting rid of it didn't realise it had got flattened out and needed re shaping to make it fit, which is done by gently warming it up.
    IMG_9712.JPG

    I've made up thin metal plates to reinforce the mounting flange. These will be pop rivetted on. Also got to drill and fit captive nuts in the chassis rails. Pics to follow.

    IMG_9713.JPG

    Also been doing more seam sealing on the underside now it's back on the jig.

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  3. #362
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Garage time isn’t easy for some and like you it has been very limited. Glad to see are still at her and she is taking shape. You going to get her into paint this year

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Paint is planned and booked for end of March / April. I don’t want to let that slip as the waiting list is long. It could go to paint now, but ideally I want all the drilling and pre fitting done. Last thing I want is to be taking a drill to it when it’s had a new coat of paint. Also if I decide on doing something different or make a mistake it’s no real issue to sort out pre paint. I’ve really only got the fuel/brake pipe clip mounts and fuel pump fitting to do as far as drilling/welding is concerned.
    The paint shop is doing all the body preparation, surface filling and final gapping before paint.
    All the running gear is prepared and sat in boxes ready for rebuilding. The plan being that once the cars off to paint I’ll build it all up, and it will be fitted at the paint shop so it will come back a rolling shell. That’s partly lead by the paint shop not liking finished shells being transported on skates, which suits me fine.
    It all sounds like a great plan, but let’s see

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fantastic work mate. It nicely come together step by step! I found so much non drilled holes after the paint job...
    Very nice attention to detail. Love it

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks skmotorsport,
    I’m sure like you, despite my best efforts I’ll still find something that needs drilling. I don’t think realistically I’ll get round to dry fitting my wiring loom, that’s going to require extra fixing holes I think.
    I’ll just try to get as much done as possible, especially in the difficult areas like underneath

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  8. #366
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Update time over the next couple of evenings.
    There's been a fair bit of test fitting and some clean and prep of parts.
    The engine splash shied came up well, but may not be used as the fit is tricky with the anti dive kit

    IMG_E0144.JPG

    The replacement radiator arrived, and test fitted all ok

    IMG_0076.JPG

    Bump stops cleaned and painted. They came up really well.

    IMG_0290.JPG

    IMG_0291.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Made up these covers for the gearbox mount brackets. I don't want to use captive nuts and without the covers I can see these becoming dirt traps. Used the mesh left over from the speaker louver replacement covered in tissue fibreglass & resin.

    IMG_0293.JPG

    IMG_0292.JPG

    Expansion tank mounting
    IMG_0333.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    She is coming on and it’s good to trial fit everything before paint as it’s a nightmare afterwards as there is always something that needs a bit of fettling to get it fitted

    Looking forward to the updates and keep them coming

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, id you get the pictures of your car back up on the site ?

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Side splash panels have these dimples pressed inwards where the lower trim securing bracket fits.
    I'd fitted the brackets over the dimples, and knocked the dimples outward. Bit of a bodge, so had to re do this.

    IMG_0350.JPG

    IMG_0351.JPG

    IMG_0352.JPG

    IMG_0354.JPG

    IMG_0362.JPG

    IMG_0363.JPG

    IMG_0367.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Bare metaled the boot recesses
    IMG_0386.JPG

    Re made the dash pod fixing brackets

    IMG_0353.JPG

    IMG_0357.JPG

    This is all stuff I realised I wasn't happy with as I approach paint time

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fuel system

    Got a bit out of sync here, so to recap, I'm running fuel (copper) and break lines under the floor like the Sierra's using Sierra plastic clips which screw to brackets welded to the floor.
    Fuel line runs marked with tape (yellow fuel, red break), and the initially formed fixing brackets.
    IMG_9714.JPG

    Making up the brackets with M5 captive nuts. They're numbered because a couple are slightly different to fit the floor shape.
    IMG_9758.JPG

    IMG_9759.JPG

    IMG_9768.JPG

    IMG_9778.JPG

    Brackets fitted

    IMG_9810.JPG

    Test fit of clips and pipe

    Attachment 87036

    At the back to take the pipes around the axel arch, 2x "S" type brackets to take M4 chimney nuts and a different type of plastic pipe clip. This reduces the radius of bend to the pipes.

    IMG_9925.JPG

    Fuel and break pipes fitted
    IMG_0210.JPG

    (Needed an extra bracket at the bottom of the bulkhead)
    IMG_0376.JPG
    Speedo cable clips fitted and checked

    IMG_0211.JPG

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  17. #373
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Looking nice and tidy, well worth all the work :-)

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  19. #374
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    i thought you would ave painted underneath before fitting pipework, or are u doing a dry build first.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    It's fitting and dry fitting, you don't want to be welding and painted car, and this is not a standard fuel line fit for a Mk2 Escort.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    IMG_9809.JPG
    This is the picture that failed above, test fitting the clips

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Box of parts for the fuel system. Steel mesh pipe is for outside and the nylon for the return line inside. The hard lines are separated at both ends by the flexible pipe to reduce vibration between the sections and give some play, without the bulk of the flexible tube running under the floor

    IMG_0147.JPG

    Fuel pump set up, ally plate fitted under the boot floor on rubber anti vibration bobbings. Power supply will run in the groove of the boot floor and exit via the lucus type grommet and connect to the pump. This saves making extra holes in the boot floor and the original hole lines up perfectly

    IMG_0269.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    That's really neat, like that
    www.instagram.com/thehighclassescort/

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Only word of caution is the pipe mount bracket spacing! If the pipes were fixed directly to the panels I think the spacing is fine but having them 'floating' at 600mm? centres will allow vibration and flex to work harden them and then crack. If it was me i'd double up the brackets / halve the spacing. Mine are in-car and use rubber lined P clips @ 300mm ctrs.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by katana View Post
    Only word of caution is the pipe mount bracket spacing! If the pipes were fixed directly to the panels I think the spacing is fine but having them 'floating' at 600mm? centres will allow vibration and flex to work harden them and then crack. If it was me i'd double up the brackets / halve the spacing. Mine are in-car and use rubber lined P clips @ 300mm ctrs.
    im with you Katana, on this one also.

  27. #381
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Concerns noted, this issue of work hardening copper pipe crops up every time someone uses it, but I've never seen anyone post pictures or describe personal experience of a failure. I don't remember seeing a vibration induced failure of copper pipe in other applications either. Like the dissimilar metal debate, yes it's a real issue but has to be taken in context.
    I've not thrown this together either, there's a recommended support spacing (can't remember off the top of my head) which I've followed, and it considerably less than 600mm (8 clips x 600mm spacing =4.8 meters, how long is an escort floor ?) Also these clips aren't floating, they are bowed, as you tighten the screw to secure the clip it flattens and clamps the pipes (the Ford clip department really thought these through at design), The 2 at the back clamp by a hooked catch. If it springs a leak, I'll be back here to let everyone know what an idiotic idea it was to use copper fuel lines.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fuel tank outlet, modified to male AN-6 (Credit to Donnie as this was inspired by his outlet modification)
    IMG_E9300.JPG

    IMG_0148.JPG
    Standard fitting with the steel weld in AN-6 fitting

    IMG_0149.JPG
    Threaded section removed and a small recess ground inside so the AN bung seats in the fitting

    Leaving a nice little channel for the weld
    IMG_0150.JPG

    Clamped up to hold it tight and square for welding
    IMG_0152.JPG

    Welded, dressed off and flats made for tightening the fitting in the tank
    IMG_0154.JPG

    IMG_0155.JPG

    The return. Inlet
    Removed the original straight steel tube and replaced with 8mm copper to take the nylon meshed return pipe
    Soldering this is a little tricky and needs some time and preparation because of how the steel and copper react to the heating. Most important is to tin both and keep every thing very clean.
    IMG_0187.JPG

    Fitting a bend as measuring makes me believe the flexible pipe will not have space to form onto a straight inlet without the possibility of kinking
    IMG_0188.JPG

    This is attached after so the correct angle is set to align when the sender unit is fitted in the tank
    IMG_0193.JPG

    IMG_0204.JPG
    Last edited by Zakspak; 18-06-2021 at 04:27.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    I'm no metallurgist but i've experienced plenty of bi-metal corrosion on land rovers where aluminium panels meet steel. Door frames and skins rot like absolute buggery

    Oddly, never seen it on an escort with aluminium wheel arches and steel wings.
    www.instagram.com/thehighclassescort/

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Also these clips aren't floating, they are bowed, as you tighten the screw to secure the clip it flattens and clamps the pipes
    Slight misunderstanding - the 'free floating' referred to the length of pipe between the mount clips - fixed rigid at either end, the middle suffers the greatest vibration.
    I've seen a few copper brake lines fracture through poor support so i'm maybe a bit paranoid - HP fuel line leak, under the car, near a hot exhaust - draw ones own conclusions !

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    She’s taking shape nicely and you just keep at it. Looking onward to seeing her in paint

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    You’re not wrong re the landies, despite my best efforts to protect the new door panels I fitted to my series 3 after about a year, tiny tell tale signs of corrosion were spotted, but it does take years for it to really come apart. That maybe because as aluminium corrodes it forms a coating ( aluminium oxide I think) which isolates the aluminium under it and significantly slows the process.
    This is why you can leave an aircraft sat our side for years and whilst it wouldn’t be airworthy, it wont collapse in on itself like an Escort or Capri would.
    And the ally arches on steel wings thing just goes to show it has to be in context. Thinking about it, probably because the landy doors are just painted but the arches are sealed with filler, paint and under seal, so if moisture is removed from the reaction the reaction stops. Anyway back to the build.....
    Last edited by Zakspak; 19-06-2021 at 07:50.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, I was there yesterday dropping some parts off and seeing the progress
    These updates are running several weeks behind. I’ll try and catch up as time allows

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, I was there yesterday dropping some parts off and seeing the progress
    These updates are running several weeks behind. I’ll try and catch up as time allows

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Made up front break lines. I'm using copper nickel brake pipe.
    Strips of masking tape to mark pipe routing

    IMG_0212.JPG

    IMG_0213.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fuel return fixings. Chassis rail tapped to M5.

    IMG_0341.JPG

    IMG_0342.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Another job, the bonnet spring lock/release. The stem isn't long enough to comfortably screw into the bonnet and catch under the locking spring. So I got an 80mm bolt, cut the original stem off about 10mm above the cone, put a chamfer on both, set them up square, welded and dressed. Wasn't sure this would work, so didn't take pictures of the process.

    IMG_0157.JPG

    IMG_0156.JPG

    Painting along with the fuel tank outlet

    IMG_0159.JPG

    IMG_0169.JPG

    Both put together.

    IMG_0171.JPG

    Now found a place to get the release spring assembly plated.
    Last edited by Zakspak; 21-06-2021 at 22:14.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    That fuel outlet with the 90* bend.

    IMG_E0171.JPG

    Whist I don't think there would have been a problem with the flexible pipe passing between the chassis rail and leaf spring,
    IMG_0268.JPG
    (You can also see the An-6 bulkhead return fitting)

    by changing the 90 to a 120 I can bring the flexible pipe comfortably to the chassis rail and use a P clip fixed to the chassis using a rivnut and M5 screw
    IMG_0340.JPG

    And it works

    IMG_0463.JPG

    IMG_0464.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fuel regulator fitted.

    IMG_0298.JPG

    Been some head scratching here to get everything to fit, regulator has to be accessible, a crank/rocker cover oil catch tank and the washer bottle being on the outside of the wing. I like everything accessible for future maintenance and repair.
    Wondered if a fuel rail mounted regulator would have been a better option ?

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Expansion tank fitting

    IMG_0333.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Nice piece of work but I query the outlet pipe size - the bit with the chamfer in the tank? Seems to replicate original bore at 1/4" / 6mm? If so, there is a chance of getting pump cavitation - all the pump feeds are -8 so nearly 0.45" bore, that outlet is equal to a -4! With HP pump feeds - bigger is better.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Katana, it’s the original feed tube, and I wondered if it might be worth either removing it or maybe drilling holes in it top to bottom, with enough static fuel sat in the pre pump fuel line and filter to provide sufficient reservoir to the pump. Now you’ve made me think I’ve got to do something to reduce the restriction it could cause just in case.
    I didn’t go with a big supply pipe as I’m running a standard Zetec, but maybe I should have as it wouldn’t have had any negatives.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    You have put a lot of work into it and it’s taking shape nicely. Looking forward to seeing her in paint, good thing about the dry fit is that once it’s back from paint she will take shape in no time

    Like the mod to the bonnet pin

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Katana, it’s the original feed tube, and I wondered if it might be worth either removing it or maybe drilling holes in it top to bottom, with enough static fuel sat in the pre pump fuel line and filter to provide sufficient reservoir to the pump. Now you’ve made me think I’ve got to do something to reduce the restriction it could cause just in case.
    I didn’t go with a big supply pipe as I’m running a standard Zetec, but maybe I should have as it wouldn’t have had any negatives.
    That's the thing with efi pumps - they are running effectively flat out, all the time with a good proportion of what's sucked out, then returned to the tank. Drilling holes in the standpipe won't achieve much as the pipe through the 'bung' is still chocked down to 1/4". Personally I'd drill it out to as close to the -8 bore as you can achieve,

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    [QUOTE=donnie;3747725]You have put a lot of work into it and it’s taking shape nicely. Looking forward to seeing her in paint, good thing about the dry fit is that once it’s back from paint she will take shape in no time

    That's what I'm hoping Donnie, and I don't want to be drilling holes in a freshly painted car. Although there's still lots to do so I don't think I'll be on the road this year

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Other stuff I've done is to finish of shaping and smoothing the arch duct outlets and shaping the arches to match. There's been quite a lot of work on the fibreglass. Various brackets fitting and checking

    Finished off the sealer and re did areas I wasn't happy with making it smoother.
    IMG_0486.JPG

    Then one last roll over before going back on the skate

    IMG_0472.JPG

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